HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION

FACULTY OF INTERNATIONAL EDUCATION

GRADUATION INTERNSHIP REPORT

AT DONG NAM BO AUTOMOBILE JOINT STOCK

COMPANY - HYUNDAI NGOC AN

NGUYEN TRONG PHUNG

Student ID: 20145011

Major: AUTOMOTIVE ENGINEERING TECHNOLOGY

Supervisor: HUYNH QUOC VIET, Ms.

Ho Chi Minh City, August 2024

 THE

SOCIALIST REPUBLIC OF VIETNAM

Independence – Freedom – Happiness

Ho Chi Minh City, August 9, 2024

INSTRUCTOR'S REVIEW
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SUPERVISOR

(Sign with full name)

 CONTENTS
CHAPTER I: INTRODUCTION TO Hyundai COMPANY/ TC MOTOR NGOC
AN.................................................................................................................................................

1.1 Introduce about the company...........................................................................................

1.2 Vision and Mission.............................................................................................................

1.3 Infrastructure and equipment...........................................................................................

1.3.1 Equipment in the workshop........................................................................................

1.3.2 Maintenance and repair workshop..............................................................................

1.3.3 Body and paint workshop...........................................................................................

1.3.4. Services at Hyundai/ TC MOTOR NGOC AN.......................................................

CHAPTER II. INTERNSHIP CONTENT.............................................................................

2.1 The practice.......................................................................................................................

2.2 Safety at work...................................................................................................................

2.3 Service Operations Internship........................................................................................

2.3.1 Maintenance service activities..................................................................................

2.3.2 General repair service activities...............................................................................

2.3.3 Body and paint service activities..............................................................................

2.3.4 Car wash service activities.......................................................................................

CHAPTER III. CONCLUSION AND RECOMMENDATIONS........................................

3.1 Conclude............................................................................................................................

3.2 Recommendations and suggestions.................................................................................

3.2.1 About the internship company..................................................................................

3.2.2 About outside work..................................................................................................

3.2.2 About internship management..................................................................................

 LIST OF FIGURE

Figure 1. HYUNDAI COMPANY/ TC MOTOR NGOC AN

Figure 2. Room kit SST

Figure 3. Battery charger

Figure 4. Refrigerant gas charging machine

Figure 5. KTV's tool cabinet

Figure 6. KTV's 3-compartment wardrobe

Figures 7. Exhaust gas analyzer.

Figure 8. Near and far beam tester

Figure 10. Repair workshop

Figure 11. Quick service

Figure 12. Place of bronze-paintin

Figure 14. Paint mixing room

Figure 15. Paint curing booth

Figure 16. Repair command

Figure 17. Six steps of service process

Figure 18. Inspection form

Figure 19. Pre-filled oil shelf

Hình 20. Scissor Lift

Figure 21. Tire inflation

Figure 22. Draining engine oil

Figure 23. Filling brake fluid

Figure 24. Brack fluid extraction

Figure 25. Gasoline additives

Figure 26. Engine additives

Figure 27. Removing the wheel

Figure 28. Cleaning the disc brakes

Figure 29. Cleaning drum brakes

Figure 30. SST for pressing brake piston

Figure 31. Cleaning the disc brake system

Figure 32. Brake system cleaning solution

Figure 33. Brake pad grinding

Figure 34. Final inspection of the brake system

Figure 35. Injector cleaning solution

Figure 36. Cleaning the combustion chamber

Figure 37. Replacing the fuel pump

Figure 38. Widening the puncture

Figure 39. Apply glue and stick tire patch

Figure 40. Technician removing tire from rim

Figure 41. Rim after tire removal

Figure 42. Replace the tire

Figure 43. PDI Checklist 1

Figure 44. PDI II Checklis

Figure 45. Spray specialized cleaning solution into the gas nozzle

Figure 46. The old steering rack is lowered for replacement.

Figure 47. Genuine new steering rack set from Hyundai

Figure 48. Install the electric power steering motor on the new steering rack (Depending on the
vehicle model, the electric power steering position will be different)

Figure 49. Installing the new steering rack into the bracket, ready to install on the vehicle

Figure 50. Remove the damaged compressor from the vehicle for inspection and replacement.

Figure 51. Old compressor (left) and new compressor

Figure 52. Reinstall the pulley into the new compressor.

Figure 53. Installing the new compressor into the vehicle

Figure 54. Reinstall the belts onto the pulleys, start the engine and check operation.

Figure 55. Removing the balance rod on the vehicle

Figure 56. Replace new balance rod and check

Figure 57. Engine compartment wiring harness (genuine spare part)

Figure 58. Proceed to remove parts in the engine compartment to replace the wiring harness

Figure 59. Engine compartment wiring harness fuse box

Figure 60. Complete engine compartment wiring harness replacement, reinstall components and
jack, start engine to test vehicle operation

Figure 61. Checking the brake caliper and disc surface quality

Figure 62. Checking the brake pads

Figure 63. Checking brake pad wear

Figure 64. After a long period of use, the brake disc will wear unevenly, reducing braking
efficiency.

Figure 65. The piston in the brake after a long time of use has been scratched and needs to be
replaced to ensure braking efficiency

Figure 66. Checking the rear brake caliper and cupen

Figure 67. KTV has lowered the gearbox.

Figure 68. Wheel alignment machine

Figure 69. Nitrogen pump

Figure 70. Wheel balancing machine

Figure 71. Activities at the copper workshop

Figure 72. Scrub bar

Figure 73. Foudation

Figure 74. Sandpaper grades for different base layers

Figure 75. Tape for painting process

Figure 76. The process of the technician peeling off the paint and lowering the eyelid.

Figure 77. Putty application process and surface inspection

Figure 78. Masking process with masking glue, preparing to spray primer
Figure 79. Spraying primer

Figure 80. Checking the primer surface, preparing for the color painting stage

Figure 81. Protective gear before entering the paint room

Figure 82. Paint and clear coat guns

Figure 83. Polishing tool

Figure 84. Spraying water on the car body

Figure 85. Spraying foam to wash the car

Figure 86. Cleaning the body and wheel area

Figure 87. Vacuuming the car floor

Figure 88. Car wash machine

Figure 89. Tire polishing

 INTRODUCTION

Our country is on the path of strong and rapid industrial development. Therefore, science
and technology in general and the automotive engineering industry in particular play a very
important role in industrial development. The automotive engineering industry is gradually
growing and affirming its importance in daily life, production, industry and society. Therefore,
it requires training engineers with high knowledge and professional qualifications to meet the
increasing needs of modern society.

To meet the high demands of domestic and international engineering enterprises as it is

today, the Business Internship subject helps students to both study and practice, helping students
consolidate their knowledge and core foundation to quickly meet the needs of enterprises,
contributing to building a strong national industry. Realizing that, right from when we are
students, we need to strive, cultivate knowledge, experience and constantly learn to use it as a
stepping stone for ourselves in the future.

Business internship is an opportunity for students to experience memorable challenges,

helping us to contact and rub against reality; get acquainted and apply the knowledge we have
learned into practice. Thereby, we can draw lessons, expand our career path, and form our own
orientation in the future. I would like to sincerely thank all the leaders of Dong Nam Bo
Automobile Joint Stock Company - Hyundai Ngoc An for creating conditions to help me
complete my work well during the internship. Due to the limited internship time, there are
inevitably shortcomings. We look forward to receiving comments and help from teachers so that
our report can be more complete.
 THANK YOU

During the internship at HYUNDAI/ TC MOTOR NGOC AN, we had the opportunity to
immerse ourselves in a professional and dynamic working environment. Through that, the group
has accumulated a lot of valuable practical experience, improved working skills and practiced
professional style.

The group would like to sincerely thank the Board of Directors, the Deputy Director of
Service and all the company's staff for creating favorable conditions and enthusiastic support
throughout the internship. The dedicated guidance of the technicians has helped us better
understand the working process and specialized knowledge. I wish the company to develop
more and more, training more good technicians to meet the increasing demands of the market.

The group would also like to express our deep gratitude to the school, the Faculty of
Mechanical Engineering and Mr. Huynh Quoc Viet for creating conditions for students to have
the opportunity to intern at a prestigious enterprise like HYUNDAI/ TC MOTOR NGOC AN.
The knowledge and experience gained during the past time will be valuable for students in their
future careers.

We know that during the internship, the group still had many shortcomings. We hope that
the company will sympathize and create conditions for me to learn and improve myself further
in future opportunities.

Sincerely thank you

 CHAPTER I: INTRODUCTION TO HYUNDAI COMPANY/ TC MOTOR
NGOC AN

1.1 Introduce about the company

Figure 1. HYUNDAI COMPANY/ TC MOTOR NGOC AN

In 1994, Dong Sai Gon Store was established with the function of specializing in trading,
distributing and maintaining imported commercial automobiles under the HYUNDAI brand.

In 1998, Vietnam entered the stage of industrialization and modernization, integrating

with the development trend of the country as well as affirming its position and legal status in the
market, NGOC AN COMPANY LIMITED was officially established.

In 2004, In June 2004, realizing the development potential of the automobile industry in
the future, life is increasingly developing, the demand for owning imported cars of the people is
increasing day by day. Faced with that great opportunity but also full of challenges, the Board of
Directors of Ngoc An Company decided to establish Dong Sai Gon Trading and Service Joint
Stock Company (HNA) According to the business license issued by the Department of Planning
and Investment on June 28, 2004 with the function of importing and directly distributing
Hyundai branded vehicles from Korea.

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 In 2005, with its efforts and continuous development, HNA has been trusted by
HYUNDAI Group to become: "Official authorized station for warranty and repair of
HYUNDAI vehicles" in Vietnam. The system is under HYUNDAI worldwide.
In 2009, gaining the complete trust of customers. With the desire to serve customers
better and better, the Showroom - Hyundai Saigon headquarters was newly built and officially
put into operation from August 2, 2009. Located at 327 National Highway 13, Hiep Binh Phuoc
Ward, Thu Duc District, Ho Chi Minh City. Currently, this place has become an official 3S
Dealer and is the leading address in the field of business and distribution of Hyundai branded
cars.

1.2 Vision and Mission

Vision
With the aspiration to become the best dealer in the world, HNA strives to always
maintain the leading position in the field of business, distribution and import of cars in the
HYUNDAI system in Vietnam.
HNA wishes to create a Vietnamese brand, demonstrating the intellectual stature and
pride of Vietnam in the international arena.
Mission
For customers: Providing HYUNDAI vehicles and world-class services. In addition to
the outstanding quality values in each product and service, there are cultural messages to satisfy
the legitimate needs of customers.
For employees: Building a professional, dynamic, creative and humane working
environment. Creating high income conditions and fair development opportunities for all
employees through training courses and vocational competition programs...
For society: Harmonizing business interests with social interests. Actively contributing to
community-oriented activities to demonstrate civic responsibility and national pride.

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 1.3 Infrastructure and equipment
Hyundai Ngoc An Service Workshop is located at:
No. 327 QL13, Thu Duc, HCMC. According to Vietnamese standards with main areas:
quick repair area, general repair area and body and paint area, beauty area, car polishing, with
facilities committed to meeting the latest standards of the Hyundai factory, can receive warranty
and maintenance of many Hyundai vehicles at the same time. Invested with advanced
equipment imported from Europe such as: engine balancing machine, tire machine, gearbox oil
change machine, gas recovery machine, ... Along with engine repair rooms, paint mixing room,
spare parts room, quick paint room - paint drying and many other modern equipment such as:
3D steering angle adjustment system, 4-post, 2-post lift system, ... to meet all repair needs of
customers with fast service and the best quality. A perfect service system from warranty,
maintenance, professional repair, genuine spare parts to enthusiastic and thoughtful after-sales
policy will bring satisfaction to even the most demanding customers.

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 1.3.1 Equipment in the workshop
The company is fully equipped with necessary equipment such as: lock set, full tip set,
force lever, automatic lever, oil filter puller, air gun, air gun, diagnostic machine, combustion
chamber cleaning machine, battery charger, gas charging machine...

Figure 2. Room kit SST

Figure 3. Battery charger

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Figure 4. Refrigerant gas charging machine

Figure 5. KTV's tool cabinet

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Figure 6. KTV's 3-compartment wardrobe

Figures 7. Exhaust gas analyzer.

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Figure 8. Near and far beam tester

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 Figure 9. Air Filter Cleaning Dust Blower

1.3.2 Maintenance and repair workshop.

With 10 bays equipped with modern equipment, repair and maintenance services always
ensure the best quality for customers in the most optimal time.

Figure 10. Repair workshop

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 Figure 11. Quick service
1.3.3 Body and paint workshop

Figure 12. Place of bronze-paintin

Figure 13. Quick paint booth

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Figure 14. Paint mixing room

Figure 15. Paint curing booth

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1.3.4. Services at Hyundai/ TC MOTOR NGOC AN

Repair and regular maintenance of the company's cars.

Replace genuine spare parts (warranty).
Paint, repair, and change the color of all types of cars.
Polish the car surface.
Car washing.

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 CHAPTER II. INTERNSHIP CONTENT
2.1 The practice

During the internship at Hyundai/TC MOTOR NGOC AN, in addition to professional

exposure to repair, maintenance, and painting services, we also had the opportunity to learn
about working style in the corporate environment. First of all, it is personal awareness in the
collective. During the internship at the company, we realized that in addition to professional
skills, personal awareness also plays an extremely important role in the overall success of the
entire company. When a customer's car comes to the dealership for service, it needs to go
through many different stages, from the first stage of reception to the final stage of delivering
the car to the customer. Because of these many stages, sometimes there will be situations where
there is no coordination between the staff of each stage, leading to delays in the delivery of the
car to the customer. Therefore, to avoid affecting the company's general process, if the
technician evaluates that the service vehicle is slower than the expected delivery time, the
technician will contact the team leader/foremanager and CVDV to agree on the time and notify
the customer to finalize the delivery time. In addition, dedication to work is also a lesson that
we have had the opportunity to learn. During the internship at the company, the technicians
always reminded us to be meticulous in our work, even the smallest tasks such as checking tire
pressure. Especially with vehicle safety systems such as the brake system, the technician must
focus on the current job, whether we have tightened the brake caliper screws or cleaned the
brake pads properly, thereby avoiding unnecessary mistakes, affecting the customer's
experience or even their lives when participating in traffic.

2.2 Safety at work

Occupational safety is an important concept in the labor process, aiming to protect the
health and life of workers. According to Clause 2, Article 3, Law on Labor Safety and Hygiene
2015, occupational safety is a solution to prevent the impact of dangerous factors, with the aim
of ensuring that workers are not injured or killed during the labor process.

Hazardous factors can be machinery, equipment, chemicals, electricity, heat, pressure,

radiation, noise, vibration, dust, toxic gases, bacteria, viruses, mold, or other factors that can be
dangerous to workers.

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 Occupational safety is considered by us to be the most important principle in the labor
process, the responsibility of the employer to ensure the safety of workers, avoiding bad
situations that may occur.

Occupational safety has great significance and purpose for workers, employers and
society. Occupational safety helps protect health, improve productivity and labor quality, reduce
treatment and compensation costs, enhance the reputation and image of the enterprise, and
contribute to sustainable socio-economic development.

Regarding occupational safety at Hyundai/TC MOTOR NGOC AN, technicians are

always strictly required to wear protective gear when performing maintenance, repair or
painting. For maintenance and repair technicians, protective shoes, gloves and helmets are
necessary equipment due to the nature of the job, which requires contact with many sharp metal
parts or checking the chassis, draining oil, etc.

For painting technicians, protective equipment is similar to that of maintenance and repair
technicians. In addition, due to the painting and polishing process having a lot of dirt due to
surface work and contact with paint chemicals, painting technicians are also equipped with
specialized glasses and masks.

2.3 Service Operations Internship

Step 1: Receive vehicle and customer records

The service advisor (CVDV) is the person who directly contacts the customer

Greeting the customer and then proceeding to cover the seats and steering wheel. Then
exploiting information about the customer's vehicle such as maintenance information, damage
symptoms, strange noises around the vehicle, scratches that the customer requests to be painted
bronze color...

Fill in all information about the customer's vehicle, contact information, observe and check
for scratches, cracks around the vehicle and items on the vehicle.

Step 2: Check and evaluate the vehicle's condition according to the customer's request

Based on the customer's request and the information provided, the CVDV directly checks
and evaluates the vehicle's condition or sends a repair technician, a paint technician to check

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and test the vehicle if necessary in some cases. The general repair technician can invite the
customer to test drive the vehicle so that the customer can accurately determine the customer's
wishes and accurately check the current condition of the vehicle.

* Technicians are not allowed to perform repairs without receiving a repair order

Step 3: Consulting and quoting service

Step 4: Assigning work and repair orders

Step 5: Performing the service

The Team Leader assigns tasks to each technician to carry out the repair orders sent to the
service department completely and accurately.

Step 6: Checking service quality

After completing the repair order, the technician must directly check the work performed
to ensure that it meets the requirements, techniques, and hygiene of the customer's vehicle, and
at the same time observe and check the related systems. Check the customer's vehicle overall
before signing to complete the repair order

The technician reports to the Team Leader and checks the service quality. If the quality
does not meet the requirements, the Team Leader must send a technician to fix it immediately.
If it meets the requirements, the Team Leader must sign a confirmation and allow the technician
to move the vehicle to the cleaning area.

Step 7: Clean and wash the car (if the repair order has a car wash order)

Step 8: Check before delivering the car

CVDV checks the car before delivering it to the customer to ensure that the customer's
requirements according to the quote have been properly and completely implemented and that
the features, interior and exterior condition of the customer's car are completely normal as when
the customer received the car. means of transport.

Step 9: Payment Step 10: Deliver the car

Step 11: Find out information after the service

Step 12: After-sales

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Figure 16. Repair command

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 2.3.1 Maintenance service activities

Figure 17. Six steps of service process

With modern equipment, advanced technology measuring machines, and 5 maintenance

bays, the maintenance service at Hyundai/TC MOTOR NGOC AN always ensures to meet all
customer needs with the fastest service and the best quality.

Not only focusing on investing in facilities, the maintenance service at Hyundai/TC

MOTOR NGOC AN has been continuously investing in professional human resources. From
technicians, service consultants to customer care specialists, all are trained in professional
architecture and soft skills according to Hyundai global standards. Customers will be
completely assured and satisfied when their car is repaired and cared for at the genuine Hyundai
service workshop.

At genuine Hyundai dealers, cars are maintained according to levels (according to the
number of kilometers traveled or the number of years of use, whichever comes first). There are
4 levels of maintenance classified alphabetically, including:

1 PM: 5k, 15k, 25k, 35k, 45k...

2 PM: 10k, 30k, 50k, 70k...

3 PM: 20k, 60k, 140k, 180k...

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 4 PM: 40k, 80k, 120k, 160k...

Depending on the different maintenance levels, there will be items that need to be checked and
replaced. Higher maintenance levels will include items that need to be checked at lower levels.
Technicians perform tasks according to specific markings that can be listed on the inspection
sheet. Two technicians will perform tasks on the newspaper. Technician A will check the
internal systems of the vehicle, including warning lights, spark plugs, wipers and washers,
electrical systems inside the cabin, rear tire condition, vehicle lightning check, left door.
Technician B will check the engine range, including various fluids such as windshield washer
fluid, coolant, battery check, oil change. Details can be shown in the table below:

Figure 18. Inspection form

Typical maintenance activities at Hyundai/ TC MOTOR NGOC AN:

General vehicle check
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 Check the lights, wipers, horn and power door systems.
Check tire pressure and condition.
Clean the engine air filter and A/C air filter, add more windshield washer fluid.
Check for leaks in oil-using systems such as brakes, power steering, and check the play
of the steering rod.
Change engine oil
Usually, after every 5000km, the vehicle needs to have its engine oil replaced for the
smoothest and most efficient operation, avoiding heat dissipation during long-term operation
that will damage the engine, reducing its long-term life. In addition to its lubricating function,
engine oil also has the function of cooling and tightening gaps during mechanical operation.
Engine oil is pre-changed by spare parts warehouse staff with many different types of
compartments and containers so that technicians can quickly use it. And the oil used is genuine
Shell

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Figure 19. Pre-filled oil shelf

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 Hình 20. Scissor Lift

Figure 21. Tire inflation

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Figure 22. Draining engine oil

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 Figure 23. Filling brake fluid

Figure 24. Brack fluid extraction

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Change engine oil filter:
With the role of retaining the mineral layer to ensure that the oil entering the engine is
clean, after a period of use, the oil filter can be completely clogged, and these dirt accumulates
every day, creating thick layers that block the oil vents. At this time, the solution that can be
taken is to clean or replace the new car oil, if not done promptly, it will lead to the case of oil
filter rule, reducing the lubrication ability of the oil with the engine. According to
recommendations, the time to replace the engine oil filter is after 10,000km.
Accessories included

Figure 25. Gasoline additives

Gasoline additives: Fuel system cleaner additives help keep the entire fuel delivery and
combustion system clean with regular use. Fuel system treatments contain injector cleaners,
octane boosters, valve protectants, upper cylinder lubricants, carbon removers, moisture
removers and fuel stabilizers combined with powerful detergents and deposit control agents
designed to counteract the performance of your vehicle resulting in improved fuel economy and
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increased vehicle performance.

Engine Additives: Mechanical protection additives are residual metal restorers that reduce
friction and wear in the engine, are completely non-hazardous and non-flammable, while still
maintaining the original properties of the engine oil. In fact, all oils, both synthetic and mineral,
degrade over time, producing oil breakdown and collecting other contaminants that reduce
engine performance. The substances contained in mechanical engine additives are capable of
treating the metal, not the oil, and are designed to improve engine power, increase life and
mileage on the same fuel feed while protecting the engine from damage caused by build-up and
spraying of coolant from mineral and base oils.

Figure 26. Engine additives

Brake system cleaning

The car brake system is one of the important parts of the car. It ensures the safety of the
people in the car during operation and transfer. However, after a period of use under high
pressure and high temperature, the car brake system will reduce its lifespan and be damaged.
Early detection of a damaged brake system will help you be safer and more effective. Therefore,
periodic protection of the brake system is extremely important. According to conventional
advertising, after a period of use, it is inevitable that there will be wear and tear that needs to be
replaced. To do so, when the brake pad surface is only 2-3 mm, it is recommended to replace it.
In addition, when braking in dry conditions, be careful and listen for creaking and loud noises,
the cause may be too lean or cracked brake pads. At this time, it is necessary to check the brake
pads to see if they are worn or not to replace them in time. In addition, if the brake pads are

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worn, it will cause the bike to drift to one side and the steering wheel or brake pedal is not firm.
At this time, it is necessary to choose a vehicle to go to the dealer for a suitable replacement.

This braking system is performed at a distance of 10 thousand km. Its purpose is to ensure
the normal operation of the braking system, a very important system of the vehicle. Early
detection of damage to the braking system is very important.

This process includes the following steps: - Remove the wheel and place it on a
specialized shelf - Remove the brake hose from the brake caliper, remove the brake caliper pin
and use a brake caliper hanger on the side of the vehicle - Use SST to push the brake piston out
Remove the brake pad and check for wear. Then clean with a specialized solution, apply
specialized grease to the brake pad head and the contact surfaces with the clamp.

Replace the brake pad in the correct position, reattach the brake, reconnect the brake oil
pipe and reattach the wheel - After brake maintenance, the vehicle is brought to the brake force
testing machine. The technician will check the braking force of the front and rear wheels to
ensure that they meet the requirements. If they pass this condition, the group will be re-checked
and the vehicle returned. to La car wash *At the 10k km light, the water will also rotate. The
reason is that the front tires have the task of guiding the vehicle, so they will wear out faster
than the rear tires, so at this time the technician will rotate the tires. The two rear tires will rotate
horizontally to the front, while the two front tires will rotate straight to the rear.

Figure 27. Removing the wheel

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Figure 28. Cleaning the disc brakes

Figure 29. Cleaning drum brakes

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Figure 30. SST for pressing brake piston

Figure 31. Cleaning the disc brake system

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Figure 32. Brake system cleaning solution

Figure 33. Brake pad grinding

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Figure 34. Final inspection of the brake system

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Injector cleaning

The fuel injector is the part responsible for supplying fuel to the vehicle, specifically
pumping fuel directly to the engine cylinders. This directly affects the vehicle's acceleration
ability. When the injector is clogged, it will reduce performance, affecting the engine's
operation.

Normally, fuel injector maintenance will be every 15,000 km. However, if the vehicle has
the following signs, the fuel injector should be checked and cleaned:

Engine performance is no longer the same as before: When the injector is clogged, the
amount of gasoline fed into the combustion chamber is less, forcing you to press the accelerator
harder but the operating system is still not the same as before.

Engine starts late or engine starts weakly: When you start the engine, gasoline will go
through the injector to be fed into the combustion chamber. If the injector is too dirty, the
gasoline will not enter the combustion chamber quickly, causing the engine to be delayed in
starting.

Engine noise is louder: When the injector is clogged, you will have to press the gas harder,
but the power is still not as you want, this will accidentally make your engine work harder,
leading to your engine being noisier.

Exhaust smoke is more: When the fuel injector is clogged, it will cause more smoke to
come out of the exhaust, because when the injector is clogged, it will cause the fuel to not burn
completely and leak into the exhaust pipe and burn in the pipe, thereby causing more exhaust
smoke.

Fuel runs out faster than normal: When you drive, you will consume a certain amount of
fuel. However, if the amount of fuel is lost too quickly than normal, it is also a sign that the
vehicle's fuel injector tip needs to be cleaned.

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 Figure 35. Injector cleaning solution

This process involves the following steps:

Remove the fuel line from the rail
Connect the hose of the cleaning kit to the fuel rail and attach the bottle of
specialized cleaning solution to the kit
Remove the pump relay on the main relay box
Use the computer to turn off the pump relay at the fuel tank
Start the engine and let it run for about 30 minutes until the engine stops
automatically.

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Remove the accessory kit, reconnect the fuel lines as before, reconnect the
fuel pump relay and use the computer to turn on the relay at the fuel tank.

Figure 36. Cleaning the combustion chamber

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Replace fuel pump

The car's fuel pump is an important part that helps bring fuel from the tank to the injector and
then pushes the fuel into the combustion chamber, helping the parts to operate continuously and
stably.
The car's fuel pump is a fairly durable part and after a period of use, the fuel pump begins to
show signs of damage and the car needs to be taken to a reputable garage for inspection and
maintenance.
In case of damage, the check engine light will not turn on, but you can recognize it through the
damaged car's fuel pump system:
The car suddenly dies
Weak pump
No sound of the fuel pump when starting

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 Figure 37. Replacing the fuel pump
Tire patch:

After the technician checks the tire condition, if a nail is found causing a flat tire, the
technician will notify the service center and the customer and decide whether we will patch
the tire or not.

Figure 38. Widening the puncture Figure 39. Apply glue and stick
tire patch
Change the tire
After a long time of use, the tire becomes worn, loses traction, and reduces safety for the user.
Reasons for needing to replace tires: swollen tires, too worn tires (about 2mm tread space),...

Figure 40. Technician removing tire from rim

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Figure 41. Rim after tire removal

Figure 42. Replace the tire

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Other maintenance services
Replace shock absorbers: after a long period of operation, the shock absorbers leak oil,
leading to the ability to absorb vibrations and the ability to reduce shock is no longer stable,
causing discomfort for the driver.
Replace engine gearbox oil: similar to the engine, the gearbox is mainly composed of
transmission gears, when the vehicle is operating, the gears move continuously at high intensity
and generate a lot of heat. Gear oil is a compound that lubricates and cools the machine parts
and gears inside the gearbox, helping the gearbox operate smoothly and stably.
In addition, it also has the effect of preventing wear and rust, increasing the life of the
car's gearbox and engine parts. According to experts' recommendations, gearbox oil should be
replaced after 40,000km of operation.
PDI - Pre-Delivery Inspection

This is the process of checking the car before selling it to the customer. The technician will
check all the functions on the car, including the items listed on the sheet. The whole process
seems similar to regular maintenance but on a deeper level.

Figure 43. PDI Checklist 1 Figure 44. PDI II Checklis

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 2.3.2 General repair service activities
With modern equipment, using advanced technology diagnostic machines, with 5 bays
serving general repair needs (3 bays upstairs and 2 bays on the ground floor), the repair service
at Hyundai/TC MOTOR NGOC AN always ensures to meet all customer needs with the fastest
service and the best quality. Not only focusing on investing in facilities, the repair service at
Hyundai/TC MOTOR NGOC AN has been continuously investing in professional human
resources. From technicians, service consultants to customer care specialists, all are trained in
professional knowledge and soft skills according to Hyundai standards. Customers will be
completely assured and satisfied when their car is repaired and cared for at a genuine Hyundai
service workshop.
Throttle cleaning
The car's throttle is the part that regulates the air entering the engine's combustion
chamber. When the driver steps on the accelerator, this part will expand (the extent of expansion
depends on how much the accelerator pedal is pressed) to let the air enter the intake manifold
and then the air filter. After a period of use, the throttle will be clogged with dirt. This causes
the opening of this part to be incorrect, causing problems such as stalling, difficulty
accelerating, consuming more fuel than normal, etc.
How to fix: Use a specialized solution to clean the dirt around the throttle, use a
cloth/brush to wipe and clean the throttle that has just been sprayed with the specialized
solution.
Cleaning the throttle not only helps the vehicle run smoothly, smoothly, and safely, but
also helps save fuel and increase the life of machine parts.

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 Figure 45. Spray specialized cleaning solution into the gas nozzle

Replace steering rack

The steering rack is a part of the car's steering system, extremely sturdy with a very long
life. However, after a long time of use or due to other impacts such as accidents, the steering
rack will gradually deteriorate and be damaged.
Signs that the steering rack needs to be replaced: heavy steering feel, steering noises due
to mechanical collision, ...
How to fix: Check the contacts of the electric power steering motor, check the
mechanical components of the steering rack or replace the entire steering rack for best results.

Figure 46. The old steering rack is lowered for replacement.

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Figure 47. Genuine new steering rack set from Hyundai

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 Figure 48. Install the electric power steering motor on the new steering rack (Depending on
the vehicle model, the electric power steering position will be different)

Figure 49. Installing the new steering rack into the bracket, ready to install on the vehicle

Replace the condenser compressor (Cooling block)

The function of the compressor is to combine with the refrigerant to compress the air
under high pressure, converting the water vapor in the air to condense into liquid. The water
then flows to the filter battery. The cold air will be blown by the fan through the air-
conditioning vents in the car.

Cause of damage: The car's compressor always operates at high capacity, so damage due
to overload and reduced operating capacity is inevitable. This greatly affects the quality of
cooling and air circulation in the car.

40
 Replace the compressor to ensure the quality of cooling and air circulation in the car,
helping the driver have a comfortable experience when using the car.

Figure 50. Remove the damaged compressor from the vehicle for inspection and replacement.

Figure 51. Old compressor (left) and new compressor

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Figure 52. Reinstall the pulley into the new compressor.

Figure 53. Installing the new compressor into the vehicle

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 Figure 54. Reinstall the belts onto the pulleys, start the engine and check operation.

Replace balance rod

There are 3 main types: steering tie rod, vertical tie rod and balance tie rod. In which,
balance tie rod is a part of the car's chassis system, with the function of ensuring the balance and
stability of the car when moving on the road, even on bumpy, difficult roads. Besides, it also has
the function of keeping the car from slipping or tipping when turning or cornering. Balance tie
rod is likened to an arm to support the car's frame, helping the car to always operate stably and
smoothly in all road conditions, even on bumpy, difficult roads. Therefore, special attention
should be paid to checking and maintaining the tie rod regularly to ensure that this part is
always in good working condition.

Cause of damage: Balance tie rod is one of the parts of the car that must operate regularly
and continuously, so it is very susceptible to wear and damage. In some other cases, a strong
impact can also lead to damage to this part. It can be seen that one of the reasons for serious car
accidents is because the driver loses control. And a damaged tie rod is an objective cause
leading to this incident. Because a damaged tie rod will make it impossible for the driver to steer
or control the direction of the vehicle, causing the vehicle to move unintentionally.

Signs of a damaged balance tie rod: the chassis often makes a creaking sound due to the

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rubber being worn or torn during use; the car is unbalanced, difficult to steer, the car shakes, or
is slippery, has a large amount of play, ...

After checking, if the tie rod is found to be damaged, it is necessary to bring the car to a
garage or reputable car dealer for timely maintenance and repair.

Figure 55. Removing the balance rod on the vehicle

Figure 56. Replace new balance rod and check

Replace engine compartment wiring harness

The engine compartment wiring harness is designed to transmit and supply electricity to
the devices on the vehicle to operate stably. In addition, the wiring harness is also covered with
many layers of rubber, helping the wiring harness in the engine compartment withstand high
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temperatures when the engine is running

As well as being waterproof, anti-rat... In addition, the wiring harness is also equipped
with many fuses, ensuring absolute safety for the user in case of electrical problems.

Cause of damage: over time and vehicle usage conditions, the rubber layer covering the
outside of the wire bundle will show signs of aging, exposing the copper core. If the vehicle is
running, the two copper cores of the wire touch each other, causing a short circuit, affecting the
vehicle's electrical system. In addition, another common cause is due to mouse bites.

After checking, if the engine compartment wiring harness is found to be damaged, it is

necessary to take the vehicle to a garage or reputable auto dealer for timely maintenance and
repair.

Figure 57. Engine compartment wiring harness (genuine spare part)

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Figure 58. Proceed to remove parts in the engine compartment to replace the wiring harness

Figure 59. Engine compartment wiring harness fuse box

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 Figure 60. Complete engine compartment wiring harness replacement, reinstall components
and jack, start engine to test vehicle operation

Replacement and repair of disc brake system

The structure of a car's disc brake consists of 4 main parts: brake disc, brake pad, brake
pad and oil. This brake assembly is designed in an open form, the parts coordinate well with
each other, helping the car to stop or slow down effectively.

Some common failures: The disc brake is locked when braking, the brake disc makes a
noise, the brake pedal is heavy: the cause is a problem with the brake booster, brake fluid
leakage, system leakage, the brake vibrates or slips due to the brake shoe, the brake shoe is
worn or damaged, the brake pad is worn or deformed.

After checking, if the engine compartment wiring is found to be damaged, the car should
be taken to a garage or reputable car dealer for timely maintenance and repair.

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Figure 61. Checking the brake caliper and disc surface quality

Figure 62. Checking the brake pads

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 Figure 63. Checking brake pad wear

Figure 64. After a long period of use, the brake disc will wear unevenly, reducing braking
efficiency.

49
Figure 65. The piston in the brake after a long time of use has been scratched and needs to be
replaced to ensure braking efficiency

Figure 66. Checking the rear brake caliper and cupen

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Lower the machine to change the gearbox oil seal:

Oil seals are a special type of seal on a car that is necessary to seal gaps and gaps. For
example, in a gearbox, an oil seal plays an important role - it is fixed at the junction between the
moving and stationary mechanisms, preventing oil from flowing out of the gearbox.

The seals are located directly on the shafts inside the gearbox, so their wear can only be
determined visually when disassembling the gearbox. However, any driver can quickly
determine the destruction of the oil seal with the naked eye, because there are obvious
symptoms such as:
Transmission oil leakage under the car.
Constantly low oil level in the gearbox.
Problems with shifting gears while driving.
Clunking noises when engaging and shifting gears.

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Figure 67. KTV has lowered the gearbox.

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Other repair activities:
Check the car's fuel pump
The car's fuel pump is the part that sucks fuel from the tank to the fuel injector with a
stable pressure. When the car's fuel pump pressure is low, it will cause a lack of fuel, leading to
engine vibration or stalling. If the pressure is high, it will cause excess fuel, causing the car to
"drink fuel", increasing operating costs, especially when gasoline prices are expensive.
Signs of a damaged fuel pump: the car is difficult to start because the fuel pump is weak
after a long period of continuous operation; the fuel pump is too hot, the check engine light will
turn on on the dashboard; the car often stalls; fuel consumption is higher than normal, ...
Replacing or repairing the fuel pump helps the car operate stably, safely and economically for
the user.
Check the shock absorber
Car shock absorbers (also known as shock absorbers) are an indispensable equipment on
every car, it eliminates the free vibrations of elastic force, helping the car to move more
smoothly when moving on uneven roads. Car shock absorbers apply damping vibrations, the
principle of the shock absorber is to use the translational motion of the shock absorber, which
can convert kinetic energy into heat energy and then send it into the hydraulic tube.

Signs of damage to the shock absorber: the front of the car is strongly depressed when
braking suddenly; the car is prone to slipping and swerving; the car vibrates, sways; the shock
absorber leaks oil, the tire wears unevenly, ...
How to check: use a shock absorber press to remove the shock spring and shock absorber, check
the elasticity of the shock absorber to make a conclusion on repair or replacement.

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Some other specialized equipm

Figure 68. Wheel alignment machine

54
 Figure 69. Nitrogen pump

Figure 70. Wheel balancing machine

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 2.3.3 Body and paint service activities
Car body painting is a process that combines 2 stages: body painting and painting. Body
painting aims to repair and help restore the original appearance and shape of a part or the
entire car body.

A professional body painting process will go through 2 main stages, including:

Body painting: The steps of bending, rubbing, straightening, ... help the car body return
to its original shape.

Painting: Intervening in each layer of paint, each small detail to give us the exact paint
color, smoothness and shine like the original paint.

For new cars, in the production process, body painting is the final finishing step to help
the car achieve the most eye-catching and shiny color.

For used cars, body painting techniques help to overcome scratches, dents, rust on the car
body surface, as well as restore the old paint layer to its original state.

Activities at the copper workshop:

The activities at the body shop are very diverse, including restoring dents on the car body
to disassembling and assembling body parts for the painting process as well as reassembling
those parts on the car. In addition, the body shop is also responsible for assembling the car's
lighting system. In addition, the body shop also has a lift, serving the car's underbody coating
process.
The work performed in this shop is:
Repairing dents and scratches on the car body
Replacing damaged body parts due to collisions and accidents
Pulling and bending to return the frame parts to their original position, replacing if the
damage is too severe according to the service consultant's request to serve the customer's needs.
Dismantling parts for painting. Purpose:
Restoring the original condition of the car not only on the outside but also behind the paint
Ensuring the aesthetics of the car.
The work process requires the worker to be meticulous and persistent. Steps to handle
deformed car bodies include:
Mark the deformed area

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 If the deformation is slight, cold processing can be carried out
In case of severe deformation, first grind to remove the paint layer in the deformed area,
then use a specialized tool kit to weld and pull the parts back. Then use a hammer to hit the
parts hard until they return to their original shape.
Then they will be marked again with anti-rust paint

Figure 71. Activities at the copper workshop

Activities at the paint shop:

Hyundai's standard painting process has 22 steps, including:

B1: Check the damaged surface
B2: Grind and peel the paint on the damaged surface
B3: Break and lower the edge of the paint peeling area
B4: Clean and apply anti-rust paint on the surface
B5: Dry and check the anti-rust paint surface
B6: Mix and apply putty on the damaged area
B7: Dry and check the putty surface
B8: Scrub the putty with a scraper and treat the surface
B9: Scrub the putty with an orbital machine
B10: Prepare the surface before priming
B11: Mix and spray the primer
B12: Dry and check the primer surface
B13: Scrub the primer with a scraper
B14: Scrub the primer with an orbital machine

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B15: Check the middle and end of the process
B16: Mix and adjust the color paint/clear paint
B17: Prepare the paint surface before applying color paint
B18: Adjust the gun and spray the color paint
B19: Adjust the gun and spray the clear paint
B20: Dry and fix the clear paint surface
B21: Polish
B22: Assemble and check the final process
- Equipment for the painting process:

Figure 72. Scrub bar

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 Figure 73. Foudation

Figure 74. Sandpaper grades for different base layers

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Figure 75. Tape for painting process

60
Figure 76. The process of the technician peeling off the paint and lowering the eyelid.

Figure 77. Putty application process and surface inspection

61
Figure 78. Masking process with masking glue, preparing to spray primer

Figure 79. Spraying primer

6

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 Figure 80. Checking the primer surface, preparing for the color painting stage

In the painting area, the following tasks are performed:

Color mixing and color adjustment according to the vehicle color (done in the paint mixing
room)

Surface preparation before coloring

Adjusting the paint gun and mixing the color, drying the paint layer

Adjusting the gun and painting

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Figure 81. Protective gear before entering the paint room

Figure 82. Paint and clear coat guns

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 The purpose of the repainting process is to help even out the gloss of the old paint and the
new paint of the car, and at the same time even out the surface of the newly painted shell.

Process:

Use masking tape to cover the plastic or chrome areas to avoid affecting these areas

Use 1200/1500 sandpaper combined with a sander to remove paint dust, for large paint dust
particles, it is necessary to handle manually to avoid affecting the surrounding paint layer.

Use 3000 sandpaper combined with a sander and water to create a flat surface

Use a polishing machine combined with a 2-in-1 polishing machine to evenly treat the paint
surface and create a certain gloss for the paint layer

Use a specialized polishing machine combined with a polishing machine to increase the
gloss of the car

Remove the masking tape, the paint treatment process is complete

Figure 83. Polishing tool

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2.3.4 Car wash service activities
The free car wash, maintenance and repair service for customers is the final step before
delivering the car to the customer. Unlike car wash, which is often dirty due to the nature of
the job, car wash, maintenance and repair is simpler, focusing more on the outside of the car
than the inside. However, the requirements for car cleaning are also emphasized, no different
from car wash, which is a part of car wash. With 8 basic car wash steps, the customer's car
will be as clean as possible before reaching the customer.
B1. Spraying water on the car body and undercarriage

Fig
u re
84.

Spraying water on the car body

66
B2. Spray car wash foa

Figure 85. Spraying foam to wash the car

B3. Wash the wheel area

B4. Wipe the body

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 Figure 86. Cleaning the body and wheel area

B5. Spray water to clean the car

B6. Blow clean the areas where water easily accumulates
B7. Wipe clean
B8. Vacuum the car floor.

Figure 87. Vacuuming the car floor

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Figure 88. Car wash machine

Figure 89. Tire polishing

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 CHAPTER III. CONCLUSION AND RECOMMENDATIONS
3.1 Conclude

Through the internship period by practical contact at the company, with the help from the
business as well as the enthusiastic guidance of Mr. Huỳnh Quốc Việt and all the teachers in the
Faculty of Mechanical Engineering, plus our own efforts, we have summarized a lot of practical
experience. Due to the lack of knowledge, practical experience as well as the lack of internship
time, this report cannot avoid mistakes. Therefore, we hope to receive help and guidance from
the teachers so that we can improve better.

3.2 Recommendations and suggestions

3.2.1 About the internship company

Hyundai/TC MOTOR NGỌC AN has created very good conditions and helped us
complete the internship process in the best way.

3.2.2 About outside work.

The knowledge we learn in school helps us know the process and operating principles of
the parts on the car. However, there are still some contents that are not closely related to the
outside, making us confused.

3.2.2 About internship management

Mr. Huynh Quoc Viet always supports us wholeheartedly and answers all our questions
during our internship. We would like to sincerely thank the Board of Directors, teachers in the
Faculty of Dynamic Mechanics, Ho Chi Minh City University of Technical Education, and Mr.
Huynh Quoc Viet for their wholehearted help and guidance. In addition, we would like to
express our sincere thanks to the Board of Directors of Hyundai Company/TC MOTOR NGOC
AN for their support and favorable conditions to help us complete our internship successfull

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