Butajira Construction & Industrialcollege

Institutional assessment for Level IV Automotive servicing operation

Management trainees’
Name ___________________ Level ________ year ______
 Sector of education:
 Sector: Automotive
 Automotive Engine servicing Management’s Package

LEVEL IV

Project Information
The necessary machines, equipment’s, tools, materials services, manual and information are given.

The candidate is expected to perform the following projects.

Assessment Place Accredited Assessment Center

N.B. This assessment package is prepared only for progressive assessment .

There for a level three certification is a perquisite Total Time allotted 4:30hours.

Assessment work sheet – A

Project tittle 1 : Prepared Action Plan (on the given situation)

Time allotted 1:00 hour

Situation As the start of your days’ work

Two(2)cars are already accepted by the pre inspection section and are now in line for engine servicing section you
are to personally check these cars prepared a job order and then assign the mechanics you have 4 mechanics.
Mechanic W, X, Y, & Z.

One engine is still in overhauling work in progress carried out Mechanic W.

Another engine ready for your final check and release the documents are already on your table for your signature.

You also have one concern, one disassembled engine is still on the work bench for a Week and now you are already 2day
behind the schedule .because the delivered overhauling Gasket is not according to the engine specifications.

As the section head your appropriate section is necessary in order to accuracy above mentioned work shop situation
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 WORKSHEET A
ACTION PLAN
Actions to be done Person Responsible Remark
(According to your priority)
Perform a final check & make Mechanics X
ready the vehicle for delivery/
/releasing /by putting ur’
signature.
Reassembling the engine by Mechanics Y
using appropriate engine gasket
according to specification.
Install the engine to the vehicle Mechanics Z
& make final check.

Performing engine overhaul Mechanics W

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 Assessment work sheet - B
Project title 2: carry out engine inspection diagnosis - Diesel (none turbo
Charged). Prepare job order and coast estimation
Time allotted: 1:30 hour

Situation: Car A has a diesel engine and the complain noted and the stop
1. Smoke is coming out of the engine compartment through the
Manifold to Tailpipe connection.
2. Abnormal whizzing noise in the engine
3. Oil leak is observed on the side of the block just below the cylinder

You are going to verify and recommend corrections on the above competency
You are also to perform trouble shooting and fault finding to check it on are
working properly.

List down the engine systems you diagnose on the worksheet provide
together with your finding & possible corrections.

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 WORKSHEET B1
INSPECTION AND DIAGNOISISE WORK SHEET
Name of
component /parts inspected Observation /findings Recommendation/
and diagnose Correction
Manifold to tail pipe Damaged manifold to tail Replace the bolt
connection bolt pipe connection bolt with new
according to
specification
Manifold to tail pipe gasket Damaged gasket Replace the
gasket with
new according
to specification
Crankshaft thrust clearance Excessively wear thrust Replace thrust
washer washer with new
according to
specification
Crankshaft front seal Damaged crankshaft front Replace the
seal seal with new
according to
specification

Prepare a job order and cost estimation on the above car (project B) Use the Forbelow
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 WORKSHEET B2

Job Order and Estimation

Car A________________________ Name of Mechanic _________________

Particulars of job/service Supplies /material Unit cost

Manifold to tail pipe connection bolt

Minco 80 birr

Manifold to tail pipe gasket Minco 120 birr

Crankshaft thrust washer Minco 600 birr

Minco 100 birr

Crankshaft front seal

Material cost 900 birr

Labor= 200 birr
Equipment= 100 birr
Total =1200birr
Profit = 10%
=10/100*1200=
Total cost = 1320 birr

ASSESSEMENT Work SHEETT- C

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Project tittle 3: Carry out Engine inspection and diagnoses EFI gasoline engine
Time allotted: 2 hour
Situation Car B has an EFI gasoline engine (first generation with check connector)
According to the owner engine just suddenly stops from running while
driving at 80km/h. At that moment also loud scrambling noise was heard
Said the owner. He tried to start the engine but to no benefit. The
pre-inspection Section suspects a broken timing belt.
 In your actual check it is indeed broken timing belt
 Do performance checks of the engine according to manufacturing
specification .
 Perform on board disconnects (use check connector) and identify
socate fault is there is any.
 List down below the components systems to be inspected and
diagnostic operations you have performed with your
recommendation and findings.

Ones the trouble is identified and corrected the check engine lamp should stop

trouble blinking meaning the fault cods been erased.

ENGINE INSPECTION AND DIAGNOSISE WORKSHEET

TIMING BELT INSTTALATION

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 Name of Observational Recommendation/
Systems/components/parts findings Remark
Checked and diagnosed

1 Cooling system THW out of range Replace/maintain

2 Timing belt Disordered/out of timing Adjust timing belt

3 timing belt Broken timing belt Replace

Institutional assessment for Level IV Automotive servicing operation

Management trainees’
7
 Name ___________________ Level:________ year:______

Choose the best answer from the given alternative

--B--1. Which one of the following is not an engine system

A. charging system B. Brake system C. Cooling system D. Fuel system

--A-- 2. Which component of engine management system is not a sensor?

A. Transmission fluid sensor B. Knock sensor

C. Crank shaft position sensor D. Hot air flow sensor

--D-- 3. Why we use ECU computer and software on vehicle

A. To write and read document we store

B. To assessing and working maintenance

C. Setting target and interpreting financial document

D. to record and manage data and produce report

--A-- 4. When we say literacy skill

A. to interpret requirement company policy and procedures demand

B. assessing work and out came

C. identifying appropriate people resource and to monitor work

D. for Performance information setting target and financial

--A-- 5. Planning skill to:

A. To organize required resource and equipment

B. to provide support to colleagues

C. to organize information asses’ information for

D. to conduct small group training sessions

--D-- 6. Which of the the following is not future of air suspension on system

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 A. self-damping B. Improve Ride Comfort and Greater Satisfice of the load

C. Constant Vehicle Height regardless of the load D. Progressive Spring Characteristics

--C-- 7. From the given systematic multifunction diagnoses method is

A. asking personal manager B. visual check and noise level testing

C. fault memory read out D. Non

--A-- 8. Which one of the following correct order

A. planning Organizing controlling evaluating

B. organizing controlling evaluating planning

C. controlling planning evaluating organizing

D. evaluating controlling organizing planning

--D-- 9. Resource exclude

A. Staff B. Money C. Equipment D. people

--C-- 10. Formal or informal evaluations of supervisor is called:_____.

A. planning B. organizing C. controlling D. except C all are answer

--C-- 11. sensors used to detect abnormal Engine vibration .

A. MAP sensor B. speed sensor C. knock sensor D. temperature sensor

--B--12. The first step of management processes is

A. Resource B. goal C. time line D. infrastructure

--E-- 13. Quality standard exclude

A. Material B. service c. product D. customer satisfaction E. none

--C-- 14. Indicate how much income should be received from specific operations of

activities.

A. Time B. Cost C. revenue/profit/ D. data

--C-- 15. Most effective plans are,

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 A. Complete B. brood c. simple D. Wide

----16. The following are true about electronic transmission exclude.

A. It has manual gear B. it has used solenoid

C. It has controlled by ECU D. it has used sensor

--D-- 17. Road-safety system and drive system except

A. ABS B. TCS C. ESP D. central door locking system

----18. Which of the following are types of theft-deterrent system except .

A. Central door locking B. Alarm switch

C. immobilization D. windows

---19. All of the followings are customers “except”

A. Internal and external customer B. co-worker

C. board member D. supervisor E. none

--A-- 20. Team work advantage

A. Open communication B. one way communication

C. One line communication D. closed communication

---21. The following determine the concept of new technology except

A. Adapt mechanical parts B. modify Electrical part

C. adapt to different operation D. adapt Electrical part

--A-- 22. The correct order of diagnostic vehicle.

A. Information – inspect - list the problem - write the solution

B. Inspect – list the problem – write the solution – information
C. List the problem – write the solution – information – inspect
D. Write the solution – information – inspect – list the problem

--D-- 23. In automatic transmission the shifting range is according to the shift

lever position except.

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 A. P-parking B. R-reverse C. N-neutral D. A-automatic

--D-- 24. Resource exclude

A. Staff B. Money C. Equipment D. Customers

--A-- 25. The following are list of customize except

A. Competitor B. internal & external customers

C. board member D. supervisor

--B-- 26. Conducting air suspension system balance adjustment primarily deals With.

A. Compressor output increment

B. Un balanced air suspension is identified
C. Decreasing air bag pressure
D. Adjusting air regulator enteral valve

--D-- 27. Which of the following is not anti-theft system on vehicle?

A. Enteral door locking system B. vehicle immobilization

C. alarm system D. adaptive cruise control

----28. Which one is not included in drive assistance system

A. Door control system B. navigation system

C. parking assistance system D. air bag system

---- 29. Which is not feature the data bus transmission in motor vehicle?

A. Transmit information using information /bits/

B. Less space require for wire harness
C. At least two lines required for each pieces of information
D. Extended electronic dynamics capability of actuator

----30. Electronically constructed transmission & power train management

System includes except

A. Automatic transmission B. differential & axle lock

C. transmission synchronizer D. automatic free wheel hub

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 --D-- 31. Electronic control of automatic gear selection is depends on except

A. Engine torque B. throttle valve or air mass C. vehicle road speed D. None

--E-- 33. Computer function on a vehicle except

A. Receiving inputs B. processing information

C. storing data & interpreting the data D. process output E. None

--B-- 34. Immobilizer is designed to prevent vehicle theft by disabling the engine, mostly

found on.

A. ABS B. Key C. dash board D. sensor

--A--35. The main function of anti-lock brake system is

A. Prevent skidding B. prevent spinning of wheel

C. prevent traction of like with road D. control vehicle speed

--B-- 36. The following is not engine control sensor

A. Knock sensor B. steering sensor C. air flow sensor D. coolant temp sensor

--B-- 37. The following are actuator except

A. Idle control valve B. injector C ignition coils D. air flow meter

--C-- 38. The following is the most impact in any work place activity to create a good

atmosphere area than the other .

A. Skill B. knowledge C. attitude D. communication

--C-- 39. The following is not anti-theft system on vehicle

A. Alarm B. door locking C. cruise system D. immobilizer system

--C-- 40. Which is not drive management information system?

A. Navigation B. Parking C. Door-locking D. ABS

--D-- 41. Mechanical modification may not include ?

A. Adapts is modify the mechanical system

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 B. Adapt ……?
C. Adapts existing mechanical system
D. Demanding or modifying electro mechanical system

--B-- 42. Team communication and operation exclude

A. Mutual concern B. Leader ship

C. Open communication D. Sharing information

--C-- 43. Electronic drive management system does not include

A. Electronic controls of automatic transmission

B. Electronic component of drive control system
C. 4WD application such as automatic free manual hubs differential & axle lock
D. Electronic control steering system

MACHING Mach column B to A

A B

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---n--1.Model of product
---c--2.Customer satisfaction
---p--3.Plan and schedule work activity
---q--4.Implementation work plan
---m--5.Clean up
---l-- 6.Diagnosis of automotive vehicle
---h-- 7.New technology
---i-- 8.Feedback
---f-- 9.Quality check
---g--10.Resource
---c--11.Develop effective work habit
---e--12.Electrical
---k--13.Mechanical
---b--14.Fluid power
---a--15.Communication include
Set by YISHAK ISRAEL
Matching Match column B to A
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A. hand sign
B. liquid and gas
C. time management strategy
D. quality product and service
E. Power Transmission through cable
F. visual (physical) inspection
G. Power and energy
H. Upgrade technology skill
I. Survey questioner interview & meting
J. transmission
K. power transmission through gear shift
L. Scan tool
M. work station read out next
N. proto type
O. work method practice & activity
P. Resources are allocated as pair
Requirement activity.
Q . cover budget operation
R. plan
 A B
---------1. Temperature sensor actually A. diode
---------2. A faulty electrical connection B. detonation sensor
---------3. Directly measure engine load C. transistor
---------4. Interval of time each injection D. refrigerant
---------5. It used a piezoelectric crystal E. inbox
---------6. One way check valve for electric current F. controlling
---------7. Female connector G. observation /oral
---------8. Base, emitter & collector H. BVI symbol
---------9. Air conditioning media I. strategic plan
--------10. Brake system J. alarm
--------11. Male connector K. retarder
--------12. Brake switch & wheel speed sensor L. thermistor
--------13. Security component M. 2 illustration
--------14. Wire to wire connector symbol N. higher than normal resistance
--------15. Quantities of materials are found O. 1 illustration
--------16. Method of assessment P. MAP sensor
--------17. Cover long term operation Q. input for ABS
R. pulse width

Oral question

I. What is the difference b/n Logbook & Action plan

II. What are the elements of action plan
III. Do you use the action plan in the workshop? If your answer is yes,
mention what are they.
IV. If the engine temperature sensor is damaged or unfortunately the engine
operator starts? Your answer is Yes or No? if yes b/c of what :

JOB WORK ORDER OF AUTOMOTIVE WORK SHOP ORGANIZATION

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 CUSTOMER

SECURITY

RECEPTION INSPECTOR JOB ORDER

/ T. MANAGER/

WORK SHOP STOR FINACE

TECHNICAL MECHANICS MAINTENANCE

QUALITU CONTROL

FINACE

RECEPTION

DELIEVERY /CUSTOMER/

Set by YISHAK ISRAEL

Institutional assessment for Level IV Automotive servicing operation

Management trainees’
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Name ___________________ Level:________ year:______
1 . A number of tracks having different maintenance arrived would you give priority

If you have a lock of labor force

A . TRUCK A which has 2000 k m left for its annual service

B . TRUCK B which has 2000 k m left for preventive maintenance

C . TRUCK C which its service time is reached b/n unloaded

D . TRUCK D which is loaded and its service time reached

2 . traction control will intervene to maintain stability of the vehicles and the

control attractive force can a number of methods as indicated below expect on

A . transmission control B . ignition control

C . brake effect D . throttle control

3 . which of the following is not included in the plan of electrical section head

A . spear part needed for maintenance and repair

B . human resource requirement for the auto electric section

C . finance and budget for salary

D . quality service providing program/technique

4 . which of the following sensor directly measured engine load

A . manifold absolute pressure sensor B . coolant sensor

C . throttle position sensor D . vehicle speed sensor

5 . precisions of test equipments means the following except one

A . carful and exact B . undetermined result

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 C . free from mistake or errors D . adhering closely to a standard

6 . which phrase is used to make an invitation

A . it was wondering if you could do the job B . would you mind giving me a hand

C . would you like to attend the conference D . please have this box deliver

7 . desirable treat that will help the worker to be successful in the job

A . dishonest B . insincerely C . negligee D . reliability

8 . when you encounter a difficult customer in a work shop the following are the
appropriate thing to do except one

A . serve them quickly but politely B . talk in a natural tone voice

C . send them out if they don’t listen to you D . keep the friendly face

9 . the three basic taste an automotive technician should be before confirm needed

to repair the vehicle data listed below expect one

A . rod test B . owner hand book C . A/B D . neither A nor B

10 . with out an RPM to the computer on in EFI engine

A . the system will go in to back up mode B . the engine will not run

C . the engine will run ,but it will be sluggish

D . the engine will start , but run very rich

11 . the service time / mileage of vehicles it indicated by

A . the speedometer B . the trip meter C . tachometer D . the odometer

12 . all of those are maintenance items except one

A . water pump leak B . transmission flush C . 50 k service D . tire rotation

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13 . during evaluating worker performance as a work shop manager

A . you should focus on the approach and relation of the

B . you should gather and use all the information chat you have recorded about

The worker

C . focus on the jobs performed on the evaluation day

D . you should give the same evaluation result for every

14 . objective

A . stated as measurable targets which clear time frame

B . reflect support and commitment of team member

C . show process D . all except C

15 . work plans are implemented of in accordance with

A . set time frame B . resource C . standard D . all

16 . work methods and practice may include but not limited to

A . legislated regulation and codes of practice

B . industry regulation and codes of practice

C . occupational health and safety practice D . all

17 . one of the following cannot be feedback in planning and organizing work activity

A . group discussion B . questionnaire C . survey D . none

18 . resource requirements are researched analyze and documented an operational

plan is developed or implemented in capsulation with

A . relevant personal C . customer

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 B . colleagues and specialist resource managers D . A and B

19 . Contingency plans

A . rental , hire purchase or alternative means of procurement of required

Materials equipment and stock

B . contracting out or outsourcing human resource and other function or task

C . restructuring or organization to reduce labor costs

D . strategic for reducing costs , wastage , stock or consumable E . All

20 . measure for monitoring or evaluating the efficiency of effectiveness of

a system Which may be used to demonstrate accountability and to identify

area for improvement

A . standards B . performance indicator C . OHS D. abnormal feedback

21 . A tactical plans develops the department of section to detail product and

service performance

A. Daily plan B . contingency plan C . 0perational plan D . All

22 . staff with advanced technical competence are not used as

A . Appoint of reference B . to identify difficult fault

C . set contingency plan D . All

23 . one of the following information is not needed to estimate the service job coast

A . type and quantity of supplies material requirement

B . space utilized for servicing C . time requirements D . none

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24 . to calculate the total job costs , one has to considers

A . to material labor B . overhead cost allowances

C . mark – up percentages D . all

25 . the people you deal with either face to face or over the telephone who buy

Products or service from you is called

A . external customer B . internal customer C . ordinary customer D . A & C

26 . customer service issues may not relate to

A. Response time B . service and pricing guarantees

C . product quality D . profit analysis

27 . one of the following is not write communication

A . E – mail B . face book C . video chat D . sins

28 . what should you consider to evaluate new or upgrade technology

A . usability B . performance C . OHS standard D . environmental E . all

Match column B to A

A B

1 . A document prepared to guide technician A . neutral start switch

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 And staff an expected output B . house keeping

2 . information provided by the manufacture C . Action plan

On vehicle data D . Hydraulic control system

3 . provided input signal to automatic E . cruise control

Transmission ECU F .calibration

4 . Tidy work shop G . job order

5 . detect the shift lever position H . class B fair

6 . fault diagnostic equipment I . quality control

7 . arrangement and location of equipment J . shop layout

8 . service and repair procedure/specification K . scan tool/OBD

9 . signal to down shift automatic transmission L . manufacture manual

10 . list of part/materials and work schedule M . specification

11 . flammable liquids N . electro hydraulic

12 . gather information verify and confirm O . tolerance

Problems, locates, isolate and perform activity P . kick down switch relay

13 . customer satisfaction Q . troubleshooting procedure

14 . fills and maintain a constant flow of liquid R . transfer cause

15 . checked accuracy of all instruments S . engine speed sensor

Set by YISHAK ISRAEL

Institutional assessment for Level IV Automotive servicing operation

Management trainees’
Name ___________________ Level:________ year:______
22
1 . when you encounter a difficult customer in a workshop the following
are some the appropriate things to do except one

A . serve them quickly but politely B . talk in a pleasant tone of voice

C . send them out if they don’t listen to you D . keep a friendly face

2 . to deal with a difficult worker .it is important to determine

A . what punishment they will have

B . the cause of the problem or tension

C . when they will be reprimanded

D . just leave it to the problematic co - worker

3 . one of the list is not appropriate in dealing with some one who is trying

To pick a fight at the work place

A . talk to the person politely but firmly

B . gather all your staff and start the fight

C . tell your superior that you have a problem and someone is causing trouble

D . let him know his behavior is in appropriate for the workplace

4 . to be a good team player , you need to ;-

A . learn to work well with other and do your own share of the work

B . mind your own and don’t mind also your co – worker

C . tell others that you are the boss

D . Encourage other to work alone

5 . A desirable trait that will help the worker to be successful in the job

A. Dishonest B . insincerely C . irresponsible D . reliability

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6 . A memorandum is also called ;-

A . A memory B . A fax C . A memo D . A logbook

7 . A skill is ;-

A . something you can do B . someone you know

C . something you know D . somebody know you

8 . the interval of time that each injector remains open is know as ;-

A . injector pulse width B . vacuum parameters

C . potentiometer D . Open loop

9 . an engine detonation ( knock ) sensor uses as ;-

A . piezo electric crystal B . Voltage divider pick up

C . potentiometer D . thermistor

10 . which of the following sensors directly measures engine load

A. Coolant sensor B . Manifold absolute pressure sensor

C . intake air temperature sensor D . vehicle speed sensor

11 . without an RPM signal to the computer on an EFI engine ?

A . the system will go in to back up model

B . the engine will run but it will be slugged

C . the engine will start but run very right

D . the engine will not run

12 . in four cylinder four stroke engine having firing order 1 – 3 – 4 – 2 and

Cylinder # 1 is at the end of compression, TDC. What would be the condition

Of the intake valve of the fourth cylinder ?

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 A . fully open B . at the start of opening C . about to close D . totally close

13 . the service time /mileage of a vehicle is indicated by

A . the speedometer B . the odometer C . the trip meter D . tachometer

14 . of the following which one is important when ordering an engine part

for purchase ?

A . service manual B . data book C . parts catalog D . vehicle history card

15 . you are given that, intake valve open 20 in exhaust stroke and close 30 in

Compression exhaust valve open 25 in power stroke and 35 intake stroke

For how much degree of crankshaft do intake and exhaust valve stay open

Respectively ?

A . 110 . 180 B . 230 . 240 C . 235 . 230 D . 240 . 235

16 . A mechanic is working on a light vehicle inline engine arrangement.

The rotary injection pump located at the left hand side of the engine looking

From the front of the engine ( pulley side ). The injection pump and engine
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 Rotations are clockwise looking from the front on timing check he found that

The timing is retarded by some degrees what would be your suggestion

to bring the timing into the specification ?

A . Turning the pump’s housing toward the engine block until the timing

Reaches to the specification

B . Turning the pump’s housing away from the engine block until the timing

Reaches to the specification

C . Remove the NO. 1 pressure line and rotate the crankshaft

D . Adjust the governor spring tension

Match column B to A

A B

1 . wide contact point gap A . plastic gauge

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2 . disengage the armature when the engine starts B . muffler

3 . damps engine sound and has catalytic convertor C . used to set dynamic timing

4 . engine displacement D . 14.7 ; 1

5 . stroboscopic light E . used to set static timing

6 . used to measure oil clearance F . over running clutch

7 . water temperature sensor G . to large dwell angle

8 . scan tool H . BDC to TDC

9 . harmful emission from diesel I . too small cycle

10 . stoichiometric ratio J . quality service

11 . arrangement and location of equipment K . house keeping

12 . after regrinding crank pin L . used undersized bearing

13 . untidy workshop M . shop lay out

14 . Lambda sensor N . air flow

15 . customer satisfaction O . feed back sensor

P . thermistor

Set by YISHAK ISRAEL Q . OBD II

R . first gear ratio

S . NOx

T . use oversized bearing

Project work procedure

Task 1 ;- Assume that the car customer bring his car shed also head light and

Turn signal lens, front wind shield mirror front bumper are broken
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 Calculates the coast and show the net profile of the component

no Part description items Unit price Total coast

1 Head light 2 2000 4000
2 Turn signal 2 300 600
3 Front wind shelled 1 6000 6000
4 Front bumper 1 3000 3000
5 Side view mirror 2 200 400
6 Lump 4 50 200
= sub total with 15 % vat =14200 * 15%

= 16330

14200 * 15/100 = 2130

= 14200 + 2130 = 16330

Labor coast

No Description of part installed Hour Labor coast

1 Head light 1 300
2 Turn signal 1 200
3 Front wind shelled 2 600
4 Front bumper 3/10 100
5 Side view mirror 1/3 400
6 Lump 1/4 100
Total coast =1700

Total coast with vat = 1700 * 15/100 = 255

1700 + 255 = 1955

Task 2 ;- assume that customer bring his car which is doesn’t have air conditioning

System and he needs air conditioning system to be fixed on this vehicle

Show the steps from receiving customer car up to delivering the car

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 Customer request
Customer needs air conditioning on his car
Drive the car to technical adviser technician data take that is possible to fays air

Conditioning

Yes

_ identify the part needs

_ calculate coast estimation tell customer after the customer agreed

_ collect the part from spar part

_ fix’s the part on the car

_ recharge air conditioning gas on the system 134a

_ make sure that the system is work or not

_ let the customer bring call the coast

_ deliver the car to the customer

No

_ advice the customer it is not possible to dies air condition system

_ deliver the car to the customer

Company
Company manager port manager

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 Service manager part compactor

Reception

Service director

Service adviser

Shops Forman

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