35.AURTTZ002 Diagnose and Repair Exhaust Systems

AURTTZ002 Diagnose and repair exhaust systems
Assessment 1 – Questioning – Written Assessment
Student Name Laljeet Singh Dhaliwal Student ID Number S32168
Unit Start Date Unit End Date
Assessment Due Date Date Submitted
This cover sheet is to be completed by the student and assessor and used as a record to determine student
competency in this assessment task
The assessment process and tasks were fully explained. Yes / No
I am aware of which evidence will be collected and how. Yes / No
I am aware of my right to appeal an assessment decision. Yes / No
I am aware that I can locate The RTO Complaints and Appeals Policy and Procedure on their Yes / No
website at (Insert Website Link)
I have discussed any additional educational support or reasonable adjustments I require in order to
undertake this assessment with the Student Support Services Officer and Trainer / Assessor, (if Yes / No
applicable). e.g. Student Handbook and Access and Equity Policy (Insert Website Link)
I have access to all required resources? Yes / No
Cheating & Plagiarism Declaration
Student Declaration: In accordance with The RTO Plagiarism Policy, I hereby acknowledge by signing this
declaration that I have not cheated or plagiarised any work regarding the assessment tasks undertaken in this unit of
competency except where the work has been correctly acknowledged.
NOTE: Student must sign this prior to submitting their assessments to the assessor
Signature Laljeet Singh Date: ______ / ______ / 20______
Satisfactory or Not Yet Satisfactory

Assessment Results
(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 Assessor Declaration: - I verify that I have adequately
is my own and that I was adequately informed of the explained and negotiated the assessment tasks with the
assessment process prior to commencing this student prior to commencing assessment.
assessment task.
Student Name: Laljeet Singh Dhaliwal Assessor’s Name:
Student Signature Date Assessor Signature Date
Document Name: Student Written Knowledge Assessment – AURTTZ002 Created Date: 12th Aug 2019
Document No: Insert RTO Name – AURTTZ002 Version No: 2.0 Last Modified
Date:
© Insert RTO Name | RTO Code: ????? | CRICOS Code: ????? Page Sequence: Page 1 of 15
Laljeet Singh
Student Guide for Written Knowledge Assessment

Overview of This is a written assessment task you will be assess on your knowledge of diagnosing and
Assessment repairing exhaust systems.
The topics that will be covered in the assessment are:
1. Prepare to diagnose and repair exhaust systems
2. Diagnose an exhaust system
3. Repair an exhaust system
4. Complete work processes
This assessment will ensure that the elements, performance criteria, performance evidence
and knowledge evidence required, and conditions are adhered to demonstrate competency
in this unit assessment task.
 Read the assessment carefully before commencing.
 Your Assessor will use the assessment criteria in this document and will provide
feedback / comment.
 You MUST answer all the questions in the assessment tasks in your own words and
own handwriting.
 This is an “Open Book” assessment, and students can use the resources listed in
the “Resources Required” section below.
Task/s to be To complete this written assessment, you will need to answer the 51 questions comprising
assessed of Multiple Choice, True and False, Fill-in the Gap and Short Answer questions.
Time allowed On average, the Assessment should take 2 – 4 hours to complete.
Location This theory assessment will be completed in a classroom under the supervision of a
trainer/assessor.
Decision making To receive a ‘satisfactory’ outcome for this assessment students MUST successfully answer
rules all questions. If a student achieves less than 100%, they can reattempt the assessment
after further study has taken place. Students who cannot achieve a minimum of 100% you
will not have satisfactorily completed this assessment
Your assessor will be looking for the following in this assessment task: -
 Work health and safety (WHS) and occupational health and safety (OHS)
requirements relating to diagnosing and repairing exhaust systems, including
procedures for working with hot components and exhaust systems producing toxic
gases
 Operating principles of features of exhaust systems and associated components,
including scavenging and back pressure
 Application, purpose and operation of exhaust systems and components, including:
o Mufflers
o Extractor pipes
o Catalytic converters
o Diesel particulate filters
 Diagnostic testing procedures for exhaust systems, including:
o Exhaust leak testing
o Vibration and noise locating procedures
o Back pressure testing
 Repair procedures for exhaust systems, including procedures for removing,
replacing and aligning components
Date:
 Post-repair testing procedures for exhaust systems.
Assessment Assessors MUST satisfy NVR/AQTF assessor requirements.

conditions
Competency is to be assessed in the workplace or a simulated environment that accurately
reflects performance in a real workplace setting.
Assessment MUST include direct observation of tasks.
Where assessment of competency includes third-party evidence, individuals MUST provide
evidence that links them to the exhaust systems that they have worked on, e.g. repair
orders.
Assessors MUST verify performance evidence through questioning on skills and knowledge
to ensure correct interpretation and application.
The following resources MUST be made available:
 Automotive repair workplace or simulated workplace
 Workplace instructions
 Manufacturer exhaust system specifications
 Two different vehicles with faults in the exhaust system components specified in the
performance evidence
 Diagnostic equipment for exhaust systems
 Tools, equipment and materials appropriate for repairing exhaust systems, including
metal heating equipment.
Resources required Learning Resources available to students include:

 Automotive Technology (A System Approach) 6th Edition – Chapters 5, 6, 7, 32 and
33
 Websites
 Trainer Handouts
Results/Re-  The Assessor will grade the assessment and record the result on the front page of
assessment 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 If the participant is unable to undertake the written assessment as designed, an interview
Adjustment (verbal questioning) may be used as an alternate approach.
Date:
Assessment 1 – Questioning
Written Assessment
1. Identify five (5) important items of personal safety when diagnosing and repairing exhaust
systems.
1 Safety shoes
2 Safety clothes
3 Safety foot glass
4 Ear muff
5 Gloves hand
True or False question

2. When inspecting or working on the exhaust system, remember that its components get very
hot when the engine is running. Contact with them could cause a severe burn. Also, always
wear safety glasses or goggles when working under a vehicle?
☒ True or ☐ False
Fill in the Gaps

3. Complete the following statement about venting engine exhaust gases using the following
words.
Words: Deadly, Direct, Engine, Exhaust, Monoxide, Nausea, Outside, Running, Tailpipe,
Ventilation
Whenever you need to have the engine running for diagnosis or service, the engine’s
exhaust must be vented to the outside. Carbon monoxide (CO) is present in the exhaust.
CO is an odourless, tasteless, and colourless deadly gas. Inhaling CO can cause brain
damage and, in severe cases, death. Early symptoms of CO poisoning include headaches,
nausea, and fatigue.
Most shops have an exhaust ventilation system. These systems collect the engine’s
exhaust and release it to the outside air. Before running an engine in the shop, connect a
hose from the vehicle’s tailpipe to the vent system. Make sure the vent system is turned on
before running the engine. If the work area does not have an exhaust venting system, use a
hose to direct the exhaust out of the building.
Date:
4. What are the three (3) functions of the exhaust system?
1. The exhaust system collects the exhaust gases from the cylinders

2. Removes harmful substances
3. Reduces the level of noise.

5. Some exhaust systems are designed with extractor pipes. These have one pipe for each
exhaust port. The pipes are designed with long sweeps that prevent back pressure. They
also provide a scavenging effect, which assists in extracting the exhaust gases from the
cylinders, thereby increasing engine performance.
6. Name the twelve [12] components of the exhaust system below.
1 Exhaust manifold
2 Exhaust header pipe
3 Gasket
4 Upstream HO2S sensor
5 Catalytic converter
6 Downstream HO2S sensor
7 Heat insulator
8 Intermediate pipe
9 Resonator
10 Hanger
11 Muffler
12 Tailpipe
7. What materials are exhaust pipes typically made from?
Mostly Aluminized steel; zinc-plated heavy-gauge steel; stainless steel
Date:
8. What is the function of the exhaust flex joint?
To allow engine to move during rapid acceleration

9. The exhaust manifold collects the burnt gases as they are expelled from the cylinders and
directs them to the exhaust pipe.
Multiple Choice question. Selected the correct answer.

10. Which of the following is NOT a metal used for producing exhaust manifolds?
A. Cast iron.
B. Aluminium.
C. Heavy-gauge sheet metal.
D. Stainless steel.
Fill in the Gaps

11. Complete the following statement about engine manifolds using the following words.
Words: Blend, Cylinder, Dual, Exhaust, Gases, Individual, Length, Manifold, Passages,
An exhaust manifold will have either three, four, five, or six passages, depending on the
type of engine. These passages blend into a single passage at the other end, which
connects to an exhaust pipe. From that point, the flow of exhaust gases continues to the
catalytic converter, muffler, and tail pipe, then exits at the rear of the car. V-type engines
may be equipped with a dual exhaust system that consists of two almost identical, but
individual systems in the same vehicle. Exhaust systems are designed for particular engine-
chassis combinations. Exhaust system length, pipe size, and silencer size are used to tune
the flow of gases within the exhaust system. Proper tuning of the exhaust manifold tubes
Date:
can actually create a partial vacuum that helps draw exhaust gases out of the cylinder,
improving volumetric efficiency.

12. The tailpipe is the last pipe in the exhaust system. It releases the exhaust fumes into the
atmosphere beyond the back end of the car.
13. Heat shields are used to.
To protect from the heat

14. Heat shields are usually made of pressed or perforated sheet metal.

15. Heat shields trap the heat in the exhaust system, which has a direct effect on maintaining
exhaust gas velocity.
16. Describe the construction of a muffler.
It is a combination of tuning chambers, formed by partitions and ventilated and solid tubes.

17. Two types commonly used are the reverse-flow and the straight-through mufflers.
Date:
18. What are the two (2) benefits of using aluminised and stainless steel in muffler
construction?
Utilising these materials decrease unit weight and prolongs their lives.

19. Many cars use a double-wall exhaust pipe to better contain the sound and reduce pipe ring.

20. Many mufflers are produced with drain holes drilled into them to allow condensation to drip
out.
21. On some older vehicles, there is an additional muffler, known as?
A resonator or silencer.
Fill in the Gaps

22. Complete the following statement about tuned exhaust headers using the following words.
Words: Cylinders, Engine, Exhaust, Flow, Headers, Improve, Pressure
Tuned exhaust headers can also improve efficiency by preventing the exhaust flow of one
cylinder from interfering with the exhaust flow of another cylinder. Cylinders next to one
another may release exhaust gas at about the same time. When this happens, the pressure
of the exhaust gas from one cylinder can interfere with the flow from the other cylinder. With
separate headers, the cylinders are isolated from one another, interference is eliminated,
and the engine breathes better.

23. The largest performance gain from using an exhaust header is that it increases the engine’s
volumetric efficiency.
Date:
24. Explain how exhaust headers increase the engine’s volumetric efficiency?
The goal of performance exhaust headers is mainly to decrease flow resistance (back
pressure), and to increase the volumetric efficiency of an engine, resulting in a gain in power
output. The processes occurring can be explained by the gas laws, specifically the ideal gas
law and the combined gas law.
25. Describe the main purpose of a catalytic converter.
It decreases carbon monoxide (CO), Carbon hydrocarbons (HC), and nitrogen oxides
(NOX). The converter also aims to minimise the noise at exhaust.

26. A catalytic converter breaks down HC and CO to relatively harmless by-products.

27. OBD-II regulation call for a monitoring system that looks at the effectiveness of the catalytic
converter.
28. Name the four [4] parts of the catalytic converter below.
1 Monolith catalyst
2 Outer shell
3 Inner shell
4 Insulation
Date:

29. A catalytic converter is part of the exhaust system and a very important part of the emission
control system.

30. A catalytic converter contains a ceramic element coated with a catalyst.

31. A catalyst is a substance that causes a chemical reaction in other elements without actually
becoming part of the chemical change and without being used up or consumed in the
process.
Fill in the Gaps

32. Complete the following statement about diesel particulate filter using the following words.
Words: Filters, Preventive, Regeneration, Soot, Trap, Vehicle
Particulate filters are placed into the exhaust system after the catalytic converter.
Sometimes, the PM filter is part of the converter assembly. Particulate filters are designed
to trap PM. Early PM filters needed to be cleaned as part of a preventive maintenance
program. Newer designs periodically burn off the collected PM and are designed to last the
life of the vehicle without any special maintenance. This is done by a special cleaning
mode, often called regeneration, initiated by the PCM. This combustion cleans the soot
from the filter.
Date:

33. Regeneration can be passive or active.
34. The diesel particulate filter is fitted with a sensor that measures exhaust backpressure. How
does this operate?
Back pressure to exhaust increases the as ash builds up in the philtre. If the sensor alerts
the PCM that it has reached a specified backpressure limit, the PCM will order the fuel
injection to spray an additional volume of fuel. The extra fuel heats up the catalytic oxidation
converter, and the fire in the PM philtre will melt off the ash. The amount of time the PCM
uses fuel to cleanse the philtre is called the regeneration period.

35. Exhaust leaks are often identified by sound, although very small leaks can be difficult to
locate.
☒ True Or ☐ False
36. What is the most effective way to identify the source of an exhaust leak?
The use of smoke machine is one of the most efficient methods of determining inside the
device the causes of a leak. As smoke is delivered to the exhaust pipe, a sign of smoke
reveals the cause of the leak.

37. Most parts of the exhaust system, particularly the exhaust pipe, muffler, and tailpipe, are
subject to rust, corrosion, and cracking.

38. Broken or loose clamps and hangers can allow parts to separate or hit the road as the car
moves causing vibrations.
Date:

39. Excessive exhaust noise from the tailpipe can be due to a muffler or resonator in which the
baffles have corroded so that they are no longer effective.

40. A restricted exhaust can be tested with an exhaust pressure gauge.
Fill in the Gaps

41. Complete the following statement about exhaust restriction testing using the following
words.
Words: Determine, Exhaust, Gauge, Hold, Manifold, Pressure, Restricted, Vacuum
There are many ways to check for a restricted exhaust. The sound of the exhaust can
indicate a restriction. With a restriction, the exhaust will wheeze as it struggles to exit the
exhaust system. Although this is not the most effective way to determine if there is a
restriction, it is a good start. Checking the pressure built up in the exhaust is the best way to
determine if the system is blocked. This is done by installing a pressure gauge in the O2S
bore in the exhaust pipe. At idle, the gauge should read less than 1.5 psi (10 kPa) and
should be less than 2.5 psi (17 kPa) at 2,500 rpm. Some technicians check for a restricted
exhaust with a vacuum gauge. With the gauge connected to the intake manifold, the
engine’s speed is raised and held. The vacuum reading should rise and either hold there or
increase slightly. If the vacuum decreases, there is an exhaust restriction.

42. A restricted exhaust system can cause ______.
A. Stalling.
B. Loss of power.
C. Backfiring.
D. All answers are correct.
Date:

43. Before replacing an exhaust system component, soaks all old connections with a
penetrating oil.

44. Checks the old system’s routing for critical clearance points before replacing an exhaust
system component.

45. Most exhaust work involves the replacement of parts. When replacing exhaust parts, make
sure the new parts are exact replacements for the original parts. Doing this will ensure
proper fit and alignment as well as ensure acceptable noise levels.
46. Exhaust system component replacement might require the use of special tools. Name eight
(8) special tools.
1 Welding equipment
2 Expander
3 Shaper
4 Muffler cutter
5 Air chisel
6 Chain pipe cutter
7 Pipe cutter
8 Hanger removal tool

47. When installing exhaust gaskets, carefully follow the recommendations on the gasket
package label and instruction forms.
Date:

48. To replace an exhaust manifold gasket, follow the torque sequence in reverse to loosen
each bolt. Repeat the process to remove the bolts. Doing this minimizes the chance that
components will warp.
☒ True Or ☐ False
49. Consider the various post repair checks that you would make during a road test exhaust
system?
After the warranty testing was carried out after the road inspection for the car to ensure that
the servicing operation was correctly performed and that the customer questions was
addressed. Test the exhaust system for leakage, and no noises or noises from the exhaust
system are detected.
Date:

50. Which source of information will give you the most detail about diagnosing and repairing
exhaust systems on the vehicle you are working on?
A. Workshop manual.
B. Owner’s manual.
C. Google.
D. Textbooks.
51. Why is it very important that the Job Card is completed correctly?
It’s a legal document and record the services history of a vehicles
Date:

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AURTTZ002 Diagnose and repair exhaust systems

Assessment 1 – Questioning – Written Assessment

Student Name Laljeet Singh Dhaliwal Student ID Number S32168

Unit Start Date Unit End Date

Assessment Due Date Date Submitted

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 have access to all required resources? Yes / No

Cheating & Plagiarism Declaration

Signature Laljeet Singh Date: ______ / ______ / 20______

Satisfactory or Not Yet Satisfactory

Feedback to Student - Please provide general feedback on the Student’s performance

Student Name: Laljeet Singh Dhaliwal Assessor’s Name:

Student Signature Date Assessor Signature Date

Student Guide for Written Knowledge Assessment

Time allowed On average, the Assessment should take 2 – 4 hours to complete.

 Post-repair testing procedures for exhaust systems.

Assessment Assessors MUST satisfy NVR/AQTF assessor requirements.

Resources required Learning Resources available to students include:

True or False question

Fill in the Gaps

4. What are the three (3) functions of the exhaust system?

1. The exhaust system collects the exhaust gases from the cylinders

True or False question

6. Name the twelve [12] components of the exhaust system below.

7. What materials are exhaust pipes typically made from?

Mostly Aluminized steel; zinc-plated heavy-gauge steel; stainless steel

8. What is the function of the exhaust flex joint?

To allow engine to move during rapid acceleration

Multiple Choice question. Selected the correct answer.

Fill in the Gaps

True or False question

13. Heat shields are used to.

To protect from the heat

True or False question

True or False question

16. Describe the construction of a muffler.

True or False question

True or False question

True or False question

21. On some older vehicles, there is an additional muffler, known as?

Fill in the Gaps

True or False question

25. Describe the main purpose of a catalytic converter.

True or False question

True or False question

True or False question

True or False question

True or False question

Fill in the Gaps

True or False question

True or False question

True or False question

True or False question

True or False question

True or False question

Fill in the Gaps

Multiple Choice question. Selected the correct answer.

True or False question

True or False question

True or False question

True or False question

True or False question

Signature Laljeet Singh Date: / / 20__