AURTTF101 Student Assessment - Theory v1.1

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Course Code AUR30620 Course Name Certificate III in Light Vehicle Mechanical Technology Unit Code AURTTF101 Unit Name Inspect and service petrol fuel systems 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: ___________________________________________ Office Use Only Date/s Received: ___/___/___ ___/___/___ ___/___/___ Date/s Assessed: ___/___/___ ___/___/___ ___/___/___ Result of Assessment: ___________ ___________ ___________ 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 /var/filecabinet/temp/converter_assets/86/ef/86ef85f2c9d0a7dc0d7a23502bf8ec13805cc250.docx Imagine Education Student Assessment Cover Sheet

Course Code and Name: AUR30620 Certificate III in Light Vehicle Mechanical Technology Unit Code: AURTTF101 Unit Title: Inspect and service petrol fuel systems 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. List five (5) safety steps everyone needs to follow when servicing a petrol engine.  Always disconnect the battery  Put a appropriate safety equipment  Keep away from any flammable  Identify the hazard associated with the work  Identify the job requirements from the workplace instruction 2. Explain how you correctly: a) trap, store and dispose of flammable liquids. b) dispose of oil and other types of filters. Use the table below for your answers. Flammable liquids Flammable liquids must be stored in a plastic cans. Make sure that the containers is sealed , labelled and secure in one place. Oil filters Put the excess oil to the right container and place the drained oil filter to the drum for collection by an EPA approved contractor to remove and dispose of your waste oil. 3. List ten (10) basic safety precautions for storage of flammable liquids  Store flammable liquids in well-ventilated area  Keep it away to the flammable sources /var/filecabinet/temp/converter_assets/86/ef/86ef85f2c9d0a7dc0d7a23502bf8ec13805cc250.docx Imagine Education Assessment Questions Part A

 Avoid storing flammable liquids on high shelves or in direct sunlight  Flammable liquid storage areas should be clearly marked with warnings and signs  Flammable liquid containers and tanks should be clearly and correctly labelled  Make sure that the stored container is in good condition  Dispense Flammable Liquids With Care  Avoid ignition sources  Dispose of flammable waste material properly  Always make sure to store the flammable liquid separate to the other 4. List five (5) types of fuels powering cars.  Propane  Petrol  Diesel  Ethanol  Natural gas 5. Name the following fuel system components and explain the usage. Component Component Name Working /Usage Fuel Injector A fuel injector is a device for atomizing and injecting fuel into an internal combustion engine. The injector atomizes the fuel and forces it directly into the combustion chamber at the precise point in the combustion cycle. Fuel Pump The fuel pump is your vehicle's unsung hero. It takes gas from the gas tank and sends it to the engine so your car, truck, or SUV can start and run. Your vehicle's fuel pump should last at least 100,000 miles or more. Fuel Filter 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. The fuel filter keeps fuel running smoothly to the engine. It's a critical part of the system because today's fuel injectors have close-fitting parts that are easily clogged by dirt and grit. Instead of creating a fine spray of fuel that burns completely, /var/filecabinet/temp/converter_assets/86/ef/86ef85f2c9d0a7dc0d7a23502bf8ec13805cc250.docx

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they start to produce a stream that doesn't completely ignite. Fuel Tank Fuel tank (gasoline): This tank stores gasoline on board the vehicle until it's needed by the engine. Carburettor In general, a car carburetor is useful for adjusting the amount of fuel and air mixture that enters the engine cylinder. Air bleeder is one of the parts in a carburetor that is used as a place for mixing fuel with air so that it can produce a smooth mist. 6. The components below play a vital role in the fuel system. Explain their role the table below. Fuel Tank Cap The cap prevents the leakage of fuel vapours from the filler neck, which can be a major source of hydrocarbon emissions. A leaking or missing gas cap can result in the release of 90 litres of fuel per year into the atmosphere. Fuel Lines A fuel line is a hose or pipe used to transfer fuel from one point in a vehicle to another. If your fuel line is blocked or leaking, your engine won't get enough fuel, or it'll get fuel in inconsistent spurts. That'll cause engine sputtering or it may force your engine to cut out. Don't run your engine if it is sputtering. A sputtering engine will likely damage itself. 7. What is the difference between the mechanical fuel pump and the electrical fuel pump. Mechanical fuel pumps are usually found on older vehicles, while newer vehicles generally use electrical fuel pumps due to them having more power and thus needing a high-pressure fuel input. For electrical fuel pumps, a computer system is used to regulate the flow rate and how high the pressure is, ensuring the is provided with exactly the right amount of fuel. Mechanical fuel pumps are generally mounted on the side of the engine, and work by drawing fuel out from the bottom of the tank using a suction process. A diaphragm creates the suction, and a valve stops the fuel from flowing back into the tank once the pump has filled up. The collected fuel is then discharged to the carburettor or through a second valve. This process is repeated as the vehicle moves, and an arm is used to drive the pump, increasing as the revs per minute are elevated. This /var/filecabinet/temp/converter_assets/86/ef/86ef85f2c9d0a7dc0d7a23502bf8ec13805cc250.docx

means that there is enough fuel going into the engine even at higher speeds when there is a demand for more. Electrical in-tank fuel pumps work in a different way. They are generally located at the top of the fuel tank, occasionally via the trunk floor or a hole under one of the seats. The pump will usually be mounted on a bracket in a case, which sits inside the fuel tank. These pumps don’t rely on the mechanical systems for drawing fuel, and are instead designed to be permanently immersed in fuel. As soon as electricity is directed to the pump, the motor starts up and begins to propel the fuel up the lines to the engine. The electronics can determine the rate at which fuel is needed, and increase or decrease pump speed accordingly. 8. Explain the function of the carburettor in the fuel system and list three (3) different types of carburettors. The carburettor is responsible for mixing gasoline and air together in just the right amounts and getting that mixture into the cylinders. There are three general types of carburettors depending on the direction of flow of air. In the constant choke carburettor, the air and fuel flow areas are always maintained to be constant. But the pressure difference or depression, which causes the flow of fuel and air, is being varied as per the demand on the engine. Solex and Zenith carburettors belong to this class. In the constant vacuum carburettor, (sometimes called variable choke carburettor) air and fuel flow areas are being varied as per the demand on the engine, while the vacuum is maintained to be always same. The S.U. and Carter carburettors belong to tills class. Multiple venturi system uses double or triple venturi. The boost venturi is located concentrically within the main venturi.The discharge edge of the boost venturi is located at the throat of the main venturi. The boost venturi is positioned upstream of the throat of the larger main venturi. Only a fraction of the total air flows though the boost venturi. Now the pressure at the boost venturi exit equals the pressure at the main venturi throat. The fuel nozzle is located at the throat of the boost venturi. 9. What is an Electronic Control Unit (ECU)? List ten (10) sensors controlled by the ECU. An ECU’s main job is to keep the engine working smoothly. On cars fitted with electronic fuel injection, an ECU can control the amount of fuel that enters the engine’s cylinders. This optimises the fuel-air mix in the cylinder when it’s compressed, which in turn maximises the car’s power and reduces the amount of fuel wasted. Different sensors that controlled by ECU: Mass Air Flow Sensor Throttle Position Sensor Oxygen Sensor Camshaft Position Sensor Crankshaft Position Sensor Intake Air Temperature Sensor Manifold Absolute Pressure Sensor Accelerator Pedal Position Sensor Knock Sensor Vehicle Speed Sensor /var/filecabinet/temp/converter_assets/86/ef/86ef85f2c9d0a7dc0d7a23502bf8ec13805cc250.docx

10. What are five (5) essential components of a fuel injection system?  Fuel tank  Fuel pump  Fuel filter  Fuel lines  Fuel Injectors 11. What is the function of the accelerator pedal? How does the accelerator pedal work in modern cars? t is the pedal located on the floor on the far-right. This pedal controls the amount of gas being fed into the engine and thereby controls the speed of the vehicle. In modern vehicles, stepping on the accelerator pedal sends an electrical signal to the engine control module (ECM). The ECM uses this information to send a control signal to an electric motor mounted to the throttle body that adjusts the position of the butterfly valve accordingly. 12. Explain the function of the air filter and air intake housing. Filters are used to prevent your engine from being damaged with dirt, dust and grit. 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. On most modern vehicles the intake system consists of a plastic air box which housing a paper air filter. 13. What are the symptoms and outcome of a bad fuel pump? Explain the outcome in the template below. Symptoms Outcome Fuel Tank Noise A damaged fuel pump might make a loud, whining sound that you'll hear from your gas tank. Difficult Starts If your vehicle’s fuel pump cannot get gas from the tank to the engine, you will have trouble starting your car. The car will struggle to start and run because the pump cannot push enough gas through. A worn pump loses its pressure and the engine is being starved of gasoline. Lower Fuel Efficiency The car is burning gas faster than usual. /var/filecabinet/temp/converter_assets/86/ef/86ef85f2c9d0a7dc0d7a23502bf8ec13805cc250.docx

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Dead Engine If the pump is not good the engine can not get a gas from the fuel tank. 14. How do you inspect the mechanical fuel pump for a pressure leak or fuel leakage? List six (6) steps  Start the car and let it idle  Visually check  Put a fuel pressure gauge  Run the pump  Note the pressure reading  Compare to the manufacturer's specification 15. What are the primary symptoms that indicate it is time to check the air filter? List five (5) symptoms.  Odd engine noises  Check engine lights  Black smoke from the exhaust  Dirty filter  Poor performance 16. List the five (5) steps used to inspect air intake housing for leakage of vacuum.  Identify All Vacuum Lines, Tubes, and Components. Do a visual inspection.  Use a vacuum tester  Check the intake manifold for vacuum leaks  Locate vacuum leaks with water  Enrich it with propane 17. Explain how you complete the following jobs when servicing a vehicle. Each job has many steps, a few of them are missing. Fill in the blanks Replacing the fuel filter 1 Make sure to turn off the engine 2 Disconnect the battery 3 Locate the fuel filter 4 Lift the vehicle if required 5 Place a bowl or bucket beneath the fuel filter 6 Remove the clips used to hold the fuel filter (remove the nuts if your vehicle is fitted with other types of fuel filter) 7 Remove the fuel lines from the filter 8 Get a new fuel filter and install it in the brackets 9 Install the fuel lines into the new filter Testing the fuel pressure 1 Attach the fuel pressure gauge 2 Turn on the tester and record the previous pressure reading 3 Start the vehicle and let it idle 4 After five minutes check the pressure reading 5 Compare both readings according to owner’s manual if there is a large gap replace the fuel pump /var/filecabinet/temp/converter_assets/86/ef/86ef85f2c9d0a7dc0d7a23502bf8ec13805cc250.docx

Changing the Air Filter 1 Locate the air filter housing 2 Remove the old filter 3 Check and clean the filter housing with a clean rag 4 Put the new air filter 5 Replace the air filter housing cover 6 Replace the lid and fasteners Checking the idle speed 1 Connect the GST (Generic Scan Tool) to the data link connector at lower crash pad. 2 Start the car 3 Check the idle speed at the gauge 4 Restart the engine 5 Read the idling rpm. Adjusting the idling speed 1 Start your car and let it complete to warm up the engine 2 Locate the Throttle body 3 Remove the Rubber covering the idle air adjuster 4 Disconnect the idle air adjustment valve 5 Turn the idler with a screw to adjust the idle 6 Reconnect the idle air adjustment valve 7 Put back the rubber Clean the air filter 1 Locate the filter and remove the cover 2 Remove the old filter 3 Clean the air filter with a clean rag 4 Reinstall the cleaned air filter 5 Replace and secure the cover Check the air intake housing and duct for damage 1 Start the engine and let it idle. Set the transmission to Park (automatic) or Neutral (manual) and apply the emergency brake. 2 Open the bonnet and do a visual check 3 Make sure that the hose is connected 4 Inspect both sides of the hose 5 Check if the hose is near or touching a hot surface. 6 Check the hose connections and tighten it 7 Check the hose if it has a crack 8 As part of your visual inspection, include the devices the vacuum hoses connect to. Check the devices for damage like cracks, dents, and loose parts. Pinch the vacuum line leading to the device, and spray soapy water on it and hear for a change in idle speed. /var/filecabinet/temp/converter_assets/86/ef/86ef85f2c9d0a7dc0d7a23502bf8ec13805cc250.docx

18. How do you conduct a post-service examination of a vehicle serviced by you, before handing back to the customer? List ten (10) checks.  Get the job card and documentation done  Test drive  Check all the lug nuts if its tighten enough  Check the work that you have done  Clean the workplace  Have a look at the interior if its cleaned  Check if there’s any leak  Check all the wirings  Check the engine oil  Double check the car before handing it to the customer 19. Under Commonwealth, State and Territory legislation, whose obligation is it to prepare a Material Safety Data Sheet for hazardous substances? The responsible for the material safety data sheets for hazardous substances is the supplier. 20. Inspecting and servicing petrol fuel systems poses several types of hazards, explain what risks and the risk mitigations are in the table below, using 50 – 100 words for each. Danger Risks and risk mitigation Electricity The gasoline vapour is highly flammable and it cause a fire or explosion even if a tiny spark coming from the battery. Always disconnect the battery when working with the fuel system. Exposure All the fuels are extremely dangerous because fuels are flammable and it can cause a fire. To prevent the risk of the fuel exposure check the surrounding if it had a spilled fuel and quickly clean it with a degreaser. Leaks Leaks in the fuel system are the common cause of car fire. Since gas is extremely combustible, it is possible that it may spark a fire, either inside the car or elsewhere, if it leaks. Therefore, fixing the leak as soon as possible is highly recommended. Storage The fuel must be stored in a right container to keep it away and does not react to other chemicals. 21. Explain the following post-service testing procedures for petrol fuel systems: a) Starting up and running the system to full operation. There are eight (8) steps. Insert the missing information in the table below. /var/filecabinet/temp/converter_assets/86/ef/86ef85f2c9d0a7dc0d7a23502bf8ec13805cc250.docx

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1. Park the vehicle and apply the hand brake. 2. Let the engine cool before doing the test 3. Locate the fuel pressure test part 4. Place a rag under the test port as fuel will be released when installing the pressure tester. 5. Put the fuel tester on 6. Turn on the ignition to run position and record the pressure reading 7. Start the engine and record the pressure reading again 8. Check for the appropriate pressure. b) Testing the system for leaks and correct operation. There are nine (9) steps but they are NOT in the right order. Sort them in the right order in the table below.  Temporarily connect the negative battery cable by hand. Cycle the ignition key to the "on" position several times and turn it off -- this will re-pressurise the system. Look at the reading on the gauge. Refer to your owner's manual for the correct psi, or "pounds per square inch," for a residual pressure test. Depending on the vehicle, the reading will be anywhere from 30 to 80 psi. The pressure should hold for several minutes without dropping. Any pressure drop below specifications indicates one leaking, or several leaking injectors.  Refer to your owner's manual for the location of the fuel pressure test fitting on the rail. Fit a fuel pressure gauge to the pressure test fitting, by screwing it on or using the push-on adapter  Disconnect the negative battery cable at the terminal. If you have found any leaking fuel injectors, now will be the time to replace them all, since bad seals usually fail around the same time. Reassemble all the components you removed in the reverse order you took them off. Remember to put the injectors back into their original fuel rail locations. Keep the negative battery cable disconnected until the end of the assembly process.  Locate the service valve port on the fuel rail. Use the tip of a screwdriver to push the pin in to depressurize the system. If your fuel rail has a removable cap, use a socket to slowly unscrew the cap while holding a rag over it.  Remove the negative battery cable from the battery. Depressurise the fuel rail, if you have pressurised it for the residual pressure test. Disconnect the fuel injector wires from the fuel injector heads, by unsnapping the clips.  Use a fuel injector puller tool to remove each injector, by placing the clasping device of the tool around the lip of the injector. Pull the injector straight up and out. Remember which injector fits into its receiving port on the fuel rail.  Make sure your vehicle sits in park or neutral, depending upon your transmission type. Apply the hand brake.  Look very closely at each fuel injector head where it connects to the fuel rail. Look for any obvious dribbling leaks or fuel spray pattern on the rail, injector body or cylinder head. Smell for gas.  Temporarily reconnect the negative battery cable to its terminal. Cycle the ignition key to the "on" position several times to re-pressurise the fuel rail. Look very carefully at the fuel injector tips. None of them should squirt or dribble any fuel. Any leaks at the injector tips indicates bad internal valve seals in the injector bodies. Replace all leaking fuel injectors. 1. Make sure your vehicle sits in park or neutral, depending upon your transmission type. Apply the hand brake. /var/filecabinet/temp/converter_assets/86/ef/86ef85f2c9d0a7dc0d7a23502bf8ec13805cc250.docx

2. Look very closely at each fuel injector head where it connects to the fuel rail. Look for any obvious dribbling leaks or fuel spray pattern on the rail, injector body or cylinder head. Smell for gas 3. Locate the service valve port on the fuel rail. Use the tip of a screwdriver to push the pin in to depressurize the system. If your fuel rail has a removable cap, use a socket to slowly unscrew the cap while holding a rag over it. 4. Refer to your owner's manual for the location of the fuel pressure test fitting on the rail. Fit a fuel pressure gauge to the pressure test fitting, by screwing it on or using the push-on adapter 5. Temporarily connect the negative battery cable by hand. Cycle the ignition key to the "on" position several times and turn it off -- this will re-pressurise the system. Look at the reading on the gauge. Refer to your owner's manual for the correct psi, or "pounds per square inch," for a residual pressure test. Depending on the vehicle, the reading will be anywhere from 30 to 80 psi. The pressure should hold for several minutes without dropping. Any pressure drop below specifications indicates one leaking, or several leaking injectors 6. Remove the negative battery cable from the battery. Depressurise the fuel rail, if you have pressurised it for the residual pressure test. Disconnect the fuel injector wires from the fuel injector heads, by unsnapping the clips 7. Use a fuel injector puller tool to remove each injector, by placing the clasping device of the tool around the lip of the injector. Pull the injector straight up and out. Remember which injector fits into its receiving port on the fuel rail. 8. Temporarily reconnect the negative battery cable to its terminal. Cycle the ignition key to the "on" position several times to re-pressurise the fuel rail. Look very carefully at the fuel injector tips. None of them should squirt or dribble any fuel. Any leaks at the injector tips indicates bad internal valve seals in the injector bodies. Replace all leaking fuel injectors 9. Disconnect the negative battery cable at the terminal. If you have found any leaking fuel injectors, now will be the time to replace them all, since bad seals usually fail around the same time. Reassemble all the components you removed in the reverse order you took them 22. You are asked to service a petrol fuel system in a vehicle that you have not worked on before. Where will you find the information you need for the inspection and service? /var/filecabinet/temp/converter_assets/86/ef/86ef85f2c9d0a7dc0d7a23502bf8ec13805cc250.docx

Check the job card and have a look at the manufacturer’s specification. 23. What can you do to help you with the interpretation of the service information? Check the service history 24. Before you inspect and service a petrol fuel system you will need to select the tools and equipment required for the job. How do you establish that these are ready for service? What is the documentation procedure must you complete? Check all the equipment and tools that you’re going to before using it. If the tools and equipment has a damage or crack put a tag on it to let the others know about it. 25. When a job has been completed there are some housekeeping duties in the workshop that you must complete. Explain how this is done in the table below. Task Housekeeping procedure Examination of tools and equipment After using the tools you must check it if it does have a damage or any fault before putting it back to the designated place. Make sure that the tools are always clean. Storage of equipment After using the equipment you must clean it first and store it to the right place. Identification, tagging and isolation of faulty equipment Identify all the equipment if it had a fault. Tag all the equipment that has a damage and put it aside. Let the manager know about the damaged equipment. Disposal of excess materials Dispose all the excess materials to the designated bin and go to the nearest car parts store and ask them if they are accepting excess materials. /var/filecabinet/temp/converter_assets/86/ef/86ef85f2c9d0a7dc0d7a23502bf8ec13805cc250.docx

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Recycling procedures Sort out all the excess materials. Do not put a fluid or liquid to the bin. Follow the manufacturer’s specification. /var/filecabinet/temp/converter_assets/86/ef/86ef85f2c9d0a7dc0d7a23502bf8ec13805cc250.docx