AURTTE104 & AURTTA104 Student Assessment - Theory v1.1
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Subject
Mechanical Engineering
Date
Jan 9, 2024
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docx
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Uploaded by PrivateMorningBat27
Course Code
AUR30620
Course Name
Certificate III in Light Vehicle
Mechanical Technology
Unit Code
AURTTE104 /
Unit Name
Inspect and service engines / Carry
AURTTA104
out servicing operations
Due Date
Assessment Name
Automotive Portfolio
Part A: Short answer questions
Student No
.
________________
Student Name
Rommel Garcia
Student Phone
0410725047
Student Email
rommelgarcia07@hotmail.com
Student Declaration
I declare that this assessment is my own work and where my work is supported by documents from
my workplace placement/employer permission has been granted.
Note:
Filling out this coversheet as part of an electronic submission and approving the above information
will operate in the same way as physically signing this cover sheet.
Student name or signature: Rommel Garcia
Office Use Only
Date/s Received:
___/___/___
___/___/___
___/___/___
Date/s Assessed:
___/___/___
___/___/___
___/___/___
Result of Assessment:
___________
___________
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Entered on Training Plan
Moderation
Signature
Note for Assessors:
Filling out the above Office Use Only section as part of an electronic submission will
operate in the same way as physically signing this cover sheet. If not physically signed, Assessor must print
their name in signature box
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Imagine Education
Student Assessment Cover
Sheet
Course Code and Name:
AUR30620 Certificate III in Light Vehicle Mechanical Technology
Unit Code:
AURTTE104 / AURTTA104
Unit Title:
Inspect and service engines / Carry out servicing operations
For this assessment you are required to answer all of the questions. You are permitted to research
the answers by reading the learner guide, text books, theory notes and accessing the internet. If
more room is needed label each task with the question number and use headings or dot points to
make your work clear for your trainer and assessor.
Please follow the
Referencing Guide
contained on your Course handbook.
Please attach a
student assessment cover sheet
to each unit submission. You must complete the
cover sheet in full detail.
1.
Where can you find the information listed in the table below?
Item
Location
Three (3) examples
Content
Three (3) examples
Workplace procedures and
safety data sheets related to
inspection and servicing of
engines
and
servicing
operations.
Service manager
Job card
Shop manual
Workshop procedures
Safety procedures
Service history
Manufacturer
specifications
related to
inspection and
servicing of engines and
servicing operations.
Manufacturer website
Car manual checklist
Service manual
Parts needed
Service procedure
Engine information
Diagnostic information and
recommended processes.
Service manual
Shop manual
Due date of services
Diagnostic procedure
Service bulletin
2.
Describe what methods you would use to locate information from the customer regarding the
inspection and servicing of engines and servicing operations. List three (3) examples.
Car manual
Job card
Car maintenance and servicing checklists
3.
What strategies can you use to interpret the information you require for the inspection and
servicing of engines and servicing operations?
Check the owner's manual
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Imagine Education
Assessment Questions
Part A
Manufacturer's specification
Service history of the vehicle
4.
Describe the workplace procedures listed in the table below.
Establish serviceability of
tools and equipment.
Serviceability of tools and equipment must be done always after
using it. Before you store them in their designated places you must
clean it and always inspect if it's still working or it has a crack.
Documentation
procedures.
Workplace documentation requirements:
● Follow privacy protocols
● Be accurate and precise
● Pay attention to details
● Alter appropriate personnel if required
● Store documentation appropriately
5.
Describe the housekeeping procedures listed in the table below.
Tools
and
equipment
procedures.
Regularly check the testing equipment to ensure it provides the
appropriate standard of security. Make sure all tools and equipment
does not have any damage before bringing it back to designated
places.
Storage of equipment
procedures.
Place your tools in a dry place. It seems obvious, but
garages and basements and other enclosed spaces,
particularly if they are not heated or air-conditioned,
may have problems with humidity. If you keep your
tools in such a location, mainly if you keep them out on
shelves or pegboards, consider investing in a
dehumidifier to maintain the level of dampness down.
They are not expensive, especially compared to your
investment in your equipment, and most of them let
you set a standard of humidity, so the dehumidifier only
turns on when it needs to.
Store the power tools in their original cases. When you
have a climate-controlled space, the hard-plastic cases
they come with are your best choice for storing power
tools. They are not only kept free from humidity but are
also well covered.
Identification, tagging and
isolation
of
faulty
equipment procedures.
All the equipment should have a tag when it's not usable. Check all
the tools and equipment if it has any fault. Report the faults
identified to the supervisor.
Safe disposal of excess
material procedures.
Used lubricants awaiting disposal are just as necessary to be stored
appropriately as the new oil, if not more so. Store used oil in a
separate location from new oil and follow local HSE guidelines for
the combination of various tyand put it pes of discarded oil or other
items, such as oily rags.
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For used filters, the best practice is to separate the metal portion for
recycling, compress the media to remove the oil and dispose of the
oil in a used-oil container. It reduces the fire risk from discarding the
entire filter in the trash. Dispose of greasy or oily rags in proper
disposal cans and do not allow them to accumulate or become a
hazard.
Recycling procedures.
Sort out all the recyclable materials and put it to the recycle bins.
6.
Describe the workplace health and safety requirements and procedures for working with the
following:
Equipment
WHS requirements and procedures
Rotating and hot
components.
Always wear a protective gear to prevent any accidents
while servicing a car
Let the car cool down before opening the cap of the
radiator
Take off all the jewelries before servicing a car
Engine oils.
Always keep the floor clean before and after servicing a
car
Wait until the engine cools down before doing a change
oil
Always wear a gloves when working with oil
High energy ignition and
charging systems.
Make sure to disconnect the battery terminals
Take off all of the jewelries when working with the wires
Always wear a protective gear
High voltage injectors.
Never wear a jewellery when working with high voltage injectors
especially diesel engines that present high pressure injectors.
Lifting and supporting
equipment.
Never trust a jack stand, Always use a jack stand to support the car
when working under the car. Use only hoists according to
manufacturer's specification and only person that has proper
knowledge about hoist.
Working in pits.
Make it sure that it's clean and work in the well ventilated area.
Hoists, including
•
List twelve (12) pre-
operational
safety
PRE-OPERATIONAL SAFETY CHECKS
Locate and ensure you are familiar with all machine operations and
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checks that apply to
two-point hoists, four-
point hoists and all
other types of hoists.
•
List six (6) operational
safety checks that apply
to two-point hoists,
four-point hoists and all
other types of hoists.
controls.
Ensure all guards are fitted, secure and functional. Do not operate if
guards are missing or faulty.
Ensure the vehicle hoist has operating and maintenance instructions
permanently located and clearly visible.
Check the capacity of the hoist compared to the weight of the
vehicle. If vehicle is too heavy, do not proceed.
Ensure the area is clean and clear of grease, oil.
Check workspaces and walkways to ensure no slip/trip hazards are
present.
Check that all safety devices are in good condition.
Ensure support arms are capable of being locked in position.
Ensure rubber pads are in good condition on all load points.
OPERATIONAL SAFETY CHECKS
Centre the vehicle on the hoist, ensuring the weight is evenly
distributed to the front and rear.
Identify the correct jacking points and place the lifting pads under
the vehicle at the front and rear on the jacking points, ensuring
contact.
Only one person shall operate the hoist at a time.
The hoist must not be operated unless it has a current certificate of
inspection.
Ensure the area is clear of people and equipment before operating.
Check vehicle stability by looking at the jacking points.
Engage manual lock.
Jack hoists.
Make sure that the vehicle doesn't have occupant and the engine is
off. Always check the jack hoist maximum load capacity if it's
enough to lift the vehicle.
Procedures
for
daily
inspection of hoists.
List two (2) for the lift
arms.
List six (6) for the chains
and cables.
The first step in finding any abnormalities in the equipment is a
visual inspection, which should be a part of a hoist owner’s daily
operation. During an inspection, the following checkpoints for
manually operated chain hoists are vital to ensuring proper
operation. Read the hoist user’s manual for the specific
requirements of your equipment.
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Check to ensure that hoists are not tagged, “Out of
Service”.
Verify hoist nameplates are present and complete.
Ensure that all warning and safety labels are not missing
and are legible.
Test run to ensure that all motions agree with control
device markings.
Run the hoist through the full range of motions, all the
way up and down.
Check to make sure that there is no load drift; the hoist
must hold load without any drift.
Check for hook damage. Inspect for: cracks, nicks,
gouges, twisting, deformation of the throat opening and
wear on saddle or load bearing point. Refer to the
owner’s manual provided by the original manufacturer.
Check hook latch operation and inspect for wear or
deformation. The latch must be present and
operational.
Deformation between the hook fitting and shank.
Load chain inspection. Check for: nicks, gouges,
deformation, flaws, heat damage, bent links, wear,
stretch, corrosion,pitch elongation and proper
lubrication.
Inspect Hand Chain for deformation and pitch
elongation.
Inspect Cable Hoist wire rope for: broken wire, broken
strands, kinks and any deformation to the rope
structure.
Reeving: Ensure that the chain or wire rope is properly
reeved and that the rope or chain is not twisted around
each other.
Limit Switches: Check to ensure that the upper limit
device stops the lifting motion of the hoist load block
before striking any part of the hoist.
Deformation and corrosion of the body frame, gear
case, gears, sheaves, bearings and chain stopper pin.
Presence of bolts and nuts.
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Wear of brake screws, linings and ratchet wheels.
Check for any sign of oil leakage on the hoist and/or on
the ground beneath the hoist.
Isolating and stabilising a
vehicle
Check the hoist regularly if it has a fault. All the repairs should
always be made with a original equipment parts. Don't operate if it
has a malfunctions or has a faulty.
Safe handling of hazardous
oils, fluids and greases
Avoid contamination during the dispensing process
Always put it to right containers
Label your lubes
Dispense lubricants using the appropriate transfer
equipment
Know your oils are still good oils
7.
Describe the environmental requirements including procedures for trapping, storing and
disposing of fluids released from inspection and servicing engines. Write your answers in the
table below.
Action
Environmental Requirements and Procedures
Trapping.
List three (3)
Always use a drip trays to catch the liquids.
Make it sure that your proper container is positioned below the oil
drain.
When you remove the drain plug, let it drop into the recycling
container.
Storing.
List three (3)
Always check the containers if there's any leak.
Never put the liquid waste into waste bins.
Use a proper container to prevent leakage.
Disposing.
List three (3)
Always put the used oil in correct container.
Go to the nearest car parts store and ask them if they are accepting
a used oil to recycle and re-use it.
Check with local authorities about disposing of used oil.
Explain how you identify
the following oils and
fluids:
•
Engine oils
•
Antifreeze
•
Transmission fluid
•
Power steering fluid
•
Brake fluid
•
Windshield wiper fluid
Puddles under the car of lime-green, orange, pink, or blue-green
after you've parked. Antifreeze makers use those dye colors to
differentiate coolant from other fluids used in cars. Engine oil is gold
or black (when dirty), and transmission fluid is dark red. The car
starts running hot or overheating
Proper power steering fluid will be fairly clear with an amber or
pinkish color to it. If it looks more brown or black, it means your
fluid has been contaminated by rubber. This often comes from
nearby hoses and seals. You'll have to flush and replace your fluid if
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it's too dirty.
So, what does brake fluid look like? It’s typically light yellow in color,
but will brown as it ages. Now that you know what color brake fluid
is, if you see it under your car around your wheel wells, you have a
leak. You’ll also need to know how to check the age and quality of
your brake fluid, so you can make sure your brake system is properly
lubricated.
Windshield washer fluid is normally blue, but can be other colors
depending on the manufacturer.
Explain how you handle
oils and fluids.
Always put a oil pans below of the bonnet of the vehicle when
working with oils.
The collected fluids must be transferred to the right containers.
The containers must be stored in right place.
8.
Identify and explain the function of the engine components in the table.
Engine components
Name and function of component
Cylinder head
They're key to controlling air flow in and
out of the cylinders and fuel deployment.
The cylinder head also holds the injectors
and valves – and contains more moving
parts than any other part of the engine.
Although largely unnoticed, the cylinder
head plays a key role in your engine.
Cylinder block
The cylinder block is one of your engine's
central components. It plays a key role in
the lubrication, temperature control and
stability of the engine and it has to be of
the highest quality so there is no room for
short cuts.
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Connecting rod
The con-rod connects the piston to the
crankshaft to transfer combustion pressure
to the crankpin. There are bearing portions
at both ends, the piston side is called the
small end, and the crankshaft side, the big
end.
Pistons
A piston aids in the transformation of heat
energy into mechanical work and vice
versa. Because of this, pistons are a key
component of heat engines. Pistons work
by transferring the force output of an
expanding gas in the cylinder to a
crankshaft, which provides rotational
momentum to a flywheel.
Valves
The valves prevent the backward flow of
blood. These valves are actual flaps that
are located on each end of the two
ventricles (lower chambers of the heart).
They act as one-way inlets of blood on one
side of a ventricle and one-way outlets of
blood on the other side of a ventricle.
Intake manifold
Featuring a series of tubes, the intake
manifold ensures that the air coming into
the engine is evenly distributed to all the
cylinders. This air is used during the first
stroke of the combustion process. The
intake manifold also helps cool down the
cylinders to prevent the engine from
overheating.
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Exhaust manifold
Bolted directly to the engine block, the
exhaust manifold is the first section of a
vehicle's exhaust system. It funnels
exhaust gases from all the cylinders and
routes them to the car's catalytic
converter. V-type engines have a separate
manifold for each cylinder bank.
Electric start
The electric starter system works by
converting electric current energy so that
it can be used to run the vehicle engine.
This type of starter is widely used on
motorcycles and cars because it allows the
vehicle engine to start and run easily.
9.
Identify and describe the function of the following in engine systems:
Lubrication.
Lubricants provide three major functions within your engine:
cooling, cleaning and reducing friction. The goal is to protect the
engine components against damage from heat, contaminants and
metal-to-metal contact.
Cooling system.
The cooling system serves three important functions. First, it
removes excess heat from the engine; second, it maintains the
engine operating temperature where it works most efficiently; and
finally, it brings the engine up to the right operating temperature as
quickly as possible.
Fuel system.
The function of the vehicle fuel system is to store and supply fuel to
the engine. The engine intake system is where the fuel is mixed with
air, atomized, and vaporized. Then it can be compressed in the
engine cylinder and ignited to produce energy or power.
Air system.
The function of the air intake system is to allow air to reach your
engine. Oxygen in the air is one of the necessary elements for the
engine combustion process.kk
10.
Describe the basic operation of the following spark ignition and compression ignition engines:
Two-stroke spark ignition
engines.
A 2-stroke engine is a type of small internal combustion engine that
uses two different piston strokes to complete one operating cycle.
During this cycle, the crankshaft rotates once while the piston goes
up and down once to fire the spark plug.
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Four stroke spark ignition
engines.
In a spark ignition engine, the fuel is mixed with air and then
inducted into the cylinder during the intake process. After the piston
compresses the fuel-air mixture, the spark ignites it, causing
combustion. The expansion of the combustion gases pushes the
piston during the power stroke.
Four stroke compression
ignition engines.
On the other hand, a four-stroke compression ignition engine works
by inducting air from the intake manifold into the cylinder during
the intake stroke, TDC to BDC (see Figure 2), then the intake valves
close and the piston then moves back toward TDC while
compressing the air to elevated temperature and pressure.
11.
Describe the following types of engine configurations.
Two-stroke spark ignition
engines
Unlike a 4-stroke petrol engine, the 2-stroke spark ignition cycle
produces power in each of its revolutions. This cycle gives way to
the traditional four strokes to run its complete cycle. Instead, it
merges two strokes into one, making one upward stroke and one
downward stroke in every revolution of the crankshaft.
Four stroke spark ignition
engines
Spark ignition (SI) engines are fueled by gasoline, propane, natural
gas, or a gasoline/alcohol blend. A spark plug ignites the air-fuel
mixture. The four-strokes of the spark ignition engine are intake,
compression, power (combustion), and exhaust. To complete the
four strokes, the crankshaft makes two revolutions.
Four stroke compression
ignition engines
Instead of spark plugs, this engine compresses the air to elevated
temperatures when it draws the mixture into the cylinder to
generate power to the vehicle.
12. Describe the types and applications of:
Engine oils.
In general, there are three types of engine oil: Mineral, Semi-
Synthetic and Synthetic Engine Oils.
Mineral oil is used as a lubricant, a cutting fluid, and as a
conditioning oil for jute fibres selected for textile production, a
process known as 'jute batching'. Spindle oils are light mineral oils
used as lubricants in textile industries. Electric space heaters
sometimes use mineral oil as a heat transfer oil.
Semi-synthetic lubricants offer fewer performance enhancements,
protect components less and degrade faster than synthetic oils.
Semi-synthetic oils are purer, better-flowing and longer-lasting than
mineral oils. Semi-synthetic lubricants should only be used in more
modern vehicles that have been designed to use them.
Synthetic oils are increasingly being used in hydraulic drives and
electromechanical drives. Some common applications include
gearbox oil, grease, and hydraulic fluid. Within USACE, synthetic
gearbox oils are extensively used on electromechanical drives.
Engine oil filters.
Every car has four main filters: the cabin filter, oil filter, fuel filter
and air filter. The function of all these filters is to enable flows and
catch impurities: the dust and contaminants in the air, the
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impurities in the fuel or the dirt in the motor oil.
The cabin air filter in your vehicle helps to ensure that there is a
proper ventilation system for the health and safety of all passengers.
Without a working cabin air filter, the air inside of a vehicle's cabin is
prone to having higher levels of harmful and odorous exhaust gases
than the air outside of the cabin.
The oil filter helps remove contaminants from your car engine's oil
that can accumulate over time as the oil keeps your engine clean.
Clean motor oil is important because if the oil were left unfiltered
for a period of time, it could become saturated with tiny, hard
particles that can wear surfaces in your engine.
A fuel filter is a filter used to screens out foreign particles or liquids
from the fuel. Most internal combustion engines use a fuel filter, in
order to protect the components in the fuel system.
Air filters are used in applications where air quality is important,
notably in building ventilation systems and in engines. Some
buildings, as well as aircraft and other human-made environments
(e.g., satellites, and Space Shuttles) use foam, pleated paper, or
spun fiberglass filter elements.
13.
Describe the difference between mineral and synthetic fluids.
Mineral oil is formulated with moderately refined base oils. However, synthetic oil is formed of highly
refined base oils. Thus, synthetic oil molecules form equal layers which provide most protection even
during extreme conditions and it helps to improve the performance of your vehicle
14.
Describe the engine inspection procedures for the following:
Oil and fluid leaks.
You will want to check the oil pan seals. Also, you will want to check
the oil pan plug. After you check the oil pan, go ahead and take a
look at the timing cover seal and the valve cover gaskets. Other
places to look for a possible leak include the oil pressure sensor, the
oil filter, and the oil cap.
Ancillary components,
including belts, pulleys and
hoses.
Visual Inspection of Belts
Search for clear indications of damage (cracking, glazing, softening,
or peeling)
Test for correct tension
Test for correct alignment
Record belt condition for future reference
Visual Inspection of Hoses
Search for clear indications of damage (leaks, cracks, hardening, or
softening)
Test cooling system for leaks using state-of-the-art pressure
technology
Record hose condition for future reference
15.
Describe the service and adjustment procedures for:
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Adjusting or replacing
engine components.
Check the problem first before doing a work and if you find the part
that need to replace, buy the part according to manufactures
specification so it will work as efficient. Do a note when its replaced
and set due date for replacement.
Replacing oil.
Warm up the engine
Lift up the car
Drain the oil
Remove the oil filter
Install the new oil filter
Put the new oil
Check the oil level
Place the old oil to the right container and dispose it properly
Replacing filter.
Step 1
Place an approved container under the filter
Remove any bolts attaching the fuel filter bracket to the vehicle
Place a clean rag near the end of the fuel inlet hose to catch spilled
fuel
Step 2
Wearing safety glasses, carefully remove the inlet hose from the
filter. Caution: The fuel system is charged with 15-60 pounds of
pressure, and the fuel will flow out of the hose forcefully! Wear
safety glasses and be prepared to catch the fuel as it spurts out.
Carefully remove the outlet hose from the filter
Step 3
Remove the filter
Install the new filter, and reattach the inlet and outlet hoses
Reattach the filter and fuel filter bracket to the vehicle
Step 4
Start the engine and check for leaks immediately
Properly dispose of the old filter, spilled fuel and rags
16.
Describe the post-service testing procedures listed in the table below.
Checking oil pressure
Describe the procedure in
six (6) steps.
Locate Oil Pressure or Temperature Sender
Firstly ensure that the engine is cool enough to work on. Apply the
handbrake, chock the wheels and put the transmission in neutral or
park.
Now locate the oil pressure or temperature sender – situated in the
engine block and often near the sump.
Remove the switch and be prepared with an oil drip tray to catch
any oil.
Find the Right Adaptor
Now attach the oil pressure gauge to the adaptor and check the
engine oil level before starting the vehicle and allowing it to reach
operating temperature.
Consult a service manual to determine what RPM the test should be
performed at, and what pressure your engine should maintain. If
necessary, have an assistant hold the engine at this RPM while you
take a reading.
A low reading could indicate a blocked oil filter, worn oil pump,
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restricted oil pickup - or simply a grade of oil that is too thin for the
engine. A high reading could be due to a faulty pressure relief valve
or other blockages.
Re-install Oil Pressure Sensor
Once you have taken the reading, switch the engine off and allow it
to cool before removing the oil pressure test gauge, and re-installing
the oil pressure sensor.
Top up the oil as necessary
Road testing for fluid leaks
Describe the procedure in
six (6) steps.
Check the engine if there's any leak.
Make sure that all wires and lines is correctly reinstalled.
Always check the malfunction indicator if it's has any fault repair it
immediately before doing a road test.
Always check the engine oils.
Check all the oils and fluids.
Checking for fluid leaks
Describe the procedure in
five (5) steps.
- Check the Valve Covers
- Check the Oil Pressure Sending Units & Oil Filter Leaks
- Check the Front Crankshaft & Rear Engine Seals
- Check the Oil Pan Gaskets
- Check the Radiator
17.
Describe the service requirements and procedures for vehicle systems and components
applicable for the components listed below.
Service Requirements for
Description
Steering and suspension
Make it sure that the joints and boots are not broken or has a fault
Check the shock absorbers if has any oil leak
Driveline and final drive
Check the boots between the movable joint and connection, make it
sure that they don't have any fault and dirts inside.
Braking
Check the brake pad if it's still thick
Always check the level of the brake fluid
Check the hose and seal if it's secure without leak
Wheels and tyres
Check the tread and the indicator to see if it needs
replacement.
Transmission
Check the oil if it's still in the correct level.
Check the oil colour
Engine
Always check the oil level with the dipstick
Check if there's any leakage around the oil filter
Battery and electrical
Check the battery label if it needs to replace or not
Check the battery voltage using a multimeter
Fuel
Make it sure the petrol type is correct according to the
manufacturer specification.
Cooling
Check the coolant if it's in correct level
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Check the hose and clamp if it's secure and no coolant leakage
18.
Describe the usage of oil filters, oils, fluids and greases listed below.
Additives
Only use the correct type of petrol that is recommended by the
manufacturer specification
Oil, fluids, grease
classifications
Only use the consumable according to the manufacturer
specification to avoid damaging the engine.
Viscosity rating
Only use the consumable according to the manufacturer
specification to avoid damaging the engine and related systems or
parts
Filter types
Only use the genuine oil filter or use the alternate filter according to
the filter conversion chart
19.
Describe the procedures for carrying out oil sampling.
Start the engine and wait until it warms up into working temperature and then set the
idle to rpm.
Remove the dust cap and make sure to clean the valve.
Put the probe into the valve and get a 100 ml oil with waste container. The 100 ml oil is
not the one we want to test so dispose it properly.
Then repeat the previous step and get a another 100 ml of oil with a sample bottle.
20.
Describe the post-service testing procedures, including resetting service interval indicators.
Always ask the customer what is the problem of their cars.
Reset the indicator according to the manufacturer's manual
Make sure that the car is safe to drive before doing a test drive.
21.
List six (6) methods and processes for documenting and reporting findings and recommendations
from the service operations and test findings.
Record all the faulty parts that found on the car in the invoice or report
Keep the replaced parts and explain the problem to the customer
Always clean the car after servicing it
List all the problems and remarks on the report
Explain to the customer if there any problem or precaution may happen after this
service
List all the parts that been replaced in the invoice
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22.
Once the servicing of a vehicle has been completed, describe three (3) work processes that must
be completed.
Complete the final inspection according to the manufacturer manual
Complete the check list and related documentation
Dispose or recycle the waste material
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4 تسلم الأسئلة بعد الامتحان مع الدفتر
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