AURLTE102 Task 1

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Feb 20, 2024

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RTO No: 91223 Assessment Task 1 AURLTE102 Diagnose and Repair Light Vehicle Engines

AURLTE102 Diagnose and Repair Light Vehicle Engines Assessment 1 – Questioning – Written Assessment Student Name JAYVEE RYEE JAYME Student ID Number SCM3144 Unit Start Date JULY 17, 2023 Unit End Date AUGUST 13, 2023 Assessment Due Date AUGUST 13, 2023 Date Submitted AUGUST 13, 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 of the Complaints and Appeals Policy and Procedure 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 Yes / No I have access to all required resources? Yes / No Cheating & Plagiarism Declaration Student Declaration: 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: 13 / 08 / 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 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 Date: 13 / 08 / 2023 Assessor Signature Date Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 2 of 33

AURLTE102 Diagnose and Repair Light Vehicle Engines JAYVEE RYEE JAYME 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 light vehicle engines. The topics that will be covered in the assessment are: 1. Prepare to diagnose and repair engine 2. Diagnose engine 3. Dismantle engine 4. Repair and re-assemble engine 5. 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. 1. Read the assessment carefully before commencing. 2. Your Assessor will use the assessment criteria in this document and will provide feedback / comment. 3. You MUST answer all the questions in the assessment tasks in your own words and own handwriting. 4. 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 101 questions comprising of Multiple Choice, True and False, Fill-in the Gap and Short Answer questions. Time allowed On average, the Assessment should take 4 – 6 hours to complete. Location This theory assessment will be completed in a classroom under the supervision of a trainer/assessor. Decision making rules The candidate MUST be able to demonstrate knowledge to complete the tasks outlined in the elements, performance criteria and foundation skills of this unit, including knowledge of:  Methods to locate and interpret information required to diagnose and repair light vehicle engines, including: o Information provided by customers and supervisors o Manufacturer specifications and procedures or equivalent documentation  Workplace procedures required to diagnose and repair light vehicle engines, including: o Establishing serviceability of tools and equipment o Documentation procedures o Housekeeping procedures, including:  Examination of tools and equipment  Storage of equipment  Identification, tagging and isolation of faulty equipment  Disposal of excess materials  Recycling procedures  Workplace health and safety (WHS) requirements relating to diagnosing and repairing light vehicle engines, including procedures for lifting and supporting light vehicle engines Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 3 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines  Environmental requirements relating to diagnosing and repairing light vehicle engines, including procedures for trapping, storing and disposing of fluids released from engines  Operating principles of light vehicle engines, including: o Combustion, including:  Air-fuel ratios and combustion cycles  Direct injection  Detonation o Engine design, including:  Swept volume and engine volume  Compression ratio  Engine efficiency, including volumetric efficiency, thermal efficiency and mechanical efficiency  Torque and horsepower, including brake horsepower  Diagnostic testing procedures for light vehicle engines, including: o Wet and dry compression tests o Cylinder leakage tests o Oil pressure tests o Checking sources of fluid leaks o Exhaust smoke diagnosis o Checking abnormal engine noises  Dismantling procedures for light vehicle engines, including procedures for: o Measuring clearances and tolerances o Inspecting components  Repair procedures for light vehicle engines, including procedures for removing, replacing and adjusting them  Assembly procedures for light vehicle engines, including procedures for removing, replacing and adjusting them  Post-repair testing procedures for light vehicle engines, including: o Checking oil pressure o Road testing under load o Checking for fluid leaks Assessment conditions Competency is to be assessed in the 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 light vehicle engines 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 engine specifications  Three different light vehicle engines with faults specified in the performance evidence  Diagnostic equipment for light vehicle engines  Tools, equipment and materials appropriate for repairing light vehicle engines. Assessors of this unit MUST satisfy the requirements for assessors in applicable vocational education and training legislation, frameworks and/or standards. Resources required Learning Resources available to students include: Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 4 of 33

AURLTE102 Diagnose and Repair Light Vehicle Engines  Automotive Technology (A System Approach) 7 th Edition – Chapters 2, 5, 6, 7, 9, 10, 11, 12, 13, 14  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 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 Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 5 of 33

AURLTE102 Diagnose and Repair Light Vehicle Engines Assessment 1 – Questioning Written Assessment 1. Identify some important items of personal safety or PPE when diagnosing and repairing engines? Safety glasses or goggles, gloves, respiratory or dust mask, hearing protection, protective clothing, closed- toe safety shoes, hair and beard protection, safety helmets, apron or shop coat, fire resistant clothing, first aid kit, fire extinguisher, emergency eye wash station, proper lighting, safety training, ventilation Fill in the Missing Words 2. Place the missing words to complete the following statement about safely removing an engine using the following words? Missing Words: engine, equipment, hoist, precautions, procedure Before removing the _______ engine________, clean it and the area around it. Also, check the service information for the correct ______ procedure_________ for removing the engine from a particular vehicle. Make sure you adhere to all ______ precautions_________. Make sure you have the tools and ______ equipment_________ required for the job. In addition to hand tools and some special tools, you will need an engine _______ hoist________ or crane and a jack. Multiple Choice question. Selected the correct answer. 3. Which of the following statements about safety glasses is true? A. They should offer side protection. B. The lenses should be made of a shatterproof material. C. Some service operations require additional eye protection to be worn with safety glasses. D. All answers are correct. True or False question 4. Be careful around belts, pulleys, wheels, chains, or any other rotating part. When working around these, make sure your hands, shop towels, or loose clothing do not come in contact with the moving parts. Hands and fingers can be quickly pulled into a revolving belt or pulley even at engine idle speed. ☐ True or ☐ False Multiple Choice question. Select the correct answer. 5. When using lifting equipment, what does SWL stand for? A. Safe weight lift. B. Safe working load. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 6 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines C. Safe working limit. D. Secure working load. 6. What precautions do you need to remember when inspecting or working on or near hot engine and exhaust components? Allowing cooling time, protective gear, use proper tools, beware of hot fluids, avoid loose clothing and jewelry, stay hydrated, ventilation, use heat shields, work area awareness, secure the vehicle, exhaust system cooling, proper jack placement, maintain clearances, use caution when removing caps or cover, proper lighting, emergency plan 7. How can you controlling hazardous substances, like engine oil and coolant that drip off engine components when diagnosing engines? Used drip pans and trays Place drip pans or trays under the engine or specific components you're working on to catch any drips or spills. These containers can prevent fluids from reaching the ground. Multiple Choice question. Selected the correct answer. 8. When working on light vehicle engines, which document should you use to find how to handle, trap, store and dispose of new or waste oils and coolants? A. Safety Data Sheet (SDS) . B. Technical Service Bulletin (TSB). C. Product Information Letter (PIL). D. All answers are correct. 9. Referring to the VACC Automotive Environmental Guide, explain the four [4] step procedure for trapping, storing and disposing of oils released from engines. 1 Trapping oils: Place drip pans or trays underneath the engine or components where oil leaks are likely to occur. Use absorbent materials, such as absorbent pads or mats, to capture and contain any oil spills or drips. Regularly inspect the absorbent materials and replace them as needed to prevent oversaturation. 2 Storing oils: Transfer collected oil from drip pans or absorbent materials into appropriate storage containers. Use containers specifically designed for oil storage and ensure they are sealed tightly to Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 7 of 33

AURLTE102 Diagnose and Repair Light Vehicle Engines prevent leaks or spills. Label the containers clearly with the type of oil and the date it was collected. 3 Disposing of oils: Identify local recycling centers or hazardous waste collection facilities that accept used oils for proper disposal. Do not mix different types of oils (e.g., engine oil and coolant) in the same container, as this can complicate proper disposal. Follow local regulations for transporting the used oil to the disposal facility. 4 Record keeping: Maintain records of the quantities of oil collected, stored, and disposed of. Keep track of disposal receipts and documentation as proof of proper disposal, which may be required for regulatory compliance. True or False question 10. Gasoline (petrol) and diesel engines are classified as external combustion engines. ☐ True or ☐ False 11. Describe the process of combustion. Combustion is a chemical reaction between a fuel and an oxidizer (usually oxygen) that releases energy in the form of heat and light. In the context of engines, such as internal combustion engines in vehicles, combustion is the fundamental process that produces power by converting the chemical energy stored in fuels into mechanical work. . 12. Name the four (4) strokes of a four (4) stroke engine below. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 8 of 33

AURLTE102 Diagnose and Repair Light Vehicle Engines A. Intake stroke B. Compression stroke C. Power stroke D. Exhaust stroke 13. Describe the four (4) stroke cycle. Intake stroke: The intake stroke begins with the piston at the top of its travel within the cylinder, close to the cylinder head. As the piston moves downward, the intake valve opens, allowing a mixture of air and fuel to be drawn into the combustion chamber from the intake manifold. The piston's movement creates a vacuum in the cylinder, which aids in pulling the air-fuel mixture into the chamber. By the end of this stroke, the piston is at the bottom of the cylinder, and the intake valve closes. Compression stroke: With both the intake and exhaust valves closed, the piston starts moving back upward, compressing the air-fuel mixture within the combustion chamber. The compression stroke significantly increases the temperature and pressure of the mixture, making it highly combustible. At the top of this stroke, just before reaching the top dead center (TDC), the spark plug (in gasoline engines) ignites the compressed mixture, causing combustion. Power stroke: The power stroke begins as the ignited air-fuel mixture rapidly burns and expands, generating a high- pressure force that pushes the piston downward. This downward movement of the piston transfers mechanical energy to the connecting rod, which in turn rotates the crankshaft. The crankshaft's rotation converts the linear motion of the piston into rotational motion, which is the primary source of power for the engine. Exhaust stroke: As the piston reaches the bottom of its travel, the exhaust valve opens. The piston then moves back upward, expelling the burned exhaust gases from the combustion process out through the open exhaust valve. The movement of the piston pushes the exhaust gases into the exhaust manifold and eventually into the exhaust system, where they are expelled from the vehicle's tailpipe. At the top of this stroke, just before reaching TDC, the exhaust valve closes, completing the cycle. True or False question Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 9 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines 14. Detonation occurs when part of the air/fuel mixture begins to ignite on its own. This results in the collision of two flame fronts. ☐ True or ☐ False True or False question 15. Detonation is caused by excessively advanced ignition timing, engine overheating, excessively lean mixtures, or the use of gasoline with too low of an octane rating. ☐ True or ☐ False Multiple Choice question. Select the correct answer. 16. To complete a four-stroke cycle in one cylinder, the crankshaft must rotate _____ degrees. A. 180. B. 360. C. 540. D. 720. True or False question 17. The ideal, or stoichiometric mixture of air and fuel for a gasoline (petrol) engine is 14.7. ☐ True or ☐ False True or False question 18. GDI systems inject gasoline directly into the combustion chamber and produces a stratified air-fuel charge that allows for complete combustion with lean air/fuel ratios. ☐ True or ☐ False Multiple Choice question. Select the correct answer. 19. In a GDI [gasoline direct injection] system, the tip of the injector is located ______. A. Inside the combustion chamber. B. On the throttle body. C. In the intake port. D. In the intake manifold plenum. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 10 of 33

AURLTE102 Diagnose and Repair Light Vehicle Engines Multiple Choice question. Select the correct answer. 20. The volume of the combustion chamber when the piston is at BDC divided by the volume of the chamber when the piston is at TDC is called _____. A. Displacement. B. Compression ratio. C. Volumetric efficiency. D. Mechanical efficiency. Multiple Choice question. Select the correct answer. 21. What is compression ratio? A. The diameter of the cylinder. B. Cylinder arrangement. C. The ratio of the air to fuel mixture. D. None of these answers is correct. Fill in the Missing Words 22. Place the missing words to complete the following statement about engine displacement using the following words. Missing Words: changed, cylinders, displacement, maintains, sum, superchargers, torque A cylinder’s _____ displacement__________ is the volume of the cylinder when the piston is at BDC. The trend in recent years has been toward smaller displacement engines fitted with turbo- or ______ superchargers_________. Many manufacturers have moved from 8-cylinder to 6-cylinder or 6-cylinder to 4-cylinder engines to improve fuel economy. Using a turbo- or supercharger ______ maintains_________ high levels of performance while the smaller engine improves economy. As an example, Ford recently announced it will be offering its 1.0 litre turbocharged 3-cylinder EcoBoost engine. An engine’s displacement is the _______ sum________ of the displacements of each of the engine’s _____ cylinders__________. Typically, an engine with a larger displacement produces more ______ torque_________ than a smaller displacement engine; however, many other factors influence an engine’s power output. Engine displacement can be _____ changed__________ by changing the size of the bore and/or stroke of an engine. True or False question 23. Engine displacement is commonly measured in cubic inches. ☐ True or ☐ False Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 11 of 33

AURLTE102 Diagnose and Repair Light Vehicle Engines 24. Describe what volumetric efficiency is? Volumetric efficiency is a measure of how effectively an internal combustion engine can draw in and utilize the air- fuel mixture during the intake stroke. It expresses the ratio of the actual amount of air-fuel mixture that enters the combustion chamber compared to the theoretical maximum amount that the engine's displacement could accommodate if the cylinder were perfectly filled. True or False question 25. Thermal efficiency is a measure of how much of the heat formed during combustion is available as power from the engine. ☐ True or ☐ False 26. Explain Mechanical Efficiency. Mechanical efficiency refers to the ratio of useful work or output produced by a machine or system to the input energy or work applied to it. In the context of engines, such as internal combustion engines used in vehicles, mechanical efficiency measures how effectively the engine converts the energy from fuel combustion into useful mechanical work that powers the vehicle's movement. 27. Describe the difference between torque and horsepower. Torque is the rotational force that an engine generates, often referred to as "twisting force." It's what allows an engine to generate the necessary force to turn the wheels and move the vehicle. While Horsepower is a measure of the rate at which work is done. It reflects the engine's ability to sustain a certain amount of work over time. Multiple Choice question. Select the correct answer. 28. _____ is a force that does work and tends to turn things. A. Inertia. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 12 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines B. Momentum. C. Torque. D. All answers are correct. 29. How much horsepower is generated by an engine running at 5800 rpm while producing 265 lbs./ft. of torque. Horsepower (hp) = (265 lb-ft × 5800 RPM) / 5252 ≈ 293.51 hp Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 13 of 33

AURLTE102 Diagnose and Repair Light Vehicle Engines 30. What is horsepower? Horsepower (hp) is a unit of measurement used to quantify the power or rate at which work is done. It was originally developed by James Watt, a Scottish engineer, to compare the power output of steam engines to the work done by horses. Horsepower is commonly used to describe the power output of engines, particularly internal combustion engines used in vehicles and machinery. True or False question 31. Brake horsepower (BHP) is the usable horsepower at the crankshaft. ☐ True or ☐ False Fill in the Missing Words 32. Place the missing words to complete the following statement about compression testing using the following words. Missing Words: Accurate, All, Battery, Button, Comparison, Compression, Consistent, Cylinders, Four, Fuel, Gauges, Hole, Increase, Install, Observe, Reading, Recorded, Remote, Revolution, Screw-in, Spark, Starter, Test, Warm, Wide-open 1 Before conducting a _______ compression________ test, disable the ignition and the ________ fuel_______ injection system. Most manufacturers recommend that the engine be _______ warm________ when testing. 2 Prop the throttle plate into a ______ wide open_________ position to allow an unrestricted amount of air to enter the _____ cylinders__________ during the test. 3 Remove ________ all_______ of the engine’s _______ spark________ plugs. 4 Connect a _______ remote________ starter button to the ______ starter_________ system. 5 Many types of compression ______ gauges_________ are available. The ______ dial_________ type tends to be the most _______ common________ and easiest to use. 6 Carefully ______ insert_________ the gauge into the spark plug ______ hole_________ of the first cylinder. 7 Connect a _______ battery________ charger to the car to allow the engine to crank at ______ consistent_________ and normal speeds needed for accurate _______ compression________ results. 8 Depress the remote starter ______ button_________ and observe the gauge’s _____ reading__________ after the first engine ______ revolution_________. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 14 of 33

AURLTE102 Diagnose and Repair Light Vehicle Engines 9 Allow the engine to turn through ______ for_________ revolutions and ______ observe_________ the reading after the fourth. The reading should ______ increase_________ with each revolution. 10 Readings observed should be ______ recorded_________. After all cylinders have been tested, a _____ comparison__________ of cylinders can be made. Multiple Choice question. Select the correct answer. 33. A wet compression test is performed on an engine after a dry compression test revealed low compression on one cylinder. If the compression on the low cylinder rises, it indicates __________? A. Leaking valves. B. Worn rings. C. Worn camshaft. D. All answers are correct. Multiple Choice question. Select the correct answer. 34. A zero reading means there is no leakage in the cylinder. Readings of __________ indicate that the cylinder will not hold any pressure. A. 10%. B. 20%. C. 50%. D. 100%. Fill in the Missing Words 35. Place the missing words to complete the following statement about cylinder leakage testing using the following words. Missing Words: adaptor, applies, air, crankshaft, compressed, compression, escaping, filler, gauge, leakage, measure, operating, pressure, radiator, source, spark, tdc, test, through If a compression _______ test_______ shows that any of the cylinders are leaking, a cylinder ______ leakage_________ test can be performed to _______ measure________ the percentage of _____ compression__________ lost and to help locate the ______ source_________ of leakage. A cylinder leakage tester _______ applies________ compressed air to a cylinder ______ through_________ the spark plug hole. The test normally includes the following steps: 1 Make sure the engine is at ______ operating_________ condition. 2 Remove the ______ radiator_________ cap, oil _______ filler________ cap, dipstick tube, ______ air_________ filter cover, and all ______ spark_________ plugs. 3 Rotate the _____ crankshaft__________ with a remote starter button so that the piston of the tested cylinder is at ________ TDC_______ on its compression stroke. This ensures that the valves of that cylinder are closed. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 15 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines 4 Insert the threaded ______ adapter_________ on the end of the tester’s air ______ pressure_________ hose into the spark plug hole. 5 Allow the ______ compressed_________ air to enter the cylinder. 6 Observe the _______ gauge________ reading. 7 Listen and feel to identify the source of any _______ escaping________ air. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 16 of 33

AURLTE102 Diagnose and Repair Light Vehicle Engines True or False question 36. An oil pressure test is used to determine the wear of an engine’s parts. ☐ True or ☐ False Fill in the Missing Words 37. Place the missing words to complete the following statement about oil pressure testing using the following words. Missing Words: adapters, clearances, contaminated, faulty, engine, gauge, high-pressure, hose, kpa, low, manufacturer’s, much, oil, operating, pressure, problems, psi, reading, relief, Run, running, screen, sensor, test, viscosity An oil ______ pressure_________ tester is a gauge with a ______high pressure_________ hose attached to it. The scale of the _______ gauge________ typically reads from 0 to 100 _______ psi________ (0 to 690 ______ kpa_________). Using the correct fittings and ______ adapters_________, the hose is connected to an ______ oil_________ passage in the ______ engine_________ block. The ______ test_________ normally includes the following steps: 1 Remove the oil pressure _______ sensor________ and tighten the threaded end of the gauge’s _____ hose__________ into that bore. 2 _____ run__________ the engine until it reaches normal _____ operating__________ temperature. 3 Observe the gauge _______ readings________ while the engine is ______ running_________ at about 1,000 rpm and at 2,500 rpm (or the specified engine speed). 4 Compare the readings to the ______ manufacturer’s_________ specifications. Excessive bearing _____ clearances__________ are not the only possible causes for ______ low_________ oil pressure readings; others are oil pump-related ______problems_________, a plugged oil pickup ______ screen_________, weak or broken oil pressure ______ relief_________ valve, low oil level, _____ contaminated__________ oil, or low oil viscosity. Higher than normal readings can be caused by too ______ much_________ oil, cold oil, high oil _____ viscosity__________, restricted oil passages, and a ______ faulty_________ pressure regulator. True or False question 38. Engine oil pressure testing should be tested with the engine cold. ☐ True or ☐ False Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 17 of 33

AURLTE102 Diagnose and Repair Light Vehicle Engines 39. Identify the following fluid leaks from a vehicle. Description Probable Source Honey or Dark Greasy Fluid Engine oil leak Honey or Dark Thick Fluid with a Chestnut Smell Transmission fluid leak Green, Sticky Fluid Coolant leak Slippery Clear or Yellowish Fluid Break fluid leak Slippery Red Fluid Power steering leak Bluish Watery Fluid Windshield washer fluid 40. On the picture of the engine gaskets and seals below, write down the seven [7] areas where engine oil leaks could occur. 1 PVC valve grommet 2 Intake manifold end seal 3 Cylinder head gasket 4 Oil pan gasket 5 Front crankshaft seal 6 Water pump gasket 7 Intake manifold gasket True or False question 41. Examining and interpreting the vehicle’s exhaust can give clues of potential engine problems. ☐ True or ☐ False True or False question 42. It is normal for white smoke to come out of the tailpipe. This is caused by the water that has condensed in the exhaust system as it becomes steam due to the heat of the exhaust system. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 18 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines ☐ True or ☐ False 43. The colour of the exhaust is used to diagnose engine concerns. For the engine types below, use the visual signs to help diagnose the problem and possible causes. Engine Type Visible Sign Diagnosis Probable Causes Petrol Grey or Black Smoke Rich air-fuel mixture or incomplete combustion. 1. Malfunctioning or dirty fuel injectors. 2. Faulty oxygen sensors. 3. Incorrect fuel pressure. 4. Clogged air filter. 5. Ignition system issues. 6. EGR valve malfunction. 7. Vacuum leaks. Diesel Grey or Black Smoke Rich air-fuel mixture or incomplete combustion. 1. Faulty or worn injectors. 2. Low compression. 3. Incorrect timing. 4. Turbocharger issues. 5. Clogged air filter. 6. Exhaust system restrictions. 7. Incorrect fuel quality. Petrol and Diesel Blue Smoke Burning oil. 1. Worn piston rings or cylinder walls. 2. Valve stem seal leakage. 3. PCV system issues. 4. Overfilled or degraded engine oil. 5. Turbocharger oil seals worn (diesel). 6. Valve guide wear. 7. Crankcase ventilation problems. Petrol White Smoke Coolant entering combustion chambers. 1. Cylinder head gasket failure. 2. Cracked cylinder head or block. 3. Engine overheating. 4. Cracked or damaged intake manifold. 5. Faulty coolant temperature sensor. 6. Coolant contamination due to internal leaks. Diesel White Smoke Coolant entering combustion chambers. 1. Cylinder head gasket failure. 2. Cracked cylinder head or block. 3. Engine overheating. 4. Cracked or damaged intake manifold. 5. Faulty coolant temperature sensor. 6. Coolant contamination due to internal leaks. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 19 of 33

AURLTE102 Diagnose and Repair Light Vehicle Engines 44. Give some examples of abnormal engine noises, including a description of the sound, and their likely causes below. Type Sound Mostly Heard During Possible Causes Ring noise Metallic rattle or knocking. Engine acceleration or deceleration. Worn or damaged piston rings, leading to excess clearance between the piston and cylinder wall. Piston slap Rapid, sharp, metallic noise. Cold starts or when the engine is cold. Excessive piston-to-cylinder clearance due to worn pistons or cylinders. Piston pin knock Sharp, metallic hammering. Engine operation, especially under load. Loose or worn piston pin (wrist pin) or connecting rod small-end bushing. Main bearing noise Deep knocking or rumbling. Engine operation, synchronized with RPM. Worn or damaged main bearings, leading to excessive clearance. Rod bearing noise Knocking or rumbling, often a "knock-knock" noise. Engine operation, synchronized with RPM. Worn or damaged rod bearings, resulting in excessive clearance. Thrust bearing noise High-pitched noise or grinding. Acceleration or deceleration. Worn or damaged thrust bearings, affecting axial movement. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 20 of 33

AURLTE102 Diagnose and Repair Light Vehicle Engines Tappet noise Rapid tapping or ticking. Engine idling or low RPM. Worn hydraulic lifters or out-of-spec valve clearances. Timing chain noise Rattling or slapping Engine operation, especially at low RPM. Loose or worn timing chain or tensioner. True or False question 45. The maximum amount of cylinder out-of-roundness allowed in most cases is 0.0015 in. (.038 mm). ☐ True or ☐ False Multiple Choice question. Select the correct answer. 46. The maximum amount of cylinder taper normally allowed is: A. 0.0015 in. (.038 mm). B. 0.006 in. (.15 mm). C. 0.015 in. (.38 mm). D. 0.06 in. (1.5 mm). Multiple Choice question. Select the correct answer. 47. A cylinder bore can be checked for out-of-roundness with a _____. A. Dial bore gauge. B. Telescoping gauge and micrometre. C. Both “dial bore gauge” and “telescoping gauge and micrometre”. D. Neither both “dial bore gauge” nor “telescoping gauge and micrometre. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 21 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines True or False question 48. A cylinder can have a taper of up to 0.010 in. (.254 mm) and be acceptable. ☐ True or ☐ False True or False question 49. A micrometre is used to measure the connecting rod journal for taper. ☐ True or ☐ False True or False question 50. A micrometre is used to measure the connecting rod journal for out-of-roundness. ☐ True or ☐ False True or False question 51. Crankshaft endplay or end clearance check is carried out with a feeler gauge. ☐ True or ☐ False True or False question 52. Crankshaft endplay or end clearance check is carried out with a dial indicator. ☐ True or ☐ False True or False question 53. Undersized bearings are being discussed. A 0.001 in. or 0.002 in. bearing can be used on a stock crankshaft journal if the oil clearance [difference between the bearing diameter and the journal diameter] is slightly excessive and the journal is not excessively tapered or out of round. ☐ True or ☐ False True or False question 54. Undersized bearings are being discussed. A 0.010 in., 0.020 in., and 0.030 in. undersized bearings are only used when the crankshaft journals have been reground. ☐ True or ☐ False Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 22 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 23 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines Multiple Choice question. Select the correct answer. 55. Plastigage is used to check the clearance between _____. A. Connecting rod journal and connecting rod bearing. B. Main bearing journal and main bearing. C. Both “connecting rod journal and connecting rod bearing” and “main bearing journal and main bearing”. D. Neither “connecting rod journal and connecting rod bearing” nor “main bearing journal and main bearing”. True or False question 56. Maximum taper for a rod journal is typically 0.001, 0.04 in (0.04, 0.001 mm) ☐ True or ☐ False 57. Describe how to use Plastigage. Plastigage is a simple and effective tool used to measure the clearance or gap between two mating surfaces, such as those found in engine bearings. It's often used in automotive and mechanical applications to ensure proper tolerances. 58. How is deck warpage checked? Checking for deck warpage is an important step in maintaining the structural integrity and safety of a deck. Warping can occur due to changes in moisture, temperature, and other environmental factors. Here's how you can check for deck warpage: Perform a visual inspection of the deck's surface. To assess the flatness of the deck surface, use a long carpenter's level or a straight board. You can use a string line to check for warping. Rolling a ball, such as a small rubber ball, across the deck surface can also help you identify uneven areas Walk across the deck, paying attention to any areas that feel uneven or give underfoot. Excessive moisture can contribute to warping. True or False question 59. To prevent cylinder head warpage during disassembly, the head bolts should be randomly. ☐ True or ☐ False Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 24 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines True or False question 60. You should rotate the engine by hand until all the cam timing marks align to ensure that the cam timing was set properly before the belt tensioner pulley to remove its tension on the belt before removing the timing belt. ☐ True or ☐ False True or False question 61. While removing the cylinder head, you should keep all rocker arms and pushrods in order. ☐ True or ☐ False Multiple Choice question. Select the correct answer. 62. Extreme care should be used when using a scraper or wire brush on parts made of _____. A. Cast iron. B. Stainless steel. C. Titanium. D. Aluminium. True or False question 63. You should use masking tape and a marking pen to label electrical connectors and vacuum line when disassembling an engine. ☐ True or ☐ False 64. Why would you want to have a digital camera available for an engine R&R job? Having a digital camera available for an engine removal and replacement (R&R) job can be incredibly beneficial. In summary, a digital camera is a practical tool that enhances your ability to disassemble, document, and reassemble an engine accurately and efficiently. It minimizes errors, saves time, and ensures that the engine R&R job is completed successfully. 65. When disassembling an engine, what should you be looking for? Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 25 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines When disassembling an engine, there are several key things you should be looking for to ensure a thorough inspection and proper reassembly. Here's a comprehensive list of what to pay attention to: Wear and Damage, Leaks, Corrosion and Rust, Cracks and Fractures, Gasket Condition, Alignment Marks, Fasteners, Seized Components, Fluid Contamination, Wiring and Connections, Vacuum Lines, Belt and Chain Wear, Timing and Alignment, Valve Train Components, Cylinder Wall Condition, Coolant Passages, Exhaust and Intake Ports, Accessories and Attachments, Bearings and Bushings, O-rings and Seals, Emission Control Components, Cleanliness True or False question 66. The flywheel for a vehicle with a manual transmission should be examined for damage and signs of clutch problems. ☐ True or ☐ False True or False question 67. Most cylinder wear occurs at the top of the ring travel. ☐ True or ☐ False True or False question 68. A cylinder wall with too smooth surface will prevent the piston rings from seating properly. ☐ True or ☐ False Multiple Choice question. Select the correct answer. 69. Which operation must be performed before removing the pistons from an engine? A. Install rod bolt protector sleeves. B. Remove the cylinder ridge with a ridge reamer. C. If the connecting rods are not marked from the factory, number the rods with a prick punch or number stamp. D. All answers are correct. True or False question 70. A lifter that has a concave contact surface must be replaced. ☐ True or ☐ False Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 26 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines Multiple Choice question. Select the correct answer. 71. Valve springs should be checked for all of the following EXCEPT: A. Freestanding height. B. Squareness. C. Compressed height. D. Open pressure. Multiple Choice question. Select the correct answer. 72. Cylinder head warpage can be measured with _____. A. A straightedge and feeler gauge. B. A dial indicator. C. A surface gauge. D. A ball gauge and outside micrometre. 73. While disassembling a cylinder head, what would indicate that the valve seals are worn or damaged? While disassembling a cylinder head, several signs can indicate that the valve seals are worn or damaged. Valve seals play a crucial role in preventing oil from entering the combustion chamber and also ensuring proper lubrication of the valve stems. Here are some indications of worn or damaged valve seals: Oil Buildup on Valve Stems, Oil Consumption, Visible Damage, Valve Stem Condition, Compression Test Results, Smoke on Startup, Valve Guide Wear, Poor Idle Quality, Valve Seat Deposit Buildup, 74. Name three (3) areas on the cylinder head where cracks are most likely to occur? 1 Combustion Chamber 2 Valve Seats and Guides 3 Coolant Passages 75. What is the most common cause of warpage in an aluminium cylinder head? The most common cause of warpage in an aluminum cylinder head is overheating. Aluminum is a metal that is more prone to thermal expansion and contraction compared to other materials like cast iron. If an aluminum cylinder head is subjected to excessive heat, it can expand unevenly, leading to warpage. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 27 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines True or False question 76. When installing a segmented oil control ring, the end gaps of the three pieces must line up. ☐ True or ☐ False True or False question 77. Tightening of a bolt should be done with an impact wrench followed by a torque wrench. ☐ True or ☐ False True or False question 78. A torque-to-yield bolt can be reused if it is not damaged. ☐ True or ☐ False True or False question 79. Gasket sealants should be used on all gasket installations. ☐ True or ☐ False True or False question 80. A gasket installed upside down or reversed may cause loss of oil pressure, overheating and engine failure. ☐ True or ☐ False True or False question 81. After the break-in period, the cylinder head and intake manifold bolts may need to be retorqued. ☐ True or ☐ False Multiple Choice question. Select the correct answer. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 28 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines 82. What keeps the cylinder head and block aligned before the head bolts are torqued? A. Head gasket. B. Friction between head gasket and block. C. Gravity. D. Dowel pins. 83. Describe how the rocker arms are adjusted on OHV engines with hydraulic lifters. Adjusting the rocker arms on Overhead Valve (OHV) engines with hydraulic lifters involves ensuring proper valve clearance between the rocker arms and the valve stems. Hydraulic lifters automatically adjust for valve lash, but periodic adjustments may be needed due to wear and other factors. Here's a step-by-step guide on how to adjust rocker arms on OHV engines with hydraulic lifters: Prepare the Engine, Remove Valve Covers, Identify the Adjusting Method, Find the Compression Stroke, Adjust Valve Lash, Recheck Valve Clearance, Repeat for Other Cylinders, Reassemble and Test, Regular Maintenance. True or False question 84. When installing a piston and connecting rod assembly, various markings can be used to make sure the installation is correct. Always check the service information for exact locations. ☐ True or ☐ False True or False question 85. When changing a timing belt or chain, a camshaft locking tool can be used to hold the camshaft in place. ☐ True or ☐ False 86. Consider the various post repair checks that you would make during a road test on the engine? During a road test following an engine repair, there are several important checks and observations you should make to ensure that the engine is functioning properly and that the repair was successful. Here's a list of various post-repair checks to consider during a road test: During a road test following an engine repair, there are several important checks and observations you should make to ensure that the engine is functioning properly and that the repair was successful. Here's a list of various post-repair checks to consider during a road test: Engine start, Idle quality, Acceleration and power, Throttle response, Noises and vibrations, Exhaust smoke, Engine temperature, Cooling system, Transmission shift, Brakes and steering, Fluid levels, Warning lights, ECM Scanning, Engine performance data, Exhaust emission, Test different driving condition, Record observations, Retest after repair Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 29 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines 87. To prevent engine damage after it has been rebuilt and to ensure good initial oil control and long engine life, the proper break-in procedure must be followed. Describe what is the proper break-in procedure? The proper break-in procedure after an engine rebuild is essential to ensure good initial oil control, proper seating of components, and long engine life. While the specifics may vary depending on the engine type and manufacturer recommendations, here is a general outline of the steps involved in a proper break-in procedure: Used the right lubricant, First start and warm ups, Vary RPM and loads, Avoid heavy loads, Avoid full throttle, Monitor Temperature, Vary driving conditions, Allow engine breaking, Check for leaks and noises, Change oil and filters, Gradual performance increase 88. What the is objective of the break-in procedure? The primary objective of a break-in procedure for a newly rebuilt or overhauled engine is to ensure the proper seating and bedding-in of various internal components. This process is critical to achieving optimal long-term performance, reliability, and longevity of the engine. Fill in the Missing Words 89. Place the missing words to complete the following statement about relearn procedures using the following words. Missing Words: based, computer, condition, engine, reconnected, resets, service, vehicles The computer in most late-model _____ vehicles__________ must undergo a relearn or initialization procedure after the battery has been ______ reconnected_________. This procedure allows the computers to learn the condition of the ________ engine_______ and make adjustments according to the engine’s restored _____ condition__________. The last time the engine was run, the computer made adjustments ________ based_______ on the engine faults present. This procedure allows the ______ computer_________ to see that those faults were corrected. Initialization also _____ resets__________ the reference for the crankshaft position sensor and PCM. Always follow the manufacturer’s procedures as outlined in the _____ service__________ information. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 30 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines 90. Why is it very important that the Job Card is completed correctly? Completing the job card correctly is of utmost importance in various industries, especially in automotive repair, maintenance, and other technical fields. Here are some reasons why completing the job card accurately and thoroughly is crucial: Documentation and Accountability, Communication, Legal and Regulatory Compliance, Customer Satisfaction, Quality Control, Efficiency and Time Management, Diagnostics and Problem Solving, Inventory Management, Performance Tracking, Warranty Claims, Knowledge Transfer, Professionalism and Reputation. In summary, completing the job card correctly is not only a matter of proper documentation but also an essential aspect of maintaining quality, communication, accountability, compliance, and customer satisfaction. It's a fundamental practice that ensures efficient operations, legal compliance, and the overall success of the work undertaken. True and False 91. An automotive technician must adhere to workshop safety guidelines and procedures when using all tools and equipment. ☐ True or ☐ False True and False 92. An automotive technician is required to document the work that was performed on a vehicle. Writing or typing in the description of the steps performed during the diagnosis of the vehicle should be worded as if the technician is talking to the customer. ☐ True or ☐ False True and False 93. Inspect your tools for cracks, broken parts, or other dangerous conditions before you use them. Never use broken or damaged tools. ☐ True or ☐ False True and False 94. For best results and long tool life, each tool used must be cleaned and checked before placing it back into the toolbox. ☐ True or ☐ False Multiple Choice question. Select the correct answer. 95. Lockout/tagout practices and procedures are intended to reduce the risk of automotive technicians’ inadvertently using tools, equipment or materials that have been determined to? Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 31 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines A. Be unsafe or potentially unsafe. B. That are in the process of being serviced. C. Both “ Be unsafe or potentially unsafe” and “That are in the process of being serviced” . D. Neither “Be unsafe or potentially unsafe” and “That are in the process of being serviced”. True and False 96. Disposing of excess engine oil, and coolants, can be dispose into their correct sealed recycling drum. ☐ True or ☐ False True and False 97. Second-hand engine components, blocks, cylinder heads etc that are in good condition can be reused on the other vehicles of the same make and model? ☐ True or ☐ False Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 32 of 33

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AURLTE102 Diagnose and Repair Light Vehicle Engines Multiple Choice question. Selected the correct answer. 98. Which source of information will give you the most detail about diagnosing faults in petrol engine systems on the vehicle you are working on? A. Workshop manual. B. Owner’s manual. C. Google. D. Textbooks. True and False 99. An automotive technician must adhere to workshop safety guidelines and procedures and follow the manufactures procedures in the workshop manual when diagnosing faults in engine. ☐ True or ☐ False 100. You are diagnosing engine mechanical fault 2007 Toyota FJ Cruiser and carrying out a compression test. Referring to the 2007 Toyota FJ Cruiser Engine Mechanical Workshop Manual, locate and interpret the engine compression pressures specification for the following: Compression Pressure: 1300kpa Minimum Compression Pressure: 1000kpa Difference between Cylinder Pressure: 100kpa Recommended Compression Test Engine RPM: 2500rpm Multiple Choice question. Select the correct answer. 101. A work order is selected or assigned to a service technician who then performs the listed tasks. The work order should be written so that the technician knows exactly what needs to be done. However, if there is any doubt, the technician should clarify the needed task with the ________ or the person who spoke to the customer. A. Service advisor . B. Service technician. C. Spare parts manager. D. New car sales manager. Document Name: Student Written Questions – AURLTE102 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 33 of 33

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AURLTE102 Task 1

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