Mercedes Benz PDF

INDUSTRIAL TRAINING
A PROJECT REPORT
Submitted By
PATEL JIGNAL BHUPENDRAKUMAR
190013102013
In partial fulfilment for the award of the degree of
BACHELOR OF ENGINEERING
in
Automobile Engineering Department
A.D. PATEL INSTITUTE OF TECHNOLOGY, ANAND
Gujarat Technological University, Ahmedabad.

MAY, 2022
COMPLETION CERTIFICATE
A. D. PATEL INSTITUTE OF TECHNOLOGY
New Vallabh Vidhyanagar, Vitthal Udyognagar, Anand, Gujarat 388121
CERTIFICATE
This is certify that the project report submitted along with the
project entitled “INTERNSHIP” has been carried out by PATEL JIGNAL
BHUPENDRAKUMAR under my guidance in partial fulfilment for the degree
of bachelor of engineering in AUTOMOBILE ENGINEERING, 8TH Semester
of Gujarat Technological University, Ahmedabad during the academic year 2021-
22.
Dr. Nimit Patel Dr. Sanjay Patel
Internal Guide Head of the Department

COMPANY CERTIFICATE
A. D. PATEL INSTITUTE OF TECHNOLOGY
New Vallabh Vidyanagar, Vitthal Udyognagar, Anand, Gujarat 388121
DECLARATION
We hereby declare that the Internship report submitted along with Internship
entitled Internship/Project submitted in partial fulfilment for degree of Bachelor
of Engineering in Automobile Engineering to Gujarat Technological University,
Ahmedabad, is a bonafide record of original project work carried out by me at
Mercedes Benz Landmark Cars Pvt. Ltd. Under the supervision of Dr. Nimit
Patel and that no part of this report has been directly copied from any students
reports or taken from any other source , without providing due reference.
Name of the Student Sign of Student
1 ____________________ ______________
ACKNOWLEDGEMENT
First of all, I am very much grateful to my college “A.D. PATEL INSTITUDE
OF TECHNOLOGY, ANAND” And especially DR. VISHAL N. SINGH, Principal for
giving me the Opportunity to complete my industrial training in renowned Automobile service
station and workshop of city which will be the building a step for my bright future.
Further, I would like to extend my vote of thanks to Dr. SANJAY M. PATEL
(Head of Department) along with Dr. NIMIT PATEL my training guide for their inevitable
part for successful completion of my Training. I sincerely thank each of them for their guidance
and helpfulness through the hard and easy timing during the preparation of the seminar and
report.
I am very much thankful to Mr. Vishesh Yadav (Trainer) who always trained
me during my training. I am also thankful to the whole staffs of the “LANDMARK CARS.”
For providing valuable information about workshop and showroom. Special thanks are being
credited to Mr. Yogesh Panchal, floor workshop manager. I am also thankful to all supervisors
& technicians who were always remained helpful to me during my training.
At the last but not the least, I am very much thankful to my friends and all other
people who are directly or indirectly involved in it and helping me for the completion of my
industrial Training and report.
-Patel Jignal Bhupendrakumar

ABSTRACT
The purpose of industrial training is to train student for practical

knowledge of (Automobile) Vehicle and repaired any part or problem of vehicle
confidently.
To fulfil this purpose, I am trained in LANDMARK CARS Pvt Ltd.,

an Authorized Service Centre of MERCEDES BENZ INDIA (MBI) and this
report is about my different types of work done during the training. After, this
training my confidence level and practical knowledge has been increased and I
am confident that my skills and experiences are a great match for this
opportunity. From all over, I feel that industrial training is not only important for
automobile department but also it is important for every department to have the
individual practical training and to improve their skills because during industrial
training we get to learn many important things and also help us to improve Skills.
I include all the points of services which I have learnt in general
service and in major service.
LIST OF FIGURES
Fig 1.1 Carl Benz……………………………………………………………… 1

Fig 1.2 Gottlieb Daimler……………………………………………………… 1
Fig 1.3 Logo History………………………………………………………….. 2
Fig 1.4 M.B. First Car………………………………………………………… 3
Fig 2.1 A-class limousine……………………………………………………... 6
Fig 2.2 GLA ………………………………………………………………….. 7
Fig 2.3 CLS…………………………………………………………………… 8
Fig 2.4 C-class………………………………………………………………… 9
Fig 2.5 E-class………………………………………………………………… 10
Fig 2.6 S-class………………………………………………………………… 11
Fig 2.7 GLC…………………………………………………………………… 12
Fig 2.8 GLE…………………………………………………………………… 13
Fig 2.9 GLS…………………………………………………………………… 14
Fig 2.10 AMG GTS…………………………………………………………….. 15
Fig 2.11 MAYBACH Heritage………………………………………………… 16
Fig 4.1 Screw-driver set………………………………………………………... 22
Fig 4.2 Fix Spanner Set……………………………………………………….. 22
Fig 4.3 T- spanner set…………………………………………………………. 22
Fig 4.4 Ring spanner………………………………………………………….. 23
Fig 4.5 Align keys ……………………………………………………………. 23
Fig 4.6 Needle nose plier……………………………………………………… 23
Fig 4.7 Broad nose plier………………………………………………………. 24
Fig 4.8 Universal plier………………………………………………………… 24
Fig 4.9 Ratchets……………………………………………………………….. 24
Fig 4.10 Box socket…………………………………………………………….. 25
Fig 4.11 Box socket(small) ……………………………………………………. 25
Fig 4.12 Various distant………………………………………………………... 25
Fig 4.13 Small box socket holder………………………………………………. 25
Fig 4.14 Combination spanner…………………………………………………. 26
Fig 4.15 Outer plier…………………………………………………………….. 26
Fig 4.16 Torque wrench………………………………………………………... 26
Fig 4.17 Adjustable wrench…………………………………………………….. 26
Fig 4.18 Hook ………………………………………………………. 27
Fig 4.19 Vernier caliper ……………………………………………………….. 27
Fig 4.20 Magnet pen……………………………………………………………. 27
Fig 4.21 Universal joint………………………………………………………… 27
Fig 4.22 Safety gloves………………………………………………………….. 28
Fig 4.23 Cleaning brush………………………………………………………... 28
Fig 4.24 Hack-Shaw…………………………………………………………….. 28
Fig 4.25 Oil filter cap………………………………………………………… 29
Fig 4.26 Wire-bird pressure…………………………………………………….. 29
Fig 4.27 Sealant filler gun……………………………………………………… 29
Fig 4.28 Sealant removal blade………………………………………………… 29
Fig 4.29 Wheel box…………………………………………………………….. 30
Fig 4.30 Hammer ………………………………………………………………. 30
Fig 4.31 Brake piston puller …………………………………………………… 30
Fig 4.32 Refractometer…………………………………………………………. 30
Fig 4.33 Coolant leakage tester………………………………………………… 31
Fig 4.34 Depth gauge…………………………………………………………... 31
Fig 4.35 Retainer wrench………………………………………………………. 31
Fig 4.36 Xentry ………………………………………………………………… 32
Fig 4.37 Medtronic……………………………………………………………… 32
Fig 4.38 Battery charger ……………………………………………………….. 32
Fig 4.39 Oil suction machine…………………………………………………… 33
Fig 4.40 Transmission jack…………………………………………………… 33
Fig 4.41 Headlight adjuster……………………………………………………... 33
Fig 4.42 Gear oil filling machine……………………………………………….. 34
Fig 4.43 Brake bleeder………………………………………………………….. 34
Fig 4.44 Hydraulic lift ………………………………………………………….. 34
Fig 4.45 Active reception lift…………………………………………………… 35
Fig 4.46 Pneumatic gun………………………………………………………… 35
Fig 4.47 Tyre changing machine……………………………………………….. 35
Fig 4.48 Potential meter………………………………………………………… 36
Fig 4.49 Wheel alignment setup………………………………………………... 36
Fig 4.50 Ac gas machine……………………………………………………....... 36
Fig 5.1 Xentry…………………………………………………………………. 41
Fig 5.2 Engine oil……………………………………………………………… 42
Fig 5.3 Oil Filter………………………………………………………………. 42
Fig 5.4 O-ring………………………………………………………………….. 42
Fig 5.5 Air filter……………………………………………………………….. 43
Fig 5.6 Brake fluid…………………………………………………………….. 43
Fig 5.7 Brake bleeder………………………………………………………….. 44
Fig 5.8 Bleeding setup………………………………………………………… 44
Fig 5.9 Medtronic ……………………………………………………………... 44
Fig 5.10 Battery charger………………………………………………………... 44
Fig 5.11 Ac filter………………………………………………………………... 45
Fig 5.12 Refractometer………………………………………………………….. 46
Fig 5.13 Summer wash …………………………………………………………. 46
Fig 5.14 Special tool (vernier caliper & depth gauge) ………………………….. 47
Fig 5.15 Brake pad chamfering…………………………………………………. 47
Fig 5.16 Brake pad paste list……………………………………………………. 48
Fig 5.17 Headlight adjuster……………………………………………………... 48
Fig 5.18 Fuel filter……………………………………………………………… 49
Fig 5.19 Gear oil / Transmission oil…………………………………………….. 50
Fig 5.20 Pressure gauge………………………………………………………… 50
Fig 5.21 Gear oil filler………………………………………………………… 51
Fig 5.22 Setup of gear oil filling………………………………………………... 52
Fig 5.23 Break cleaner, plastic & rubber care, rust off………………………… 52
Fig 6.1 Location of water pump……………………………………………….. 53
Fig 6.1.2 Back view of water pump……………………………………………... 53
Fig 6.1.3 Water pump……………………………………………………………. 53
Fig 6.2 Location of injector……………………………………………………. 54
Fig 6.2.1 Damaged injector……………………………………………………… 54
Fig 6.2.3 New injector…………………………………………………………… 54
Fig 6.3 Cam shaft and engine drive chain…………………………………….. 55
Fig 6.3.1 Replacing drive………………………………………………………... 55
Fig 6.4 Door trim panel………………………………………………………... 56
Fig 6.4.1 Power window actuator……………………………………………….. 56
Fig 6.5 Shock absorber replacement…………………………………………... 57
Fig 6.5.1 Shock absorber………………………………………………………… 57
Fig 6.5.2 New shock absorber…………………………………………………… 57
Fig 6.6 Damaged charge air hose……………………………………………… 58
Fig 6.6.1 Location of charge air hose……………………………………………. 58
Fig 6.7 Engine lifter…………………………………………………………… 59
Fig 6.7.1 Engine mount(1) ……………………………………………………… 59
Fig 6.7.2 Engine mount(2) ……………………………………………………… 59
Fig 6.8 Location of oil cooler…………………………………………………. 60
Fig 6.8.1 Fuel filter housing……………………………………………………... 60
Fig 6.9 RPM sensor……………………………………………………………. 61
Fig 6.9.1 RPM sensor location…………………………………………………... 61
Fig 6.10 Car matting removed………………………………………………….. 62
Fig 6.10.1 Car matting drying…………………………………………………….. 62
Fig 6.10.2 Car matting……………………………………………………………. 62
Fig 6.10.3 Car matting removed (2) ……………………………………………… 63
Fig 6.10.4 Car matting removed (3) ……………………………………………… 63
Fig 6.11 Rear parking camera…………………………………………………... 64
Fig 6.11.2 Location of camera……………………………………………………. 64
Fig 6.12 Oil cooler……………………………………………………………… 65
Fig 6.12.1 Oil cooler back view…………………………………………………... 65
Fig 6.13 Seat belt……………………………………………………………….. 66
Fig 6.14 Stabilizer link………………………………………………………….. 67
Fig 6.14.1 Stabilizer link back view………………………………………………. 67
Fig 6.15 Sunroof actuating motor………………………………………………. 68
Fig 6.15.1 Roof top trim open…………………………………………………….. 68
Fig 6.15.2 Guide rail……………………………………………………………… 69
Fig 6.15.3 Guide rail (2) ………………………………………………………….. 69
Fig 6.15.4 Guide rail side view…………………………………………………… 69
Fig 6.15.5 Guide rail spring channel (in or out) …………………………………... 69
Fig 6.15.6 New guide rail………………………………………………………… 70
Fig 6.15.7 Damaged lock of guide rail……………………………………………. 71
Fig 6.16 Engine chamber……………………………………………………….. 72
Fig 6.16.1 Inside upper view (under chamber) …………………………………… 73
Fig 6.16.2 Sealant tube……………………………………………………………. 73
Fig 6.16.3 Sealant removal………………………………………………………... 73
Fig 6.16.4 Sealant filler gun………………………………………………………. 74
Fig 6.16.5 Chamber inner view (2) ………………………………………………. 74
Fig 7.1 Schematic Representation Of Contactor………………………………. 75
Fig 7.2 Variable sensor………………………………………………………... 76
Fig 7.2.1 Coolant temperature…………………………………………………… 76
Fig 7.3 Inductive sensor……………………………………………………….. 77
Fig 7.4 Schematic representation……………………………………………… 77
Fig 7.5 Hall effect principle…………………………………………………… 78
Fig 7.6 Piezo sensor…………………………………………………………… 79
Fig 7.7 Hot film sensor………………………………………………………... 80
Fig 7.8 Hot wire sensor………………………………………………………... 81
Fig 8.1 Bumper removal………………………………………………………. 82
Fig 8.1.1 Front overview………………………………………………………… 83
Fig 8.1.2 Radiator removal………………………………………………………. 83
Fig 8.1.3 Radiator………………………………………………………………… 84
Fig 8.1.4 Engine removal………………………………………………………… 85
Fig 8.1.5 Transmission…………………………………………………………… 86
Fig 8.1.6 Transmission disassembly……………………………………………... 85
Fig 8.1.7 Torque convertor………………………………………………………. 87
Fig 8.1.8 Removing chamber below crankshaft…………………………………. 87
Fig 8.1.9 Crankshaft inner view………………………………………………….. 88
Fig 8.1.10 Showing broken connecting rod……………………………………….. 88
Fig 8.1.11 Engine block showing pistons…………………………………………. 89
Fig 8.1.12 Crankshaft……………………………………………………………… 89
Fig 8.1.13 Crankshaft remove……………………………………………………... 90
Fig 8.1.14 Engine block damage…………………………………………………... 90
Fig 8.1.15 Damage engine block piece……………………………………………. 90
Fig 8.1.16 Broken connecting rod………………………………………………… 90
LIST OF TABLES
Table 2.1 Sindelfingen plant in Germany………………………… 5

Table 2.2 A-class limousine……………………………………… 6
Table 2.3 GLA…………………………………………………... 7
Table 2.4 CLS……………………………………………………. 8
Table 2.5 C-Class………………………………………………… 9
Table 2.6 E-Class…………………………………………………. 10
Table 2.7 S-Class…………………………………………………. 11
Table 2.8 GLC……………………………………………………. 12
Table 2.9 GLE……………………………………………………. 13
Table 2.10 GLS……………………………………………………. 14
Table 4.1 Hand tools……………………………………………... 22
Table 4.2 Power tools…………………………………………….. 32
Table 5.1 Service A……………………………………………… 38
Table 5.2 Service B………………………………………………. 38
Table 5.3 Service C……………………………………………….. 39
LIST OF CHARTS
Chart 3.1 Layout of Workshop…………………………… 19

Chart 3.2 Layout of Store ………………………………... 20
Chart 3.3 Organization chart……………………………… 21
TABLE OF CONTENTS
ACKNOWLEDGEMENT…………………………………………………... I
ABSTRACT………………………………………………………………….. II
LIST OF FIGURES………………………………………………………… III
LIST OF TABLES………………………………………………………….. IV
LIST OF CHARTS…………………………………………………………... VI
CHAPTER-1
INTRODUCTION OF MERCEDES BENZ………………………. 1
1.1 Introduction……………………………………………… 1
1.2 History of Mercedes Benz……………………………….. 1
1.3 Logo History……………………………………………. 2
1.4 Mercedes Benz First Car………………………………… 3
CHAPTER – 2
THE PRODUCTION NETWORK………………………………… 4
2.1 The Production Network: - The World-Wide Plants……….. 4
2.2 Sindelfingen/Germany………………………………………. 5
2.3 List of Cars…………………………………………………. 6
2.3.1 Mercedes Benz A-Class Limousine…………………... 6

2.3.2 Mercedes Benz GLA…………………………………. 7
2.3.3 Mercedes Benz CLS………………………………….. 8
2.3.4 Mercedes Benz C-Class………………………………. 9
2.3.5 Mercedes Benz E-Class………………………………. 10
2.3.6 Mercedes Benz S-Class……………………………….. 11
2.3.7 Mercedes Benz GLC………………………………… 12
2.3.8 Mercedes Benz GLE…………………………………. 13
2.3.9 Mercedes Benz GLS…………………………………. 14
2.4 Mercedes Benz AMG………………………………………. 15
2.5 Mercedes Benz Maybach Heritage………………………… 16
2.6 Description Of AMG………………………………………. 17
2.7 Description Of Maybach…………………………………… 18
CHAPTER – 3
WORKSHOP LAYOUT & ORGANIZATION CHART…… 19
3.1 Workshop Layout……………………………………………. 19
3.2 Store Layout ……………………………………………….. 20
3.3 Organization Chart………………………………………….. 21
CHAPTER – 4
TOOLS & EQUIPMENTS USED IN WORKSHOP…………….. 22
4.1 Hand Tools …………………………………………………. 22
4.2 Power Tools ………………………………………………… 32
CHAPTER – 5
TYPES OF MAINTENANCE & VEHICLE SERVICE…………. 37
5.1 Breakdown Maintenance…………………………………. 37
5.5.1 What Is Vehicle Breakdown Maintenance?..................... 37
5.1.2 Reasons for Vehicle Breakdown………………………... 37
5.2 Preventive Maintenance……………………………… 37
5.2.1 What Is Preventive Maintenance?...................................... 37
5.2.2 Types of Preventive Maintenance……………………... 37
5.2.2.1 Periodic Maintenance……………………………………. 37
5.2.2.2 Predictive Maintenance……………………………….... 38
5.3 Service…………………………………………………… 38
5.3.1 Service -A……………………………………………… 38
5.3.2 Service -B………………………………………………... 39
5.3.3 Service -C………………………………………………... 40
5.3.4 Service At 45,000 Km…………………………………… 40
5.3.5 General Repair…………………………………………... 40
5.4 The Parts Used in Service………………………………. 41
5.4.1 The Parts Used in Service -A………………………….... 41
5.4.2 The Parts Used in Service -B…………………………… 49
5.4.3 The Parts Used in Service -C…………………………… 50
CHAPTER – 6
WORK PERFORMED AT WORKSHOP………………………… 53
6.1 Major Work……………………………………………… 53
53
1. Water Pump…………………………………………..
54
2. Injector……………….………………………………..
55
3. Engine Drive Chain……………………………………
56
4. Power Window Actuating Motor………………………
5. Shock Absorber……………….………………………… 57
6. Charge Air Hose ……………………………………… 58
7. Engine Mounting………………………………………. 59
8. Water L-Bow / Inlet…………………………………… 60
9. RPM Sensor……………………………………………. 61
10. Car Matting Removal…………………………………… 62
11. Rear Parking Camera………………………………….. 63
12. Oil Cooler Housing……………………………………. 65
13. Seat – Belt……………………………………………… 66
14. Stabilizer Link…………………………………………… 67
15. Roof Guide Rail………………………………………… 68
16. Chamber…………………………………………………. 72
CHAPTER – 7
SENSORS & TYPES OF SENSORS……………………………… 75
7.1 What Are Sensors?.......................................................... 75
7.2 Types of Sensors………………………………………. 75
7.2.1 Contactors………………..……………………………. 75
7.2.2 Variables Sensors…………………………………… 76
7.2.3 Inductive Sensors……………………………………. 77
7.2.4 Hall Effect Sensors……….…………………………. 78
7.2.5 Piezo Sensors…………………………………………. 78
7.2.6 Hot Film Sensors…………………………………… 79

7.2.7 Hot Wire Sensors…………………………………… 81
CHAPTER – 8 82
CASE STUDY………………………………………………. 82
8.1 Case Study on Engine Dis-assembly……………………
OVERALL ANALYSIS OF INTERSHIP……………………. 91
CONCLUSION……………………………………………………… 92
REFERENCE ………………………………………………………. 94
ANNEXURE - 2……………………………………………………. 95
REQUEST LETTER…………………………………………. 96
SURPRISE VISIT PHOTO.……………………………………… 97

Project Id: - 216162
CHAPTER - 1
Introduction of Mercedes-Benz
Introduction
 Mercedes-Benz is a global automobile marque and a

division of the German company Daimler AG. The
brand is known for luxury vehicles, buses, coaches, and
Lorries. The headquarters is in Stuttgart, Baden-
Württemberg. The name first appeared in 1926 under
Daimler-Benz.
 Mercedes-Benz traces its origins to Daimler-Motoren-

Fig: - 1.1 Carl Benz’s
Gesellschaft's 1901 Mercedes and Karl Benz's 1886
Benz Patent-Motorwagen, which is widely regarded as the first gasoline-
powered automobile. The slogan for the brand is "the best or nothing".
History of Mercedes-Benz
 Mercedes-Benz traces its origins to Carl Benz’s

creation of the first petrol-powered car, the Benz
Patent, financed by Bertha Benz and patented in
January 1886, and Gottlieb Daimler and
engineer Wilhelm Maybach's conversion of a
stagecoach by the addition of a petrol engine later
that year.
Fig: - 1.2 Gottlieb Daimler
 The Mercedes automobile was first marketed in 1901 by Daimler-

Motoren-Gesellschaft (Daimler Motors Corporation).
GUJARAT TECHNOLOGY UNIVERSITY 1 A.D. PATEL INSTITUTE OF TECHNOLOGY

 Emil Jellinek, an Austrian automobile entrepreneur who worked with

DMG, created the trademark in 1902, naming the 1901 Mercedes 35 HP
after his daughter Mercedes Jellinek.
 Jellinek was a businessman and marketing strategist who promoted

"horseless" Daimler automobiles among the highest circles of society in
his adopted shome, which, at that time, was a meeting place for the "Haute
Volée" of France and Europe, especially in winter. His customers included
the Rothschild family and other well-known personalities.
 But Jellinek's plans went further: as early as 1901, he was selling Mercedes
cars in the New World as well, including US billionaires Rockefeller,
Astor, Morgan and Taylor. At a race in Nice in 1899, Jellinek drove under
the
 Pseudonym "Monsieur Mercédès", a way of concealing the competitor's

real name as was normal in those days. The race ranks as the hour of birth
of the Mercedes-Benz brand. In 1901, the name "Mercedes" was registered
by Daimler-Motoren-Gesellschaft (DMG) worldwide as a protected
trademark. The first Mercedes-Benz brand name vehicles were produced
in 1926, following the merger of Karl Benz's and Gottlieb Daimler's
companies into the Daimler-Benz company on 28 June of the same year.
 Logo history
 In June 1909, Daimler-Motoren-Gesellschaft (DMG) registered both a

three-pointed and a four-pointed star as trademarks, but only the three-
pointed star was used. To DMG, the star symbolized Gottlieb Daimler's
aims for universal motorization: on land, water and in the air.
Fig:-1.3

Mercedes Benz First Car
Fig: - 1.4
 1886 Benz Patent Motor Car.
 The Benz Patent-Motorwagen ("patent motorcar"), built in 1885, is

widely regarded as the world's first production automobile, that is, a
vehicle designed to be propelled by an internal combustion engine. The
original cost of the vehicle in 1885 was 600 imperial German marks,
approximately 150 US dollars (equivalent to $4,086 in 2017).
 The vehicle was awarded the German patent number 37435, for
which Karl Benz applied on 29 January 1886. Following official
procedures, the date of the application became the patent date for the
invention once the patent was granted, which occurred in November of that
year.
 Benz unveiled his invention to the public on 3 July 1886, on the Ringstrasse
in Mannheim.

CHAPTER - 2
The Production Network
The production network: The worldwide plants

 The worldwide production network of Mercedes-Benz Cars extends to four
continents, has been considerably expanded in recent years and continues
to grow. Here is an overview followed by details of the Sindelfingen plant.
 Vehicle Plants:-
 Bremen/Germany
 East London/South Africa
 Hambach/France
 Iracemápolis/Brazil (from 2016)
 Kecskemét/Hungary
 Rastatt/Germany
 Sindelfingen/Germany
 Tuscaloosa/USA
 Passenger car assembly locations (e.g. Completely/semi–knocked-down:

delivered parts kits are locally assembled):-
 Bangkok/Thailand
 Ho Chi Minh City/Vietnam
 Jakarta/Indonesia
 Pekan/Malaysia
 Pune/India

Sindelfingen/Germany
Plant foundation 1915
Production Mercedes Benz CLS, CLS Shooting Brake, E-Class (Saloon and
Estate), S-Class, S-Class Coupé, Mercedes-AMG
GT,Mercedes-Maybach S-Class
General Manager Michael Bauer
Site area in sq. m. 2.950,697
Built-on area in sq. m. 1.299,463
Number of employees at the

location/MBC
2014 25,948/25,513
2013 26,134/22,108
2012 25,947/22,161
Table: - 2.1
 The Sindelfingen plant is Daimler AG's largest production plant.

 The Mercedes-Benz Technology Centre includes the Research &
Development unit for new Mercedes-Benz models.
 The Sindelfingen plant is the competence centre for the production of
executive and luxury-class vehicles.
 The Sindelfingen location is one of the world's leading competence centres
in the automotive sector for safety, innovation and design.
 The 20 millionth vehicle since the plant was founded will leave the
production line in the 100th anniversary year 2015.

Fig: - 2.1
Mercedes-Benz A-Class
Ex-Showroom Price in New Delhi
42-44 Lacs* - 30.94 Lakh*
Engine(cc) 1.3 Litre Petrol (Turbo-Charged),

2.0 Litre Diesel
Max Torque 320Nm

@1400-3000rpm
Engine Description 4 Cylinder 134.10bhp 16V In-Line Diesel

Engine
ARAI (Automotive Research

Association of India) Mileage 14.17 Km/litre
Max Power
134.10bhp@3600-4400rpm
147 bhp
Seating
5
Transmission Type
7 Speed Automatic

Fig: - 2.2
Mercedes-Benz GLA
45-49 Lacs Lakh* - 33.03 Lakh*
Engine(cc)
2.0 Litre Diesel43
Max Torque
300Nm@1600-3000rpm
400Nm
Engine Description
4 Cylinder

Association of India) Mileage 19.0 kmpl
15 Km/litre
Max Power
@3600-4400rpm
187.74 bhp
Seating 5
Transmission Type
8 Speed Automatic

Fig: - 2.3
Mercedes-Benz CLS
85 Lacs
Engine(cc) 2143
2.0 Litre
Max Torque
500Nm50Nm@1400-3400rpm
Engine Description 4 Cylinder2.2-litre 170bhp 16V In-Line

Diesel Engine

16.13 Km/Litre0 kmpl
Association of India) Mileage
Max Power
250 bhp0bhp@3400-4000rpm
Seating 4
Transmission Type
9 Speed Automatic

Fig: -2.4
Mercedes-Benz C-Class (Sedan)

50-72 Lacs.74 Lakh* - 75.2 Lakh*
Engine(cc)
2.0 Litre (Petrol & Diesel)
Max Torque
370Nm475nm@2250-5000rpm
Engine Description
2.0-litre 170bhp 16V In-Line petrol Engine
4 Cylinder
Association of India) Mileage 12.6 Km/Litre
Max Power
345 bhp@6000rpm
Seating
5
Transmission Type 7 Speed Automatic

Fig: - 2.5
Mercedes-Benz E-Class
67-85 Lacs
Engine(cc) 2.0 Litre Petrol

3.0 Litre Diesel82
Max Torque
600 Nm1750-4500rpm
Engine Description
V6

Association of India) Mileage 8-12 Km/Litre
Max Power
281 bhp
Seating 5
Transmission Type 9 Speed Automatic

Fig: -2.6
Mercedes-Benz S-Class
1.60-1.70 CrLakh - 1.5 Cr*
Engine(cc) 3.0 Litre

5.0 Litre
6.0 Litre
Max Torque
1000 Nm
Engine Description
V6 / V8 / V12
ARAI (Automotive Research 10.98 kmpl

Association of India) Mileage 5-7 Km/Litre
Max Power
612 bhp5750-6500rpm
Seating
4
Transmission Type
9 Speed Automaticatic

Fig: -2.7
Mercedes-Benz GLC
62-68 Lacs
Engine(cc)
2.0 Litre (Diesel / Petrol)
Max Torque
400 Nm
Engine Description
4 Cylinder
ARAI (Automotive Research 12.6 Km/Litre

Max Power
197 bhp0.89bhp@5000rpm
Seating
5
Transmission Type
9 Speed Automatictomatic

Fig:- 2.8
Mercedes-Benz GLE
85 Lacs -1.25 Cr
Engine(cc)
3.0 Litre
Max Torque
700 Nm
Engine Description
6 Cylinder
ARAI (Automotive Research 9 Km/Litrepl

Max Power
325 bhp62.07bhp@5500-6000rpm
Seating
5
Transmission Type 9 Speed Automatictomatic

Fig:- 2.9
Mercedes-Benz GLS
1.16-2.47 CrLakh* - 1.02 Cr*
Engine(cc)
3 Litre96
Max Torque
730 Nm2000-4200rpm
Engine Description
V6

Association of India) Mileage 5-9 Km/Litrekmpl
Max Power
550 bhp384.87bhp@6100rpm
Seating
4-7
Transmission Type
9 Speed Automatic

Fig:- 2.10
Mercedes-AMG
Two men with a passion for motorsport and engineering founded AMG. Hans
Werner Aufrecht and Erhard Melcher saw an opportunity on every wide open
road, an invitation in every curve, an affirmation in every victory: for more
performance and more power. Today, this passion is infused into the very DNA
of every Mercedes-AMG. Just like its numerous successes on racetracks around
the world.
Two men, three letters.

 Over 50 years ago, a unique company arose as a result of an
overwhelming passion for motorsports.
 A as in Aufrecht, M as in Melcher and G as in
Großaspach: the names behind these three letters were the starting
point for the rapid development from a two-man operation to a global
brand. The story starts in the 1960s: the two engineers, Hans Werner
Aufrecht and Erhard Melcher, were working on the 300 SE racing
engine in the Development Department at Daimler-Benz until the
company discontinued all motorsports activities.
 Yet the hearts of Aufrecht and Melcher beat unabated for motorsports.
In Aufrecht’s house in Grossaspach, they spent their spare time further
honing the performance of the engine.

MAYBACH
HERITAGE
Fig: - 2.11
Maybach
 Maybach Motorenbau (German: [ˈmaɪbax]) is a defunct German
car manufacturer that today exists as a sub-brand of Mercedes-Benz. The
company was founded in 1909 by Wilhelm Maybach and his son,
originally a subsidiary of Luftschiffbau Zeppelin GmbHand was itself
known as Luftfahrzeug-Motorenbau GmbH until 1912.
 In 1960, Maybach was acquired by Daimler-Benz. The brand returned as a

standalone ultra-luxury car brand in the late 20th century, sharing
significant components with Mercedes-Benz. After slow sales, the
Maybach name returned once again as a sub-brand of Mercedes-Benz,
which is owned by Daimler AG. Daimler currently produces an ultra-
luxury edition of the Mercedes-Benz S-Class under the Mercedes-
Maybach brand.
 The company first built an experimental car in 1919, introduced as a

production model two years later at the Berlin Motor Show. Between 1921
and 1940, the company produced a variety of opulent vehicles, now
regarded as classics. The company also continued to build heavy-duty
diesel engines for marine and rail purposes.

Mercedes-AMG
Type Gesellschaft mit beschränkter Haftung
 Automobile manufacturing Engine manufacturing.

Industry
Fate acquired by DaimlerChrysler (1999), and operating under Daimler

AG
Predecessor AMG Motorenbau und Entwicklungsgesellschaft mbH
Founded Burgstall a. d. Murr, Germany (1967)
Headquarters Affalterbach, Germany
Area served Worldwide

Key people Tobias Moers (CEO)
Products  AMG A
 AMG C
 AMG CLA
 AMG CLS
 AMG E
 AMG G
 AMG GLA
 AMG GLC
 AMG GLE
 AMG GLS
 AMG GT
 AMG S
 AMG SL
 AMG SLC
Services Research and development

Type Division
Industry Automotive
Fate Absorbed by Mercedes-Benz as a sub-brand
Successor Mercedes-Maybach
Founded 1909
Founder Wilhelm Maybach
Headquarters Stuttgart, Germany
Products Luxury vehicles
Parent Daimler AG

CHAPTER – 3
Workshop Layout & Organization Chart
Chart: - 3.1

STORE LAYOUT
Chart: - 3.2

Organization Chart
Head of Workshop (HOD)
e Manager Vice Manager
Job Controller/Floor Body Shop Manager Advisers

Manager
DT CST CMT
Diagnosis Technician (Certified Service Tec.) (CERTIFIED
MAINTAINENCE TEC.)
JOB Paint Body

Repair Repair
Technician. Controller. Tec. Tec.
Washing team.
Parts. Warranty. VPC

Vehicle parking Control.
Chart: - 3.3

CHAPTER - 4
Tools and Equipments used in Workshop
Hand Tools. Table 4.1

Figure. Name. Use.
Fig. 4.1
Screw Driver To remove & tight
set. screw from parts.
To loose & tight

Fig. 4.2
Fix Spanner Set. Bolt from any
parts.
To connect Socket
Fig. 4.3
T-Tommy & extension to
(3-Size) remove & fit the
bolt.

Figure. Name. Use.
Fig. 4.4 To loose & tight bolt

Ring Spanner Set. from any parts.
Fig. 4.5 To open star bolts

Align Keys. which are not with
any spanner
Fig. 4.6 To remove the

Needle Nose Plier. cotton pin and
damage bolt and cut
wire end etc.

Figure. Name. Use.
Fig. 4.7 To Press the bud connector or

Broad Nose plier to remove any kind of push
button etc.
Fig. 4.8 To hold something or to open

Water Pump Plier or pipe any kind of lock from hose
wrench or universal plier pipe.
Fig. 4.9
Ratchets (Small & Big )
Use to remove bolts with box
spanner.

Figure. Name. Use.

Fig. 4.10 Use to open bolts
Box Socket.
with hexagonal
(Big ratchet)
shape.
Fig. 4.11
Box Socket. Use to open small
(Small ratchet) hexagonal bolts.
Fig. 4.12
Distant Use to extend box
(Small, medium, socket to bolt.
long, Slim,)
Fig. 4.13
To open box bolts
Small box
Socket holder with hand.
(Spanner)

Figure. Name. Use.
Fig. 4.14 To lose and tight

Ring + fix bolt from any part.
Spanner.
Fig. 4.15 To remove the

Outer Plier cotter pin and
damage bolt.
Fig. 4.16 To tight bolts at

Torque range.
specific torque.
Fig. 4.17
To lessen or fit the
Adjustable
wrench. tie-rod.

Figure. Name. Use.
To remove clip from

Fig. 4.18
Hooks hose pipe and
different parts.
Fig. 4.19 To measure

Vernier thickness of disc.
To remove fallen
Fig. 4.20
Magnet pen. bolts in compact
areas.
Use for complicated

Fig. 4.21
Universal joint bolts at different
(spanner) angle.

Figure. Name. Use.
Fig. 4.22 To wear every

Safety gloves. time when
working.
Fig. 4.23 To clean Disk hub

Cleaning Brush. or any rusted area
to be clean.
Fig. 4.24 To cut any part or

Hack Saw. to make groves on
bolt.

Figure. Name. Use.
Use to remove oil filter

Fig. 4.25
Oil Filter cap. ( different size)
Fig. 4.26
Wire Bud Presser. To press bud connecter.
Fig. 4.27 Use to fill sealant in

Sealant filler gun. chamber and other parts.
Fig. 4.28
To remove stick sealant
Sealant remover
blade. at the chamber or other
parts.

Figure. Name. Use.
Fig. 4.29
To remove wheel bolts.
Wheel box (17)
Fig. 4.30 To remove any fixed

Hammer. bolt or to give shape to
anything.
Fig. 4.31
To move brake piston
Brake Piston Puller.
backwards.
Fig. 4.32
To measure coolant
Refractometer.
gravity.

Figure. Name. Use.
Fig. 4.33
To create
Coolant leakage
Tester. pressure in the
coolant reservoir
and check the
leakage.
To measure the
Fig. 4.34 depth of brake
Depth Gauge.
pad.
To hold the
Fig. 4.35
propeller shaft at
Retainer Wrench.
it position.

Power Tools.
Table 4.2
Figure. Name. Use.
Fig. 4.36
Mercedes- To diagnose
Benz whole vehicle
Diagnosis system.
Tab.
Fig. 4.37
Medtronic To test the
(Battery battery
tester) condition.
Fig. 4.38
Battery To charge the
charger. battery.

Figure. Name. Use.
Fig. 4.39
Oil Suction Machine. To remove oil by suction.
Fig. 4.40
Transmission Jack. Use to remove Gear box or to
change Mount etc..
Fig. 4.41
Head light adjuster. To adjust headlight.

Figure. Name. Use.
Fig. 4.42
Gear Oil Filling machine. To fill up gear oil.
Fig. 4.43
Brake Bleeder. To Replace Brake Oil.
Fig. 4.44
Hydraulic Lift. To lift up the vehicle.

Figure. Name. Use.
Fig. 4.45
Active Reception To Check
Lift. Under Body
of vehicle.
Fig. 4.46
Pneumatic Air gun. To blow of
the dust or use
any kind of
work.
Fig. 4.47
Tyre Changing To change the
Machine. tyre of the
vehicle.

Figure. Name. Use.
Use to measure voltage or the

Fig. 4.48
Potential meter resistance in the wire.
Fig. 4.49
Wheel Alignment Setup. Used for wheel alignment of
any vehicle.
Fig. 4.50
AC Gas Machine To Recover Ac Gas.

CHAPTER - 5
Types of Maintenance & Vehicle Service.
5.1 Breakdown Maintenance.
5.1.1 What Is Vehicle Breakdown Maintenance?

A vehicle breakdown is the mechanical failure of a vehicle in such a way that the
underlying problem prevents the vehicle from being operated. Vehicle
Breakdown can occur for a large number of reasons.
5.1.2 Reasons for Vehicle Breakdown.

 Alternator.
 Battery dead.
 Broken V-Belt.
 Engine Overheating.
 Flood water intake.
 Wiring Cutting.
5.2 Preventive Maintenance.
5.2.1 What Is Preventive Maintenance?

It is a regular maintenance (cleaning, inspection, oiling, etc...), to retain the
healthy condition of vehicle and its parts. It is further divided into periodic
maintenance and predictive maintenance. Just like human life is extended by
preventive medicine, the Vehicle parts service life can be prolonged by doing
preventive maintenance.
5.2.2 Types of Preventive Maintenance.

5.2.2.1 Periodic Maintenance.

It is time-based maintenance consists of periodical inspection, servicing and

cleaning of vehicle and replace parts to prevent sudden failure and process
problems.
5.2.2.2 Predictive maintenance.
This is a method in which the service life of a part is predicted based on inspection
or diagnosis. Compare to periodic maintenance, predictive maintenance is
condition based maintenance. It manages trend value by measuring and
analysing.
5.3 Service.
In Mercedes-Benz Service is divided into 4 stages.
Note: - There is no free service provided by the Mercedes-Benz.
 15,000 Km Service.
 45,000 Km Check-up Service.
 General Repair (GR)
15,000 service is the basic service. After that moving on to further service Adds-
on the different service item which is require to maintain at specific kilometres
which is mentioned in further table.
I. Service A (15,000 Km).
Service-A
 General Check-up.  Battery Test.
 (It Consist of over view of
vehicle.)
 Diagnosis (initial Test)  Brake pad Chamfering.
 Measurement.
 Engine Oil Replace.  Coolant Gravity Test.
 Oil Filter Replace. (If Required)  Diagnosis.
 Dust filter Replace. (If Required )  Repair Check Up if fault found.
 Air filter Replace. (If Require )  Diagnosis (Final Test)
 Ac Filter Replace. (If Required)  Washing.
 Brake Bleeding.

 Windshield washer (Summer

Wash.)
Table: -5.1
Note: - The items displayed “if Required” are either Replace or Cleaned.
This is the basic 15,000 km Service-A. If any Item is required to replace then it
is added to estimate and if customer approves then added to the vehicle.
II. Service B (30,000 Km).
Service-B
 Diagnosis (initial Test)  Fuel Filter Replace.

 Engine Oil Replace.  Brake pad Chamfering.
 Measurement.
 Oil Filter Replace. (If not changed  Coolant Gravity Test.
in 1st service)
 Dust filter Replace. (If not changed  Diagnosis.
in 1st service)
 Air filter Replace. (If not changed in  Repair Check Up if fault found.
1st service)
 Ac Filter Replace. (If not changed in  Diagnosis (Final Test)
1st service)
 Brake Bleeding.  Washing.
 Windshield washer (Summer
Wash.)
Table: - 5.2
Note: - In this Service the things Marked “If not changed in 1st service” are either
replace or cleaned.
This is the Service-B in which the additional item to be replace is the things
which are not replaced in Service-A and the Fuel filter.

III. Service-C (60,000 Km).
Service-C
o (It Consist of over view of
vehicle.)
 Diagnosis (initial Test)  Transmission/Gear Oil Change.
 Engine Oil Replace.  Fuel Filter Replace.
 Oil Filter Replace.  Brake pad Chamfering.
o And measurement.
 Dust filter Replace.  Coolant Gravity Test.
 Air filter Replace.  Diagnosis.
 Ac Filter Replace.  Repair Check Up if fault found.
 Brake Bleeding.  Diagnosis (Final Test)
 Windshield washer (Summer  Washing.
Wash.)
Table: - 5.3
Note: - This is Service-C in this Service all things are need to be replace
(Compulsion).
This is Service-C in this the addition item need to be replace is the
transmission/gear oil.
IV. Service At 45,000 Km.

 Service at 45,000 Km. is the basic Check-up provided by
Mercedes-Benz.
 In this service the general check is done and the parts which are
damage or need to be replace or check, is estimate given and
inform to customer that this are need to be replace. And if
Customer approves than that part is replaced or repaired.
V. General Repair (GR).
 It is the Service Provided to Customer if customer is facing any

kind of problem in the vehicle weather it is an interior matter or

the driving related or any kind of noise coming from vehicle or

any message coming on the cluster.
 In this if there is the noise problem, then the test drive is taken by
the expert technician and the problem is to be found out and then
it is informed to customer that this part is damage so noise is
coming from the vehicle so it needs to be replaced so if customer
approves then it is replaced.
5.4 The parts or the items used in the service.

I. Service-A. (15,000 Km).
Fig. 5.1 Diagnosis Tab.
 This is the diagnosis tab which is specially designed for Mercedes Benz.
 The diagnosis tab is used to Diagnosis the whole Vehicle and scans each and
every control unit of the vehicle.
 It Shows the Fault in any control unit of the vehicle with complete details and
also shows the location of the fault.
 It is also use for adaptation if any part which is replaced in the vehicle.

 This is the engine Oil Used in Mercedes-Benz.

 Grade:- SAE OW-40 MB 229.5 & 5W-40
Fig. 5.2 Engine Oil.
Fig. 5.3 Oil Filter. Fig. 5.4 O-Rings.
 Material: - Cellulose Cartridge.

 Type: -Cartridge Style.
Fig.5.5 Air Filter.

 Material: - Cotton Gauze.

 Shape: - Panel.
Note: -
 Shape changes according to vehicle type.
 This filter has the ability to clean air up to 99%.
 Grade: - Dot 4 Plus

 MB 331.0
Fig. 5.6 Brake Fluid.

1. Filler Cap.
2. Pressure Gauge.
5 4 3. Brake Fluid
Reservoir Tank Cap
(vehicle).
1
4. Power Wire.
5. Pressure hose pipe.
2
3
6. Container.
7 7. Brake bleeder tank.
Fig. 5.7 Brake Bleeder. Fig. 5.8 brake bleeding

Setup.
C Fig. 5.10 Battery Charger.
Fig. 5.9 Medtronic.
A. Printer.
B. Medtronic/(Battery E. Use To charge the Battery.
Tester).
C. Positive (+) Clamp.
D. Negative (-) Clamp.

 Use to measure battery

voltage.
 We have to enter which type
and how much volt battery is
used.
 It gives message. Weather its
good, or to charge. Or to
replace the battery.
Type: - Charcoal Filter.

Material: - Cellulose With active charcoal.
Fig. 5.11 Ac Filter.

Fig. 5.12 Refractometer.
 To test Coolant density.

 The unit in refractometer used is in “Degree Celsius”.
Temp. [°C] Density [g/cm³]

-40 1.1682
-35 1.165
-30 1.1616
-25 1.1582
-20 1.1547
-15 1.1514
-10 1.1481
-5 1.1448
 The Minimum Density of coolant is -25 Degree Celsius [1.1582 g/cm3.]

 If it’s below – 25 Degree Celsius then the whole coolant must be replaced.
 This is the Mixture Added to Windshield Washer
tank which work as cleaning agent with water to
clean the windshield.
Fig: - 5.13 Summer Wash

Fig. 5.14 Special tool (Vernier calliper and depth gauge).

 These Special tools are used to measure thickness of brake pad, brake disc and
Tyres.
 So with the help of this it is decide whether to replace brake pad, brake disc, Tyre
or not.
A. Depth Gauge.
 Use of measuring Depth of tires & Brake pad.
 Min. thickness of brake pad: - 3mm.
 Min. thickness of tire: - mark on tire.
B. Vernier Caliper.
 Used for measuring thickness of brake disc.
 Min. thickness of FR disc:- 29.4 (depend on size of disc used)
 Min. thickness of RR disc:- 11.4 (depend on size of disc used)
 In each service brake pad

are needed to be chamfer
so that noise doesn’t
come while braking.
 The calliper are also need
to be clean with brush.
Fig. 5.15 Brake Pad Chamfering.

 Paste is added to
remove noise while
braking.
 This is the list of
brake pad paste.
 Each and every
model has different
paste to be added.
 In some models it’s
not require to add
paste.
Fig. 5.16 Brake Pad Paste List.
 This is the Headlight

Adjuster.
 It is use to adjust the
headlight which is out of
focus.
Fig 5.17 Headlight adjuster

II. Service-B (30,000 Km).

 As Mentioned earlier that each Service has an additional Item added to be
replace according to the kilometre driven.
 So, Service-B has the Fuel Filter to be replace.
1. Inlet
2. Outlet.
Fig. 5.18 Fuel Filter.

 Fuel Filter also known as Diesel filter.
 It is been replace in every Service-B.
 The Inlet Port Is bigger than Outlet Port.
III. Service-C (60,000 Km).

 The Service-C adds on the Gear Oil to be replace.
 It is been replace at every 60,000 kilometres.
 The power tool use to replace Gear Oil is called.

 Grade: - Universal
HypoidGetrielbeol (ATF DTC)
 SAE 75W-85
 SAE: - Society of automobile
engineers.
 75W:-75 degree Fahrenheit (F)
Winter.
The first number of the designation specify the
oil viscosity at cold temperature, the second
number specifies the oil viscosity at high
temperature.
 5G-tronic Gearbox: - Red Colour Gear
oil.
 7G-tronic Gearbox: - Blue Colour Gear
Fig. 5.19 Gear Oil / Transmission Fluid. oil.
 9G-tronic Gearbox: - Gold Colour Gear
oil.
Fig. 5.20 Showing Pressure of 2 Bar in Gear oil

Filler Gauge at which gear oil is filled.
Fig. 5.20 Showing pressure 2 bar.

A. Oil Filer Cap.
B. Pressure Gauge.
C C. Digital Level
D
Meter.
D. Pressure Hose Pipe.

A
E. Container.
B F. Fluid level Scale.

E
 Transmission Fluid
Fig. 5.21 Gear Oil Filler is filled up at 2 bar
pressure.
 Fig 5.22 shows

Gear oil filling
setup.
Fig. 5.22 Gear oil filling Setup.

 Cleaning and lubricating sprays.

 This are the Cleaning and
Lubricating sprays used in the
Mercedes-Benz.
 Brake Cleaner: - Use to clean stuff.

 Plastic & Rubber Care: - Use on
plastic and rubber parts when noise
coming from them.
 Rust off: - Added to parts which are
having rust on the surface.
Fig. 5.23 Brake Cleaner.

Plastic & rubber Care.
Rust Off.

CHAPTER - 6
Work Performed at Workshop.
 Major Work.
What is Major Work?
Major Works in automobile means the part or the system which is to be given the
main concern. Parts Such as Shock absorber, water pump, Stabilizer Link Etc. …
This things are to be check whether they are at good condition or Not. If they are
not proper or there is any problem in that part then the customer to be given alert
that it would to need to repair or change the part immediately or it would cause
more problem to the vehicle.
1) Water Pump.
 Water Pump Replace (Non -Repairable).

Reason: - Leakage.
Fault Identification: - Slight Faded Yellow Marks on the Wall of Water
pump and outside area.
Location: -
Fig. 6.1 Location of Water pump. Fig. 6.1.2 Back View of Water pump
Fig. 6.1.3 Water pump

2) Injector.
 Injector Replace (Repairable).
Reason: - Not spray not proper/Blockage.
Repair Procedure: - By cleaning it with cleaning agent.
Fault Identification: - Low Pickup.
Physical Fault Identification: - Tip of injector Block.
Location: - In between the Cam Shafts.
Fig. 6.2 Location of injector. Fig. 6.2.1 Damaged Injector.
 To Remove Injector all the Wiring cables are need to remove on top of
engine.
 It consisting the fitting of 2 nuts.
Fig. 6.2.3 New Injector.

3) Engine Drive Chain.

 Engine Drive Chain Replace (Non - Repairable).
Reason: - Lock broken.
Fault Identification: - Hard noise while engine running.
Physical identification: - Broken lock of Chain.
Location: - Connected to End of Cam Shaft.
Torque applied to tensioner bolt: -
Fig 6.3 Cam Shaft and Engine drive chain.
 It Consist of tensioner bolt which is to be release

to remove the drive chain.
 If the one Lock of the Chain is Broken then the
whole chain needs to be replaced.
 To remove chain drive first the wiring is to be
removed from the top of tappet cover and then all the
injectors are need to be removed.
 Then the tappet cover need to be remove and
then the both the cam shaft.
 To remove camshaft there are 8 Clamp named A-
H to be fitted in that order.
Fig.6.3.1 Replacing Drive

4) Power Window Actuating Motor.

 Power Window Actuating Motor Replace (Non-Repairable).
Reason: - Short.
Fault Identification: - Power window not functioning.
Location: - Under door trim panel.
Fig. 6.4 Door Trim Panel.
Fig. 6.4.1 Power window Actuating motor.
 To open PW actuating motor whole door trim panel needs to be

open.
 Trim panel consist of 3 Screw and 1 Clam Strip and it’s fitted
with Push buttons.
 Actuating motor is fitted with 2 bolts.

5) Shock Absorber
 Shock absorber Replace (Non- Repairable)
Reason: -Leakage
Fault Identification: - Leakage visible on the shock absorber (visual).
Location: - Under Wheel Housing.
Torque applied on the fitting bolts: - 100nm @ 90 degree.
Fig. 6.5 Shock Absorber replacement.
 Shock Absorber Consist of 5 bolt fitting

1 at bottom,
1 at middle and
3 at bushing.
 Shock Absorber is by using special tools called
spring holder which are different for each model.
Fig. 6.5.1 Shock Absorber Fig 6.5.2 New Shock Absorber

6) Charge Air Hose.

 Charge air Hose Replace (Non- Repairable).
Reason: - Wear/Leakage.
Fault Identification: - Leakage of coolant (visual) Wear Cut marks on
pipe (visual)
Location: - Fig. 6.15
Fig. 6.6 Damaged Charge air Hose.
 Charge air Hose is fitted with the 2 Round Lock Clip at both ends.
Fig. 6.6.1 Location of Charge air hose

7) Engine Mounting.
 Engine Mounting Replace (Non Repairable).
Reason: - Leakage.
Fault Identification: - Leakage Marks on Mounting or else Engine
Vibration On steering.
Special Tool Used: - Engine Lifter/Holder.
Fig. 6.7 Engine Lifter (Special tool).
Fig. 6.7.1 Engine Mount (1) Fig. 6.7.2 Engine Mount (2)
 Engine Mount Consist the fitting of 3 bolt 2 at bottom and 1 and top.

8) Water L-Bow/Inlet.
 Water L-Bow/Inlet Replace.

Reason: - Leakage.
Fault Identification: - Leakage found under Fuel filter Housing (visual).
Location: -
Fig. 6.8 Location of L-bow
Fig. 6.8.1 Fuel Filter Housing
 To remove L-Bow the EGR Cooler and the vacuum Tank is to be removed.
 It consists of 3 bolt fitting and in old ones 4 bolt fitting.

9) RPM Sensor.
 RPM Sensor Replace (Repairable).
Reason: - Electrical Short Out or Wire Cut down or Socket Broken.
Identification: - Fault Found in diagnosis tab or cut out marks on wire
(visual) or broken socket (visual).
Location: - Wheel housing wall/Under wheel arch.
Fig. 6.9 RPM Sensor.
Fig. 6.9.1 RPM Sensor Location.
 RPM sensor are used to measure the engine speed.

 RPM sensor Uses Hall effect sensor For Measurement.

10) Car Matting Removal.

 Car Matting Removal for Check and Drying.
 Reason: - Flood Water Check.
 So Need to remove weather there is water inside the car or not.
 So the front matting are removed to check and if there is water then the
whole car matting are removed for drying.
Fig. 6.10 Car Matting Removed. Fig. 6.10.1 Car matting Drying.
Fig. 6.10.2 Car Matting.

Fig. 6.10.3 Car Matting Removed -2 Fig. 6.10.4 Car Matting Removed-3
 Car matting are also removed if there is any shortage in the main fuse box.
 Car matting are just having push buttons or just get fitted under support.
11) Rear Parking Camera.

 Rear Parking Camera Replace (Repairable).
Reason: - Old Camera not Working / Wire Cut down.
Fault Identification: - Not showing anything on display while taking
reverse. And no fault in wiring of camera or showing camera fault in the
diagnosis tab.
Location: - Under the Trunk Lock.

Fig. 6.11 Rear Parking Camera.
Fig. 6.11.1 Location of Rear Parking Camera
•Reverse parking camera used for parking the vehicle easily.

•Rear parking camera can be repairable if there is fault in the wire/ wire
being cut.
•Then the wire can be shouldered and using wire taped it can be repair or
you can use the bud connector for the cut down wire.

12) Oil Cooler/Oil Filter Housing.

 Oil Cooler / Oil filter Housing replace.
Reason: - Leakage.
Fault Identification: - Leakage (Visual).
Location: - Below EGR Cooler (according to Vehicle model).
Fig. 6.12 Oil Cooler.
 Oil Cooler Contain 2 inlet and 2 out let.

 1st Inlet/outlet for oil &
 2nd Inlet/outlet for coolant.
 Oil Inlet/outlet are small holes.
 Coolant inlet/outlet are bigger holes.
 To remove Oil cooler EGR Cooler and
Vacuum Tank needs to be removed. And also
throttle body.
Fig. 6.12.1 Oil Cooler (back view)

13) Seat Belt.

 Seat Belt Removal and Refitting or Replace.
Reason: - Wear or any kind of problem.
Fault Identification: - Seat Belt Wear out or the pretensioner motor
Problem.
Location: - B – Pillar (LH/RH).
Torque on seat belt bolts: -
Fig. 6.13 Seat Belts.
 To remove the seat belts the B-pillar trim panel needs to be remove.
 Trim panel are having metal clips for the fitting.
 The seat belts are having fitting of 2 bolts one in middle and one at bottom.
 Pretensioner motor having 2 sockets for controlling.

14) Stabilizer Link (Torsion Bar).

 Stabilizer Link replace (non-Repairable).
Reason: - Leakage or Bush Wear.
Fault Identification: - Leakage marks on bush or the Bush wear out.
Location: - Connected to the lower arm.
Fig. 6.14 Stabilizer Link. Fig. 6.14.1 Stabilizer Link (BV)
 Stabilizer link Leakage Marks.

 Stabilizer link having fitting of 2 bolts.
 Top: - connected to shocker and
 Bottom: - connected to lower arm.

15) Roof Guide Rail.

 Roof Guide Rail Replace (Non - Repairable).
Reason: - Damage / Noise while opening.
Fault Identification: - Noise from the roof while opening or closing
(Hearable) or Damage Guide Rail (Visible).
Location: - Underneath the Glass.
Fig. 6.15 Sunroof Actuating motor
Fig. 6.15.1 Roof Top Trim Open.

Fig. 6.15.2 Guide Rail (1)
Fig. 6.15.3 Guide Rail (2)
Fig. 6.15.4 Guide Rail (Side View)
 Guide rail Have 3 Spring Channel All three are connected to other guide
rail and these spring passes through 2 motors for their movement.

Fig. 6.15.5 Guide Rail Spring Chanel (In/Out)
Fig. 6.15.6 New Guide Rail.
 To Remove the Guide Rail There must be Whole roof top trim needs to be
remove.
 Then there are 4 bolts on each side of guide rain on under roof top.
 Roof top trim having metal clips which are used for fittings.
 Guide rail is having one small bolt at the end.
 For removing rail both the actuating motors needs to be removed, which
are present under the roof trim as shown in fig.6.45 and 6.48.
 Before removing rail wind deflector and the soft sunroof winder needs to
be removed.
 So, this is the procedure for removing Sunroof Guide Rail.

Fig. 6.15.7 Damaged lock of Guide Rail.
 Damaged Lock of guide rail which doesn’t allow to close the roof
properly and makes noise while closing.
 And Glass roof is supported and fitted on guide rail with 2 bolts at each
side.
 After all completion the adaptation of guide rail is done for proper
working when button is pressed.

16) Chamber
Chamber Remove.
Reason: - Oil Leakage.
Fault Identification: - Oil Leakage Seen Through the Joint Area.
Location: - Under engine Plate.
Fig. 6.16 Engine Chamber.
 To Reomove chamber we have to set the vehicel on the lift and remove all
the wheels.
 After that we have to remove engine cover plate which is under the vehicle.
 Afterwards we have to remove all the engine oil from the vehicle through
the oil chamber.
 After that we have to remove all the bolts of the chamber (13 bolts).
 We also needed to remove the v-belt.

Fig. 6.16.1 Inside Upper View (under Chamber).
 After that we have to seprate the chamber As it have partition as shown in

fig. 6.57 with the help of spanner.
 As by this way the chamber is removed.
 As there is a leakage the Sealant of the chamber must be replace for leakage
stopage.
Fig. 6.16.2 Sealant tube Fig. 6.16.3 Sealant Remover.

 With the help of sealant remover we can remove old sealant.
Fig. 6.16.4 Sealant Filler Gun.
 With the help of sealant gun we can put the sealant tube in it and Stick
the sealant to the chamber.
Fig. 6.16.5 Chamber inner View (2)

CHAPTER – 7
Sensors & Types of Sensors.
What Are Sensors?
A sensor is a device, module, or subsystem whose purpose is to detect events or
changes in its environment and send the information to other electronics,
frequently a computer processor.
A sensor is always used with other electronics, whether as simple as a light or as
complex as a computer.
Each and every control unit uses different types of sensors.
 Types of sensors: -
 Contactors.
 Variable sensor.
 Inductive sensor.
 Hall-effect sensor.
 Piezo sensor.
 Hot-film sensor.
 Hot-wire sensor.
1. Contactors.
 Contactors are making break sensors.
 This contactor change of state is cause by position, level,
temperature or pressure.
 Contactors are often used to actuate a warning light.
 Contactors can also give signal to the computer.
 There are variable symbols for the contactors depending on the
parameters influencing the state of the contactors.
Fig. 7.1 Schemetic Representation of a contactor.

Checking contactors:
Continuity or not depending on the physical state of the sensor.
2. Variable Sensor.
 Variable resistor are sensors which vary continuously.
 Thermistors are resistors whose value varies with the temperature.
 The potentiometer and the rheostat comprise a resistive strip.
 A metallic cursor moves over the resistive strip.
 The computer measures the voltage between the cursor and one end of
the resistive strip.
 The rheostat can also be used to vary the amperage of the current
passing through the electrical consumers.
 This type of sensors are used for measuring coolant temperature.
Fig. 7.2.1 Coolant Temperature.
Fig. 7.2 Variable Sensor
Checking Thermistor
 Sensor supply voltage.
Change in resistance with temperature.
 In case of negative temperature coefficient (NTC) Resistor, the
resistance decreases when the temperature increases.
 In case of positive temperature coefficient (PTC) Resistor, the
resistance increases when the temperature decreases.

3. Inductive sensor.
 The inductive sensor employs the principles of magnetic induction.
 The pulse generator consists of a coil wound around a permanent
magnet.
 The modification of the magnetic field creates an induced current in the
coil.
 The pulse generator is often used with a toothed wheel.
 When a tooth moves closer, the signal increases.
 When a tooth moves away, the signal decreases.
Fig. 7.3 Inductive Sensor.
Fig. 7.4 Schematic Representation.
 Inductance is an electrical property of a coil. Movement of the core

modifies the coil’s inductance.
Checking the pulse generator.

 Verification of the air gap between the sensor and the target.
 Sensor Resistance.

4. Hall Effect Sensor.

 Hall-effect sensor works on the principle of Hall Effect.
 The Hall effect is the production of a voltage difference (the Hall
voltage) across an electrical conductor, transverse to an electric
current in the conductor and to an applied magnetic field perpendicular
to the current. It was discovered by Edwin Hall in 1879.[1] For clarity,
the original effect is sometimes called the ordinary Hall Effect to
distinguish it from other "Hall effects" which have different physical
mechanisms.
 The Hall Effect sensor is used to detect the cam shaft position or the In
the RPM sensor.
Fig. 7.5 Hall Effect Principle.
Checking the Hall Effect sensor.

 Sensor Power Supply.
5. Piezo Sensors.
 Piezo sensors a piezoelectric crystal produces a voltage when it is
subjected to press conversely, a voltage applied to a piezoelectric
crystal modifies its volume. The piezoelectric transducer employs the
piezoelectric effect.

Fig. 7.6 Piezo Sensor.
 An impact or a pressure applied to the piezoelectric transducer creates

a voltage across the terminals of this transducer.
 The piezo resistive transducer consists of a piezo resistive cells
electronics stage.
 A pressure variation causes a variation in the resistance of the piezo
resistive cell.
 The electronics stage concerts this variable resistance into a variable
volte the piezo resistive transducer is used to measure a pressure.
Checking the piezoelectric transducer.
 Continuity and insulation of the transducer’s wiring harness.
 Transducer power supply by the computer.
6. Hot-Film Sensor.
 Hot-film sensors there exists a type of temperature sensor which
measures temperature changes on a surface.
 The hot-film sensor employs the following principle: a resistor is heated
with a stable current and this resistor reaches a stable temperature, an
air flow over this resistor reduces the resistor temperature. The current
passing through the resistor must then increase to maintain the
temperature constant.

 The current variation required to maintain a resistor temperature stable

corresponds to the air flow.
 The hot-film sensor measures the current required to maintain the
temperature.
 The hot-film sensor is used to measure the air flow entering the engine.
Fig. 7.7 Hot-Film Sensor.
Checking the hot-film sensor

 Sensor power supply by the computer sensor power consumption.

7. Hot-Wire Sensor.
 The hot-wire sensor employs a thermistor.
 The hot-wire sensor is used in particular to measure the oil level in the
engine.
Fig.7.8 Hot wire Sensor.
Checking the hot-wire sensor (e.g., oil level sensor)

 Sensor resistance.
 Check continuity of the circuit between instrument panel and sensor.
The ultrasonic transducer employs the principle of the sonar. The photodiode
converts a luminous signal into an electrical signal. The photodiode is used in the
infrared transmitters for central locking of doors and boot. The resistance of a
photo resistor varies according to the luminosity.

CHAPTER – 8
Case Study
Case Study on Engine Disassembly.
 The reason for the engine disassembly is the engine breakdown.

 Reason for engine breakdown was the Flood Water entered to the engine
compartment also Called Hydro lock.
 So let’s start with the engine break down Vehicle Checking.
 Point to cover in checking whether the water has entered into engine or not.
 WARNING: - Never try to start the vehicle which has engine Break down
Because Hydro lock.
 Points Mentioned below.
 Check air intake whether there is water or not.
 Check Vehicle floor by removing mating.
 To check weather connecting rod is damaged or not, then rotate the engine
by driving the main pulley with the help of spanner with hands.
 If the engine rotates then the connecting rod is ok. If doesn’t then
connecting is bent or damaged and it might have also caused damage to the
engine block.
 So the process of engine disassemble is shown through figures below.
Fig. 8.1 Bumper Removal.

 So, the First step is to remove the Front Bumper of the Vehicle.
Fig. 8.1.1 Front Overview
 So, after removing bumper next step is to remove the head lights.
 After that the main clap in the front is removed also called radiator support.
 After removing radiator support all the hose pipe are to be removed
connection from radiator and then all other connections are removed.
Fig: - 8.1.2 Radiator Removal

Fig. 8.1.3 Radiator. Removal
 So, after removing the connections the radiator is been removed.

 So, after removing the radiator the engine joining bolts are removed.
The engine is having the fitting of 6 or 7 bolts according to size of the
engine.
 And after removing bolts all the electrical connecting sockets are
removed.
 After wards with the help of the engine lifting jack the engine is been
pulled out.
Fig. 8.1.4 Engine removal.

 With the help of engine crane the engine is just pulled forward so
that transmission box can come out.
Fig. 8.1.5 Transmission.
 The next step is to dismantle the transmission box from the engine
so that engine can be moved to engine room for disassembly work.
Fig. 8.1.6 Transmission disassembly.
 For removing transmission from the engine, it consists of fitting of

round about bolts (13-16 bolts).
 The middle rod type thing is the main driving shaft of gear box.

Fig. 8.1.7 Torque Converter (fluid Coupler).
 Torque converter is present in the transmission box and helps to

transfer rotating power from a prime mover, like an internal
combustion engine, to a rotating driven load. In the vehicle with an
automatic transmission, the torque converter connects the power
source to the load.
 After removing transmission, the engine is taken to the engine room
for disassemble.
 After wards the from the engine jack the engine is transferred to the
engine lifter. Engine lifter if the lift which helps to hold engine and
can rotate engine 360 degree so we don’t have to move crane again
and again.
Fig. 8.1.8 Removing Chamber/Oil pan below crank shaft.

Fig.8.1.9 Crank shaft view
 After removing oil pan you will

able to see crank shaft and check
whether there any damage to
connecting rod or not.
 Figure 7.11 is showing broken

connecting rod.
 As we found out there is the broken
connecting rod so we need to remove
pistons of engine.
Fig.8.1.10 Showing broken Connecting rod.

 Afterwards we have to removal all the components of the engine one

by one such as pulleys, turbo, clamps, cam shaft etc.
 As we removal all the parts we will left with the engine block itself.
Fig 8.1.11 Engine Block Showing pistons.
 So, in this fig. is shown that piston and piston cylinder have got rust due
to the water. So, to remove rust we have to spray 2 cans of rust off and
fill the cylinder with the oil for 1 day.
 After that we have to remove the crank shaft for removing the pistons.
Fig. 8.1.12 Crank Shaft.

Fig.8.1.13 Crank Shaft Removed.
 So after removing the crank shaft we found that block was also damaged,
a small piece fell out of the block.
Fig 8.1.14 Showing Engine Block damage.
 As the engine block is

damaged the engine is send
for repairing.
Fig. 8.1.15 Damaged engine block piece.

Fig. 8.1.16 Broken Connecting rod.
 After removing the pistons, we found the connecting rod was broken into
half.
 As the connecting rod is broken into half due to hydro lock, so piston needs
to be replaced.
 So, this was the complete disassembly of the engine.

Overall Analysis of Internship
 My Likes:
 I like the behaviour of the whole staff of the workshop.
 They were very kind to me and another Trainee.
 Availability of all spare parts.
 The workplace is very clean and all safety things are Present in it.
 There is wide infrastructure of workshop.
 All Type of General & Special Tools are available in the Workshop.
 The vehicle is delivered at the promised time.
 PEP 180 Premiere Express Prime working very fast and delivered car of general
service in only 180 Minutes.
 My Dislikes:
 Some Equipment & Tools are not clean.
 The oil Feeding machine is not working properly.
 Some Pneumatic gun is not work properly.

CONCLUSION
After successful completion of training, I am able to perform different types of services in the
vehicle which are described as follow:
I can do General Services of Mercedes Benz Cars. Further I am able to do running

service of Mercedes Benz Cars like (Including Brake Pad Change, Brake Booster Change,
Clutch Plate Change, Oil Chamber Removing, Top-Up Brake Paddle, Auto Tensioner Change,
Timing Belt Change, Tie-Rod Change, Knuckle Change, Shock Absorber Change, Shock
Absorber Bush Change, Gear Box Removing, Engine Valve Timing, Nozzle Testing, Radiator
Change, intercooler change, clutch release bearing change, diesel injector change, heater coil
change).
The report has an introduction to industrial training. I presented information about the
engine, transmission and modern features. In future, experiences of this industrial training will
very helpful to my career.

REFERENCE: -
1. https://www.carwale.com/mercedes-benz-cars/s-class/
2. www.wikipedia.com/mercedesbenz/history/mbgermany/images.download.html/
3. https://www.mercedes-benz.co.in/passengercars/mercedes-benz-cars/models/s-
class/saloon-wv223/explore.html
4. https://www.google.com/search?q=gle+mercedes&oq=gle+mer&aqs=chrome.0.0i433
i512j0i457i512j0i512l5j69i57j0i512l2.2862j0j7&sourceid=chrome&ie=UTF-8
5. https://www.mercedes-amg.com/en/footer/about-us/history.html
6. https://en.wikipedia.org/wiki/Mercedes-
Benz#:~:text=The%20Mercedes%20automobile%20was%20first,after%20his%20dau
ghter%20Mercedes%20Jellinek.
7. https://www.motorauthority.com/news/1124539_the-origins-of-mercedes-three-
pointed-star-logo
8. https://en.wikipedia.org/wiki/Carl_Benz
9. https://ythi.net/abbreviations/english/what-does-amg-mean-what-is-the-full-form-of-
amg-
2/#:~:text=Aufrecht%20Melcher%20Grossaspach%20(AMG)%20is,small%20Germa
n%20town%20named%20Grossaspach.
10. https://www.shop.mercedes-
benz.co.in/inventory/used?utm_medium=google&utm_source=cpm&utm_content=se
arch_alwayson_raodster_usedcar_generc_jan22%3fcsref%3dmc-sem_cn-
IND_WS_MBC_Generic_Individual_Luxury_Exact_AO_ci-Google_si-g_pi-kwd-
355276455755_cri-591487595730_ai-
used%20mercedes%20benz%26kpid%3dgo_cmp-15922990745_adg-
130452704610_ad-591487595730_kwd-355276455755_dev-c_ext-
&gclid=CjwKCAjw9qiTBhBbEiwAp-
GE0d_qshJBkc8ZkXlViwMXlhHDkpJcvFIe8uCJl1Vfb2rFJ3kaUs

REFERENCE BOOKS: -
1. http://landmarkcarsgujarat.com/E-
Class/?utm_source=Google_Search&utm_medium=CPC&utm_campaignname=Sok|
Benchmark|Search|C-Class&gclid=CjwKCAjw9qiTBhBbEiwAp-
GE0agVj5_6stX3mS0XnfwjAOBycNCSloO1Dm7EPkWQzj8UI-
_Kt6S6LhoCk5oQAvD_BwE
2. https://www.amazon.in/Mercedes-Benz-Buses-Reference-Guide-
Collectors/dp/1599714396
REFERENCE PERSON: -
Guided by: -
1. Mr. Yogesh Panchal (Workshop Manager)
2. Mr. Vishesh Yadav (Technician)
3. Dr. Nimit Patel (Guidance Faculty)

ANNEXURE – 2

REQUEST LETTER

SURPRISE VISIT PHOTO
Date: - 04/04/2022
Fig: - Surprise Visit

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INDUSTRIAL TRAINING

PATEL JIGNAL BHUPENDRAKUMAR

In partial fulfilment for the award of the degree of

Automobile Engineering Department

A.D. PATEL INSTITUTE OF TECHNOLOGY, ANAND

Gujarat Technological University, Ahmedabad.

New Vallabh Vidhyanagar, Vitthal Udyognagar, Anand, Gujarat 388121

project entitled “INTERNSHIP” has been carried out by PATEL JIGNAL

BHUPENDRAKUMAR under my guidance in partial fulfilment for the degree

of bachelor of engineering in AUTOMOBILE ENGINEERING, 8TH Semester

of Gujarat Technological University, Ahmedabad during the academic year 2021-

Dr. Nimit Patel Dr. Sanjay Patel

Internal Guide Head of the Department

New Vallabh Vidyanagar, Vitthal Udyognagar, Anand, Gujarat 388121

entitled Internship/Project submitted in partial fulfilment for degree of Bachelor

of Engineering in Automobile Engineering to Gujarat Technological University,

Ahmedabad, is a bonafide record of original project work carried out by me at

Name of the Student Sign of Student

First of all, I am very much grateful to my college “A.D. PATEL INSTITUDE

OF TECHNOLOGY, ANAND” And especially DR. VISHAL N. SINGH, Principal for

giving me the Opportunity to complete my industrial training in renowned Automobile service

Further, I would like to extend my vote of thanks to Dr. SANJAY M. PATEL

& technicians who were always remained helpful to me during my training.

industrial Training and report.

-Patel Jignal Bhupendrakumar

The purpose of industrial training is to train student for practical

To fulfil this purpose, I am trained in LANDMARK CARS Pvt Ltd.,

Fig 1.1 Carl Benz……………………………………………………………… 1

Table 2.1 Sindelfingen plant in Germany………………………… 5

Chart 3.1 Layout of Workshop…………………………… 19

LIST OF FIGURES………………………………………………………… III

INTRODUCTION OF MERCEDES BENZ………………………. 1

1.2 History of Mercedes Benz……………………………….. 1

1.3 Logo History……………………………………………. 2

1.4 Mercedes Benz First Car………………………………… 3

THE PRODUCTION NETWORK………………………………… 4

2.1 The Production Network: - The World-Wide Plants……….. 4

2.3 List of Cars…………………………………………………. 6

2.3.1 Mercedes Benz A-Class Limousine…………………... 6

2.3.3 Mercedes Benz CLS………………………………….. 8

2.3.4 Mercedes Benz C-Class………………………………. 9

2.3.5 Mercedes Benz E-Class………………………………. 10

2.3.6 Mercedes Benz S-Class……………………………….. 11

2.3.7 Mercedes Benz GLC………………………………… 12

2.3.8 Mercedes Benz GLE…………………………………. 13

2.3.9 Mercedes Benz GLS…………………………………. 14

2.4 Mercedes Benz AMG………………………………………. 15

2.5 Mercedes Benz Maybach Heritage………………………… 16

2.6 Description Of AMG………………………………………. 17

2.7 Description Of Maybach…………………………………… 18

WORKSHOP LAYOUT & ORGANIZATION CHART…… 19

3.1 Workshop Layout……………………………………………. 19

3.2 Store Layout ……………………………………………….. 20

3.3 Organization Chart………………………………………….. 21

WORK PERFORMED AT WORKSHOP………………………… 53

6.1 Major Work……………………………………………… 53

6. Charge Air Hose ……………………………………… 58

8. Water L-Bow / Inlet…………………………………… 60

10. Car Matting Removal…………………………………… 62