AURTTZ102 Task 1

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Strathfield College *

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AUR40216

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Feb 20, 2024

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RTO No: 91223 Student Task 1 AURTTZ102 Diagnose and Repair Exhaust Systems
AURTTZ102 Diagnose and repair exhaust systems Assessment 1 – Questioning – Written Assessment Student Name JAYVEE RYEE JAYME Student ID Number SCM3144 Unit Start Date OCTOBER 30, 2023 Unit End Date NOVEMBER 05, 2023 Assessment Due Date NOVEMBER 05, 2023 Date Submitted NOVEMBER 05, 2023 This cover sheet is to be completed by the student and assessor and used as a record to determine student competency in this assessment task The assessment process and tasks were fully explained. Yes / No I am aware of which evidence will be collected and how. Yes / No I am aware of my right to appeal an assessment decision. Yes / No I am aware that I can locate The RTO Complaints and Appeals Policy and Procedure on their website at (Insert Website Link) Yes / No I have discussed any additional educational support or reasonable adjustments I require in order to undertake this assessment with the Student Support Services Officer and Trainer / Assessor, (if applicable). e.g. Student Handbook and Access and Equity Policy (Insert Website Link) Yes / No I have access to all required resources? Yes / No Cheating & Plagiarism Declaration Student Declaration: In accordance with The RTO Plagiarism Policy, I hereby acknowledge by signing this declaration that I have not cheated or plagiarised any work regarding the assessment tasks undertaken in this unit of competency except where the work has been correctly acknowledged. NOTE: Student must sign this prior to submitting their assessments to the assessor Signature JAYVEE RYEE JAYME Date: 05 / 11 / 2023 Assessment Results Satisfactory or Not Yet Satisfactory (Please circle the assessment result for this task) Feedback to Student - Please provide general feedback on the Student’s performance Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 2 of 17
AURTTZ102 Diagnose and repair exhaust systems Student Declaration: - I verify that the work completed is my own and that I was adequately informed of the assessment process prior to commencing this assessment task. Assessor Declaration: - I verify that I have adequately explained and negotiated the assessment tasks with the student prior to commencing assessment. Student Name: JAYVEE RYEE JAYME Assessor’s Name: Student Signature JAYVEE RYEE JAYME Date: 05 / 11 / 2023 Assessor Signature Date Student Guide for Written Knowledge Assessment Overview of Assessment This is a written assessment task you will be assess on your knowledge of diagnosing and repairing exhaust systems. The topics that will be covered in the assessment are: 1. Prepare to diagnose and repair exhaust systems 2. Diagnose an exhaust system 3. Repair an exhaust system 4. Complete work processes This assessment will ensure that the elements, performance criteria, performance evidence and knowledge evidence required, and conditions are adhered to demonstrate competency in this unit assessment task. Read the assessment carefully before commencing. Your Assessor will use the assessment criteria in this document and will provide feedback / comment. You MUST answer all the questions in the assessment tasks in your own words and own handwriting. This is an “Open Book” assessment, and students can use the resources listed in the “Resources Required” section below. Task/s to be assessed To complete this written assessment, you will need to answer the 51 questions comprising of Multiple Choice, True and False, Fill-in the Gap and Short Answer questions. Time allowed On average, the Assessment should take 2 – 4 hours to complete. Location This theory assessment will be completed in a classroom under the supervision of a trainer/assessor. Decision making rules To receive a ‘satisfactory’ outcome for this assessment students MUST successfully answer all questions. If a student achieves less than 100%, they can reattempt the assessment after further study has taken place. Students who cannot achieve a minimum of 100% you will not have satisfactorily completed this assessment Your assessor will be looking for the following in this assessment task: - Work health and safety (WHS) and occupational health and safety (OHS) requirements relating to diagnosing and repairing exhaust systems, including procedures for working with hot components and exhaust systems producing toxic gases Operating principles of features of exhaust systems and associated Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 3 of 17
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AURTTZ102 Diagnose and repair exhaust systems components, including scavenging and back pressure Application, purpose and operation of exhaust systems and components, including: o Mufflers o Extractor pipes o Catalytic converters o Diesel particulate filters Diagnostic testing procedures for exhaust systems, including: o Exhaust leak testing o Vibration and noise locating procedures o Back pressure testing Repair procedures for exhaust systems, including procedures for removing, replacing and aligning components Post-repair testing procedures for exhaust systems. Assessment conditions Assessors MUST satisfy NVR/AQTF assessor requirements. Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting. Assessment MUST include direct observation of tasks. Where assessment of competency includes third-party evidence, individuals MUST provide evidence that links them to the exhaust systems that they have worked on, e.g. repair orders. Assessors MUST verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application. The following resources MUST be made available: Automotive repair workplace or simulated workplace  Workplace instructions  Manufacturer exhaust system specifications Two different vehicles with faults in the exhaust system components specified in the performance evidence Diagnostic equipment for exhaust systems Tools, equipment and materials appropriate for repairing exhaust systems, including metal heating equipment. Resources required Learning Resources available to students include: Automotive Technology (A System Approach) 6 th Edition – Chapters 5, 6, 7, 32 and 33 Websites Trainer Handouts Results/Re-assessment The Assessor will grade the assessment and record the result on the front page of this document (S) – Satisfactory if all observable behaviours are correct and (NS) not satisfactory if any areas are left incorrect Feedback will be provided on either result Where a student receives a ‘NS – Not Satisfactory’ result, the assessor will discuss the area of the non-compliant observable behaviour and an opportunity given for re-assessment. This may be through direct observation or a different method of assessment e.g. verbal/oral questioning, problem solving exercise. If the outcome is again not satisfactory the student result will be deemed (NYC) not yet competent. Additional feedback will be given, and a time agreed upon for further assessment after additional training and skills practice has taken Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 4 of 17
AURTTZ102 Diagnose and repair exhaust systems place, this information will be recorded, dated and signed in the re-assessment area on the last page of this document Where all the assessment tasks have been graded (S) Satisfactory, the student will be deemed C – Competent for the practical component and the result recorded and signed in the area indicated on the last page of this document Reasonable Adjustment If the participant is unable to undertake the written assessment as designed, an interview (verbal questioning) may be used as an alternate approach. Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 5 of 17
AURTTZ102 Diagnose and repair exhaust systems Assessment 1 – Questioning Written Assessment 1. Identify five (5) important items of personal safety when diagnosing and repairing exhaust systems. 1 Protective Gear 2 Well-Ventilated Area 3 Vehicle Stability 4 Fire Safety 5 Safe Lifting and Posture True or False question 2. When inspecting or working on the exhaust system, remember that its components get very hot when the engine is running. Contact with them could cause a severe burn. Also, always wear safety glasses or goggles when working under a vehicle? True or False Fill in the Gaps 3. Complete the following statement about venting engine exhaust gases using the following words. Words: Deadly, Direct, Engine, Exhaust, Monoxide, Nausea, Outside, Running, Tailpipe, Ventilation Whenever you need to have the ____ engine______ running for diagnosis or service, the engine’s ____ exhaust______ must be vented to the outside. Carbon ____ monoxide______ (CO) is present in the exhaust. CO is an odourless, tasteless, and colourless ____ deadly______ gas. Inhaling CO can cause brain damage and, in severe cases, death. Early symptoms of CO poisoning include headaches, _____ nausea_____, and fatigue. Most shops have an exhaust _____ ventilation_____ system. These systems collect the engine’s exhaust and release it to the ___ outside_______ air. Before running an engine in the shop, connect a hose from the vehicle’s _____ tailpipe_____ to the vent system. Make sure the vent system is turned on before ____ running______ the engine. If the work area does not have an exhaust venting system, use a hose to ____ direct______ the exhaust out of the building. 4. What are the three (3) functions of the exhaust system? Exhaust Gas Removal, Noise Reduction, Emissions Control Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 6 of 17
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AURTTZ102 Diagnose and repair exhaust systems True or False question 5. Some exhaust systems are designed with extractor pipes. These have one pipe for each exhaust port. The pipes are designed with long sweeps that prevent back pressure. They also provide a scavenging effect, which assists in extracting the exhaust gases from the cylinders, thereby increasing engine performance. True or False 6. Name the twelve [12] components of the exhaust system below. 1 Exhaust manifold 2 Exhaust head pipe 3 Gasket 4 Upstream HO2S sensor (used for fuel control) 5 Catalytic converter 6 Downstream HO2S sensor (used for catalyst testing) 7 Heat insulator 8 Intermediate pipe 9 Resonator 10 Hanger 11 Muffler 12 Tailpipe 7. What materials are exhaust pipes typically made from? Steel, aluminum, cast iron 8. What is the function of the exhaust flex joint? Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 7 of 17
AURTTZ102 Diagnose and repair exhaust systems Flexibility, reduction of stress, vibration and noise reduction, emission control True or False question 9. The exhaust manifold collects the burnt gases as they are expelled from the cylinders and directs them to the exhaust pipe. True or False Multiple Choice question. Selected the correct answer. 10. Which of the following is NOT a metal used for producing exhaust manifolds? A. Cast iron. B. Aluminium. C. Heavy-gauge sheet metal. D. Stainless steel. Fill in the Gaps 11. Complete the following statement about engine manifolds using the following words. Words: Blend, Cylinder, Dual, Exhaust, Gases, Individual, Length, Manifold, Passages, An exhaust manifold will have either three, four, five, or six ___ passages_______, depending on the type of engine. These passages ___ blend_______ into a single passage at the other end, which connects to an _____ exhaust_____ pipe. From that point, the flow of exhaust ____ gases______ continues to the catalytic converter, muffler, and tail pipe, then exits at the rear of the car. V-type engines may be equipped with a ____ dual______ exhaust system that consists of two almost identical, but ___ individual______ systems in the same vehicle. Exhaust systems are designed for particular engine- chassis combinations. Exhaust system _____ length_____, pipe size, and silencer size are used to tune the flow of gases within the exhaust system. Proper tuning of the exhaust ____ manifold______ tubes can actually create a partial vacuum that helps draw exhaust gases out of the ____ cylinder______, improving volumetric efficiency. True or False question 12. The tailpipe is the last pipe in the exhaust system. It releases the exhaust fumes into the atmosphere beyond the back end of the car. Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 8 of 17
AURTTZ102 Diagnose and repair exhaust systems True or False 13. Heat shields are used to? Heat dissipation, protection, noise reduction, fuel efficiency Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 9 of 17
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AURTTZ102 Diagnose and repair exhaust systems True or False question 14. Heat shields are usually made of pressed or perforated sheet metal. True or False True or False question 15. Heat shields trap the heat in the exhaust system, which has a direct effect on maintaining exhaust gas velocity. True or False 16. Describe the construction of a muffler. A muffler, also known as a silencer, is an essential component of a vehicle's exhaust system designed to reduce the noise generated by the engine's exhaust gases. Mufflers have a complex internal structure, and their construction can vary depending on the type and design. The specific design and construction of mufflers can vary based on the intended purpose. Performance mufflers may have a more streamlined design with fewer baffles to improve exhaust flow, while quieter mufflers focus on sound reduction, incorporating more complex internal structures to muffle noise. The choice of muffler depends on the vehicle's intended use and the desired noise level. True or False question 17. Two types commonly used are the reverse-flow and the straight-through mufflers. True or False 18. What are the two (2) benefits of using aluminised and stainless steel in muffler construction? Corrosion resistance, durability True or False question 19. Many cars use a double-wall exhaust pipe to better contain the sound and reduce pipe ring. True or False Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 10 of 17
AURTTZ102 Diagnose and repair exhaust systems True or False question 20. Many mufflers are produced with drain holes drilled into them to allow condensation to drip out. True or False 21. On some older vehicles, there is an additional muffler, known as? Resonator Fill in the Gaps 22. Complete the following statement about tuned exhaust headers using the following words. Words: Cylinders, Engine, Exhaust, Flow, Headers, Improve, Pressure Tuned exhaust headers can also _____ improve_____ efficiency by preventing the exhaust flow of one cylinder from interfering with the _____ exhaust_____ flow of another cylinder. _____ cylinder_____ next to one another may release exhaust gas at about the same time. When this happens, the ____ pressure_____ of the exhaust gas from one cylinder can interfere with the ____ flow_____ from the other cylinder. With separate _____ headers_____, the cylinders are isolated from one another, interference is eliminated, and the _____ engine_____ breathes better. True or False question 23. The largest performance gain from using an exhaust headers is that it increases the engine’s volumetric efficiency. True or False 24. Explain how exhaust headers increase the engine’s volumetric efficiency? Exhaust headers can increase an engine's volumetric efficiency by improving the flow dynamics of exhaust gases, reducing back pressure, and enhancing the engine's ability to breathe efficiently. The combination of reduced back pressure, improved scavenging, enhanced flow dynamics, lower temperatures, and customization leads to increased volumetric efficiency. As a result, the engine can breathe more easily, leading to improved horsepower and torque, making it a popular modification in the world of performance and racing. 25. Describe the main purpose of a catalytic converter. The main purpose of a catalytic converter is to reduce harmful emissions produced by a vehicle's engine, specifically by converting toxic gases into less harmful substances. It plays a crucial role in reducing air pollution and meeting environmental regulations. The main purpose of a catalytic converter is to reduce harmful emissions from a vehicle's exhaust by facilitating chemical reactions that convert pollutants into less harmful substances, Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 11 of 17
AURTTZ102 Diagnose and repair exhaust systems contributing to cleaner air and environmental protection. True or False question 26. A catalytic converter breaks down HC and CO to relatively harmless by-products. True or False True or False question 27. OBD-II regulation call for a monitoring system that looks at the effectiveness of the catalytic converter. True or False 28. Name the four [4] parts of the catalytic converter below. 1 Monolith catalyst 2 Outer shell 3 Inner shell 4 Insulation True or False question 29. A catalytic converter is part of the exhaust system and a very important part of the emission control system. True or False True or False question 30. A catalytic converter contains a ceramic element coated with a catalyst. True or False Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 12 of 17
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AURTTZ102 Diagnose and repair exhaust systems True or False question 31. A catalyst is a substance that causes a chemical reaction in other elements without actually becoming part of the chemical change and without being used up or consumed in the process. True or False Fill in the Gaps 32. Complete the following statement about diesel particulate filter using the following words. Words: Filters, Preventive, Regeneration, Soot, Trap, Vehicle Particulate ____ filters______ are placed into the exhaust system after the catalytic converter. Sometimes, the PM filter is part of the converter assembly. Particulate filters are designed to ____ trap______ PM. Early PM filters needed to be cleaned as part of a ____ preventive______ maintenance program. Newer designs periodically burn off the collected PM and are designed to last the life of the ____ vehicle______ without any special maintenance. This is done by a special cleaning mode, often called ____ regeneration______, initiated by the PCM. This combustion cleans the _____ soot_____ from the filter. True or False question 33. Regeneration can be passive or active. True or False 34. The diesel particulate filter is fitted with a sensor that measures exhaust backpressure. How does this operate? The exhaust backpressure sensor in a diesel particulate filter (DPF) system operates by measuring the pressure in the exhaust system downstream of the DPF. This sensor is essential for monitoring the condition of the DPF and ensuring that regeneration processes, either passive or active, are functioning properly. The exhaust backpressure sensor in a DPF system continuously monitors exhaust pressure downstream of the filter. It provides data to the engine control module, which uses this information to initiate regeneration processes, ensuring the DPF remains clean and effective in reducing emissions. True or False question 35. Exhaust leaks are often identified by sound, although very small leaks can be difficult to locate. Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 13 of 17
AURTTZ102 Diagnose and repair exhaust systems True or False 36. What is the most effective ways to identify the source of an exhaust leak? Listening for Hissing or Popping Sounds, Visual Inspection, Smoke Test, Feeling for Air, Exhaust Gas Analyzer, Pressure Test, Diagnostic Scan Tool, Seek Professional Help True or False question 37. Most parts of the exhaust system, particularly the exhaust pipe, muffler, and tailpipe, are subject to rust, corrosion, and cracking. True or False True or False question 38. Broken or loose clamps and hangers can allow parts to separate or hit the road as the car moves causing vibrations. True or False True or False question 39. Excessive exhaust noise from the tailpipe can be due to a muffler or resonator in which the baffles have corroded so that they are no longer effective.  True or False True or False question 40. A restricted exhaust can be tested with an exhaust pressure gauge. True or False Fill in the Gaps 41. Complete the following statement about exhaust restriction testing using the following words. Words: Determine, Exhaust, Gauge, Hold, Manifold, Pressure, Restricted, Vacuum Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 14 of 17
AURTTZ102 Diagnose and repair exhaust systems There are many ways to check for a ____ restricted______ exhaust. The sound of the exhaust can indicate a restriction. With a restriction, the exhaust will wheeze as it struggles to exit the ____ exhaust______ system. Although this is not the most effective way to ____ determine______ if there is a restriction, it is a good start. Checking the pressure built up in the exhaust is the best way to determine if the system is blocked. This is done by installing a _____ pressure_____ gauge in the O 2 S bore in the exhaust pipe. At idle, the _____ gauge_____ should read less than 1.5 psi (10 kPa) and should be less than 2.5 psi (17 kPa) at 2,500 rpm. Some technicians check for a restricted exhaust with a _____ vacuum_____ gauge. With the gauge connected to the intake _____ manifold_____, the engine’s speed is raised and held. The vacuum reading should rise and either _____ hold_____ there or increase slightly. If the vacuum decreases, there is an exhaust restriction. Multiple Choice question. Selected the correct answer. 42. A restricted exhaust system can cause ______. A. Stalling. B. Loss of power. C. Backfiring. D. All answers are correct. True or False question 43. Before replacing an exhaust system component, soaks all old connections with a penetrating oil. True or False True or False question 44. Checks the old system’s routing for critical clearance points before replacing an exhaust system component. True or False True or False question 45. Most exhaust work involves the replacement of parts. When replacing exhaust parts, make sure the new parts are exact replacements for the original parts. Doing this will ensure proper fit and alignment as well as ensure acceptable noise levels. True or False 46. Exhaust system component replacement might require the use of special tools. Name eight (8) special tools. Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 15 of 17
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AURTTZ102 Diagnose and repair exhaust systems 1 Exhaust pipe cutter 2 O2 sensor socket 3 Exhaust hanger removal tool 4 Exhaust flaring tool 5 Exhaust pipe expander 6 Exhaust manifold spreader 7 Exhaust stud and nut removal tool 8 Muffler clamps and hangers True or False question 47. When installing exhaust gaskets, carefully follow the recommendations on the gasket package label and instruction forms. True or False True or False question 48. To replace an exhaust manifold gasket, follow the torque sequence in reverse to loosen each bolt. Repeat the process to remove the bolts. Doing this minimizes the chance that components will warp. True or False 49. Consider the various post repair checks that you would make during a road test exhaust system? Listen for unusual noise, Check for Exhaust Leaks, Examine the Tailpipe, Monitor Engine Performance, Observe Emissions, Check for Odors, Assess Fuel Efficiency, Watch for Warning Lights, Verify Proper Heat Shield Installation, Check for Vibration, Assess Braking Performance Multiple Choice question. Selected the correct answer. 50. Which source of information will give you the most detail about diagnosing and repairing exhaust systems on the vehicle you are working on? Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 16 of 17
AURTTZ102 Diagnose and repair exhaust systems A. Workshop manual. B. Owner’s manual. C. Google. D. Textbooks. 51. Why is it very important that the Job Card is completed correctly? Completing the job card correctly is essential for professionalism, transparency, and the smooth operation of service businesses. It benefits both the service provider and the customer by ensuring accurate records and efficient service delivery. Document Name: Student Written Knowledge Assessment – AURTTZ102 Created Date: 12 th Aug 2019 Document No: © Strathfield College – AURTTZ102 Version No: 2. 0 Last Modified Date: © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 17 of 17