3 - AURLTE004 K

AUR40216
Harman Singh Bhullar

Student Name:
Student ID: SAE5421
Assessment Summary
3 - AURLTE004 – Diagnose complex faults in light
Unit Details
vehicle petrol engines
This is a summative assessment, which requires each

student to have adequate practice prior to undertaking this
Assessment Type assessment
This assessment Must also be undertaken in a
simulated automotive workshop
Assessment 1 Written Task

Assessment Methods
Assessment 2 Demonstration
Version: 5.0 Acumen Education Pty Ltd © Page 1 of 67

Assessment Tool | AURLTE004
Contents
Assessment information......................................................................................................3
Purpose.........................................................................................................................3
Unit description............................................................................................................3
Key competencies.........................................................................................................3
Foundation skills..........................................................................................................3
Performance evidence...................................................................................................4
Knowledge evidence.....................................................................................................4
Assessment Conditions.................................................................................................5
Pre-requisites................................................................................................................6
Terminology used.........................................................................................................6
Completing the assessments/Expectations....................................................................6
Assessment...................................................................................................................6
Summary of assessment methods and tasks..................................................................6
Instructions...................................................................................................................7
Required resources.......................................................................................................7
Reasonable adjustment.................................................................................................7
Plagiarism policy..........................................................................................................8
Academic appeals.........................................................................................................8
Reassessment process...................................................................................................8
Assessment records......................................................................................................9
Declaration...................................................................................................................9
Assessment submissions and contact details.................................................................9
Assessment 1 – Written Questions....................................................................................................12
Instructions for Students.............................................................................................12
Assessment 2 – Practical demonstration...........................................................................43
Instructions for Students:...................................................................................................................43
Decision-making rules.......................................................................................................................44
Resources required for assessment....................................................................................................45
Observation Task...............................................................................................................................47
Student Instructions...........................................................................................................................48
Repair Order 1...................................................................................................................................50
Skill Observation Checklist and Assessment Outcome: Assessment 2, Task 1................................53
Repair Order 2...................................................................................................................................56
Repair Order 3...................................................................................................................................62

Assessment information
Purpose This document represents the main assessment instrument for the unit of
competency AURLTE004 – Diagnose complex faults in light vehicle petrol engines
Unit description This unit describes the performance outcomes required to diagnose complex faults in light
vehicle petrol engines and determine the repair action necessary to restore system
performance. It involves confirming the existence of a fault, choosing the diagnostic
procedure and tools, applying the diagnostic procedure, reporting conclusions and making
repair recommendations.
Complex faults are outside the normal scope of a technician s diagnosis and repair work.
They include intermittent faults, multi-system faults, faults introduced as a result of system
repairs, and indirect faults caused by the influence of external systems, requiring the
application of complex diagnostic processes to resolve.
It applies to those working in the automotive service and repair industry. The petrol
engines include those of light vehicles or light commercial vehicles.
No licensing, legislative, regulatory or certification requirements apply to this unit at the

time of publication.
Key 1. Identify and confirm the work requirement

competencies 2. Prepare to carry out diagnosis
3. Apply diagnostic procedures
4. Complete work processes
Foundation skills Learning skills to: Locate and evaluate appropriate sources of
information efficiently.
Apply diagnostic skills to different vehicles.

Reading skills to: Research, organise and interpret technical information from
manufacturer and workshop literature when seeking light vehicle
petrol engine specifications and
procedures.
Writing skills to: Legibly and accurately fill out workplace
documentation when reporting diagnostic findings,
making repair recommendations, and recording parts and
material used.
Oral Clarify instructions, gain information from customers
communication and supervisors, report diagnostic findings and make repair
skills to: recommendations.
Numeracy skills to: Measure petrol engine components and use basic
mathematical operations, including addition and
subtraction, to calculate tolerances and deviations

from manufacturer specifications.
Use gauges and interpret units, such as kilopascals and pounds per
square inch (PSI).
Planning and Plan own work requirements and prioritise and sequence actions to
organising skills to: achieve required outcomes and ensure tasks are completed within
workplace
timeframes.
Technology Use precision measuring equipment, such as
micrometers.
skills to:
Use specialised diagnostic equipment, such as:
 compression gauges
 vacuum gauges
 cylinder leak-down gauges
 oil pressure gauges
Performance Evidence of the ability to:

evidence  diagnose a complex fault in three different light vehicle petrol engines
 the above diagnosis must involve two of the following types of complex faults:
o an intermittent fault
o a fault that affects more than one system
o a fault introduced as a result of a system repair
o an indirect fault caused by the influence of external systems
Knowledge  work health and safety (WHS) and occupational health and safety (OHS) requirements
evidence relating to diagnosing complex faults in light vehicle petrol engines, including
procedures for:
o working with hot engine components and rotating engine components
o controlling hazards associated with hazardous substances, including engine oil and
coolants
 environmental requirements, including procedures for trapping, storing and disposing
of fluids released from petrol engines
 types of complex faults relating to light vehicle petrol engines,including:
o intermittent
o multi-system
o introduced as a result of system repair
o indirect, caused by the influence of external systems
 types, function and operation of light vehicle petrol engines, including:
o intake, exhaust, lubrication, cooling and engine mounting systems and
components
o valve timing and variable valve timing
 testing procedures for light vehicle petrol engines, including:

o abnormal noise analysis

o compression testing
o cylinder leak-down testing
o oil pressure testing
o component failure analysis
 types, functions, operation and limitations of diagnostic testing equipment required to
diagnose complex faults in light vehicle petrol engines
 procedures for accessing and interpreting scan tool system data, including:
o diagnostic trouble codes (DTCs), including:
 conditions that set the DTCs
 conditions for running DTCs
o live data
o freeze frame data
o waveforms
o vehicle continuous and non-continuous monitored systems
 methods and processes for documenting and reporting diagnostic findings and
recommendations
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 light vehicle petrol engines that they have worked on, e.g.
repair orders.
Assessors must verify performance evidence through questioning on skills and knowledge
to ensure correct interpretation and application.
The following resources must be made available:
 automotive repair workplace or simulated workplace

 workplace instructions
 manufacturer light vehicle petrol engine specifications
 three different light vehicles with complex faults in their petrol engines
 engine diagnostic equipment, including:
o compression gauge
o vacuum gauge
o cylinder leak-down gauge
o oil pressure gauge
 tools, equipment and materials appropriate for diagnosing complex

faults in light vehicle petrol engines

Pre-requisites NIL
Terminology The following terms are used in each assessment task to guide the student and assessor as
used to what is expected from each assessment task:
1. Instructions: Provides a brief description about the assessment task and broadly
indicates what the Student is required to do.
2. Conditions of assessment: Outlines the conditions in which the assessment must be
undertaken. In some cases, it will give options for the student about what to base the
assessment task on and whether it is practical demonstration or project.
3. Description of task/decision making rules: Advises the student and the assessor of the
task description and the criteria that the assessment must meet in order for a
satisfactory result to be awarded.
4. Due Date - the date on which assessment falls due.
Completing the Assessors must ensure that students completely understand the assessment process and
assessments/Ex various assessment tasks before undertaking the assessments. This assessment tool is
pectations structured in a way that each assessment task clearly outlines the:
 Instructions for completing the assessment task;
 Conditions in which the assessment must be conducted;
 Evidence that must be presented by the student; and
 Decision-making rules by which the evidence will be judged.
Every assessment task will require satisfactory completion in order for students to be
deemed Competent. The students will need to adhere to any guidelines on length of
answers required where stipulated. Please note, a paragraph is three or more sentences.
This unit is being offered as a part of Certificate IV in Light Vehicle Mechanical

Technology. You will not qualify to receive Certificate of completion until you attain
competency in all the units offered as part of
this qualification.
Assessment Each assessment task has a section for the assessor recording the assessment outcome as
either ‘Satisfactory’ (S) or ‘Not Satisfactory’ (NS). Once the student satisfactorily
completes all assessment tasks, the assessor will complete the assessment summary cover
sheet and record either a “Competent” (C) or “Not Competent” (NC) outcome.
When awarding any assessment result, assessors must ensure that feedback
for the student is recorded in the spaces provided after each assessment task and on the
record of assessment outcome.
Summary of The assessment methods that are used in this assessment tool are:
assessment Assessment Method of
Description
methods and Task # Assessment
tasks 1 Questions You are required to answer 27 short answer
questions related to this unit.

2 Demonstrati  Diagnose a complex fault in three

on different light vehicle petrol engines.
Instructions:  You can seek clarification regarding the assessment required to be done.
 You can ask for reasonable time from Assessor for preparation of project or
Assessment.
 You can seek information on additional reading material and reference for completion
of the assessments.
 If you have any special needs, you can seek assistance from Assessors depending upon
the nature of the need.
 You can seek assistance from assessor while using special diagnostic equipment
 Review the observation checklist/decision making rules to know what is expected of
you. You may refer to the observation checklist for observation based assessments at
any stage prior to the commencement of your assessment. You must not refer to this
checklist whilst you are being assessed.
 Your assessor will also explain to you the observation process prior to the
assessment.
Required Each assessment task in this assessment tool outlines specific resources that the student
resources must have access to as part of the assessment process. Assessors must ensure that students
have appropriate access to these
resources before any assessment is conducted.
Reasonable Acumen Education enables reasonable adjustments to be made to assessment procedures
adjustment for students with special needs, such as people with disabilities or with language or literacy
difficulties. Assessing knowledge is usually assessed through written or oral, short-answer
tests where assessors seek to determine the extent of the student’s knowledge.
Following are some of the examples of adjustments that can be made for the students:
 Ask questions orally instead of in a written format
 Provide equipment such as text enlargers, image enhancers, and voice recorders.
 Give the student more time to complete the assessment;, allocate a different time
for completion of the assessment;
 Offer a separate, quiet room.
 Modifying or providing equipment
 Adapting delivery strategies
 Ensuring that course activities are sufficiently flexible, providing
additional support to student where necessary
 Customising resources and activities within the training package or accredited
course
 Monitoring the adjustments to ensure student needs continue to be met

Plagiarism Acumen education takes a systemic approach to the treatment of plagiarism in academic
policy work. The policy is intended to promote honesty in learning and assessment and respect for
the work of others. Contravention of this policy will result in students being penalized.
Please read the plagiarism policy available in your student handbook and
to be aware of the consequences and to understand your rights and responsibilities.
Academic  Where a student wishes to appeal an assessment they are required to notify their
appeals assessor in the first instance. Where appropriate the assessor may decide to re-assess
the student to ensure a fair and equitable decision is gained. The assessor shall
complete a written report regarding the re-assessment outlining the reasons why
assessment was or was not granted.
 If this is still not to the student’s satisfaction the student shall formally lodge an appeal
by submitting a written letter within one week of receiving the results using the form
10.1 for Complaints and appeals outlining the reasons for the appeal. They shall lodge
this with student administrations department and the appeal shall be entered into the
‘complaints and appeals register’.
 The Operations Manager shall be notified and shall seek details from the assessor
involved and any other relevant parties. A decision shall be made regarding the appeal
either indicating the assessment decision stands or details of a possible re-assessment
by another assessor appointed by Acumen.
The student shall be notified in writing of the outcome with reasons for the decision. The
student shall also be provided the option of activating the external appeals process if they
are not satisfied with the outcome. The
student is required to notify Acumen if they wish to proceed with the external
appeals process.
Reassessment 1. Student will be assessed as being competent only upon satisfactory completion of all
process the assessments in a unit.
2. If a student is not able to demonstrate satisfactory completion of all of the required
assessments of the unit, the result for that unit will be recorded as Not Competent.
3. If a student has submitted all the tasks and successfully completed more than 50%* of
the assessment tasks for a unit, they will be provided with specific feedback and invited
to re-submit their assessment.
4. If a student has submitted and not successfully completed more than 50%* of the
assessment tasks for a unit, they will be required to undertake the unit again.
5. In the case of re-submission, the following actions shall occur:
 The student must apply for resubmission within one week of the result is made
available to him/her. This means that the student is

responsible to acknowledge that he/she has received the result and has been
deemed NC for the units of competency undertaken.
 Reassessment may need to be arranged every weekend on Saturday evenings in
order to minimize disruption.
6. If a student is assessed as “Not Competent’ after the resubmission, he or she will be
identified as a student-at-risk and an Academic Performance Improvement (API) Plan
will be created during an Intervention Strategy Meeting between the Acumen’s
Operations Manager, Trainer & Assessor and student. The date for a third assessment
will be nominated by the student in consultation with Trainer & Assessor, but should be
no longer than 1 month from the previous re- submission date.
7. One re-submission is allowable per unit per student free of cost. Additional re-
submissions will be charged at $200.
If the student remains ‘Not Competent’ after a third re-submission, he or she will be
notified that this result is final and he or she will be unable to successfully complete the
course in which they are enrolled at this point.
* Due to the variance in the amount of work completed for each assessment task in a unit,
50% will be determined by the number of assessment tasks submitted as opposed to the
amount of evidence
submitted.
Assessment We are required to retain a copy of your assessment and all other evidentiary records.
records If you require a copy of this assessment submission
please be sure to copy it prior to submitting it to us.
Declaration You must sign the student declaration confirming the authenticity of your submitted work,
understanding the requirements to complete the assessment tasks and that the assessment
process including the provisions for re-submitting and academic appeals were explained to
you and that you understand these processes on the assessment summary cover sheet.
Acumen Education cannot assess any submitted work until the declaration is received.
Assessment You must submit this completed assessment tool to your trainer on the due date. Please feel
submissions and free to contact us if you have any questions regarding the assessment process:
contact details Phone: 03 9044 6402/03 84151244

For Assessor Only -ASSESSMENT COVER

SHEET
This form is to be completed by the assessor and used as a final record of student competency.
All student submissions including any associated checklists (outlined below) are to be attached to this cover sheet before placing on
the students file. Student results are not to be entered onto the Student Database unless all relevant paperwork is completed and attached to this form.
Student
Student Name:
ID No:
Contact
Email:
number:
Unit Code &
Title AURLTE004 – Diagnose complex faults in light vehicle petrol engines
 
First Submission Subsequent submission
Result
Please attach the following documentation to this form S = Satisfactory NS
= Not Satisfactory

Assessment 1 Written Task S | NS

Assessment 2 Demonstration – Diagnosing faults S | NS
Final Assessment Result for this unit
 
(Student will be assessed as being competent only Competent Not Competent (Comments)
upon satisfactory completion of all the above
mentioned assessments)
The Evidence provided is:
 Valid  Sufficient  Authentic  Current
Student Declaration:
I acknowledge that I understand the requirements to complete the assessment tasks. The assessment process including the
provisions for re-submitting and academic appeals were explained to me and I understand these processes. I understand the
consequences of plagiarism and confirm that this is my own work and I have acknowledged or referenced all sources of
information I have used for the purpose of this assessment.
Student’s Signature: Date: / /
Final feedback:
Assessor: I declare that I have conducted a fair, valid, reliable and

flexible assessment with this student, and I have provided Signature:
appropriate feedback.
Date: / /
Administrative use only
Entered onto Student

Management Database Date Initials

USE FOR REASSESSMENT ONLY
Assessment Task No/s
Components
Competent - C Not Competent - NC

Result of Reassessment
(Please circle the Final Assessment Outcome)
Feedback to Student
Please provide general feedback on the Student’s performance.
Assessor: I declare that I have conducted a fair, valid, reliable and flexible assessment with this student,
and I have provided appropriate feedback.
Trainer/Assessor Signature Date

Assessment 1 – Written Questions
Instructions for Students:
 This is the first of the two assessment tasks you must complete satisfactorily to be deemed competent in
this unit.
 In this task, you must answer twenty seven (27)questions that cover the knowledge requirements of
this unit.
 Read the Assessment description carefully.
 Assessment may be submitted inMicrosoft Word format or may be handwritten. Clearly label your work with
your name, unit code, unit title, Assessment Task and respective Question number with the answer to all the
documents and sheets that are attached to your submission.
 Assessment may be completed in your own time and is due one week after the module end date.
 Acknowledge clearly when and how you are drawing on the ideas or phrases ofothers.
 Consult your assessor when you are unsure about how to acknowledge the contributions of others to your
thought and writing.
 Read the Plagiarism policy and procedure carefully to understand the consequences that you could face if
your work is plagiarized.
 Seek clarification regarding the assessment required to be done, if you do not understand the task.
 Ask for reasonable time from Assessor for preparation of project or Assessment.
 Seek information on additional reading material and reference for completion of the assessments.
 Students with special needs can seek assistance from assessors depending upon the nature of the
need.
 Add your name, Student ID, unit code and assessment task number to all project work, documents and
sheets you attach to your submission.
 Submit this document along with your assessment work.
 Assessment may be completed in your own time and is due one week after the module end date.

Written Questions
List 5 precautions you should take while working on the hot and rotating engine components.
1
 Requires the use of corresponding PPE security.

 Make sure long hair is wrapped up tightly.
 Weapons rolled.
 Don't put on clothes that match loose.
 Must wear protective gloves for thermal use.
Satisfactory Not Satisfactory (Comments)
List 3 hazards associated with replacement of engine oil. List any 3 safety precautions that should be
2
followed.
Hazards
 Has caused burning eyes.
 Sensitive to garbage.
 Daily skin contact gives rise to a number of skin problems.
 Sliding Risk.

Precautions
Use of corresponding PPE instead of engine oil.
Clean hands immediately after handling the engine oils.
Use right bundled storage facilities to store engine oils;
List 3 hazards associated with working with coolants. List any 3 safety precautions to be followed?
3
Hazards
 Touching or pouring the refrigerant onto the body may result in serious injury.
 Triggers strong grounding.
 Always keep the head, hands and clothes away from the moving fan when turning on the refrigeration
system and running the engine to avoid physical injury.
Precautions
 Use of suitable PPE when handling refrigerants.
 Add used antifreeze to suitable container.
 Make sure the negative battery terminal is protected when working on the electric fans.

What are the environmental requirements for trapping, storing and disposing of fluids released from
4
petrol engines? (in about 50 -70 words)
 Collect the refrigerant in clearly labeled drums or tanks stored in a packed underground
field.
 Select an EPA licensed contractor to remove waste coolant for recycling, processing or disposal;
 Hold a waste transport permit from the Contractor for a period of 24 months.
Satisfactory  Not Satisfactory (Comments)
The engine is misfiring under load but does not do it all the time and engine light pops
5 up intermittently. What would be the cause? Diagnose this issuein about 100-150 words.
Cause:
A defective ignition coil, fouled spark plugs as per manual repair instruction would be the most likely triggers
here.
Diagnostic procedure:
 Plug-in Coil Check.
 Check the DTCs confirm that No. 2 cylinder ignition coil is missfire detection.
 Spark appears suggesting no misfire at the moment.
 However, as per customer concern, misfires occur intermittently and further testing is required.
 Change No.2 coil to No.3 ignition coil, and test the Scan tool for DTC. The scanning tool displays
No.2 cylinder misfire detection which needs additional testing to validate the fault.

Spark appears indicating there is no misfire at the moment.

However, misfires occur intermittently as per customer concern so it is recommended that further testing be carried out.
Shift No.2 coil to No.3 ignition coil and check the Scan Tool for DTC. The scanning tool displays No.2 cylinder misfire de
Check the Side Connector Ignition Coil wire brace. The wire will be loose in the cable harness connection, and will be abo
Remove cable harness connector terminals to solve the problem. Check for ignition coils on all other wires, and check if th
a. Describe four signs of a tank filled with contaminated or bad fuel.

6 b. List three system DTCs that pop up when contaminated fuel is introduced?
c. Describe the diagnostic procedure to resolve this issue in about 100-120 words.
Four signs of a tank filled with contaminated or bad fuel are:
 Engine to work approximately or without power / output.
 Engine that is harder to get started than usual.
 Mismanagement tingling or backfiring.
 Engine warning light on illuminated.
DTCs that may pop are:

P0132-O2 High voltage circuit (Sensor 1 at the bench). P0420-
Under Threshold Output catalyst system (Bank 1). P0300 —
Spontaneous / Multiple cylinder misfire.
P0101-Mass Air Flow (MAF) sensor output.

Diagnostic procedure
Remove the tank as required by process of the manufacturer.
Disconnect all electrical connections related to your health.
Pour out all the fuel in the tank.
Remove filter from the gas.
Switch over the tank, then press on the bottom to remove the debris. Turn the tank over, then touch the bottom to clear the
Clean all fuel lines in a sound way.
Using a new fuel filter to fit the fuel pump and install the Tank.
The fresh-fuel tank is refilled.
Eliminate all DTCS, start the engine and check any irregularities including misfires and engine lights. Read the Live data f
 Satisfactory  Not Satisfactory (Comments)
Customer complains that there is a delay in vehicle starting and engine light is ON all the time, a day
after performing 80,000 km service.
7  Technician checked for service history and found that the following service items have been replaced
i.e. Engine oil, oil filter, Air filter, fuel filter, spark plugs and brake fluid flush.
Describe the diagnostic procedure to resolve this issue in about 100-150 words.
 Attach your scanner and get details. DTC P0136 Oxygen bank 1 Sensor 2 shows up. Check that the
fuel pressure is as specified, and that there is no vacuum leak in the induction system as specified in
the repair manual.
 Fuel pressure test. The results didn't meet the manufacturers' criteria.
 Open the fuel pump and the fuel pressure regulator valve and check whether the fuel pressure is not
below the specified limit.
 Remove the fuel pump assembly in the tank and check if the fuel pump is in good working order.
 Check fuel pressure regulator valve that is not installed correctly due to damage to O- rings. The fuel
pressure regulator will not hold the fuel pressure anyway.
 Disconnect the pressure regulator valve and replace it with new O-rings and refixes, as per
manufacturer procedures.
 Confirm the fuel pressure specified by the fabricator;
 Scanning tool displays P0136 oxygen sensor as issue code due to low fuel pressure.
 Delete DTC. Just make sure there is no starting delay, and there is no light from the engine turning
on.

a) Describe the Intake air system in petrol engine vehicle in about 40-50words.
b) List 4 types of intake manifolds.
8
c) Explain Variable intake manifold function and operating procedure. (in about 40 - 60 words)
a. The Intake air system

The principle of air induction directs the engine cylinders outward to the petrol. The induction
system consists of ductwork which channels outside the air to an air cleaner removing dirt from the
air. Ductwork connects the filter with the throttle body and an intake manifold which distributes the
air to the engine cylinders within the induction system.
b. Types of Intake Manifolds:

 Carburetor manifolds for engine.
 EFI Engine intake manifolds.
 The variable intake manifold.
 Single divisions or multiples.
c. Variable intake manifold:

Most engines have multipliers of variable intake, which are controlled by PCM. These manifolds change the
size of the region of the Plenum and or change the length and effective diameter of the runners according to the
engine speed and load. The use of these multipliers lets the engine attain high volumetric output at more than
one engine rpm.

a. What are catalytic convertors? (30-50 words)

9 b. Briefly explain the two types of catalytic convertors and their functions
c. List five exhaust system components of a light vehicle petrol engine.
Catalytic convertors
These are mounted on the engine's exhaust panel, which resembles a small muffler. Their outer body is
stainless steel, while inside there is a honeycombed ceramic block containing a number of noble metals
including platinum , palladium, and rhodium. These metals cause a chemical reaction for moving the exhaust
gasses.
The two types of catalytic converters are:

 The two-way converter or oxidizer converts to water and carbon dioxide unburnt or partially burnt
fuel;
 In addition, the three-way converters (now the most common type) use the oxidizing process to
transform nitrogen oxides into harmless nitrogen.
Exhaust system components:

 Exhaust Multiplier.
 Exhaust pipe and sealed catalytic converter.
 Tricks.
 Acoustic resonator.
 Blinding fire on tailpipe.
 Clamps, hoops and suspension doors.
 Sensoring oxygen to exhaust air.

a. What is the purpose of lubricating oil in light vehicle petrol engine? 20-30 words.
10
b. Explain the function and operation of a relief valve in 30-40 words.
Purpose:
1. Minimize Wear.
2. Reduces debris and outages of electricity.
3. Turns power off.
4. Reduces engine noise.
5. They 're a bolt.
6. Cleans internal parts of the engine.
Relief Valve:
The relief valve controlls the pressure in the lubrication system. If the necessary pressure is reached the valve
opens to stop it from increasing further; excess oil is then bypassed into the intake side of the oil pump.
a. What is the importance of cooling system in a light vehicle petrol engine?

11
b. What are the different ways in which a heat can transfer? (in about 100 words)
Importance of cooling system

A cooling mechanism fills the engine block with a liquid coolant which moves through passages. As the
coolant flows through these channels, the heat from the engine produced by the combustion of the air-fuel
mixture in the cylinders is taken up. Then the hot fluid makes its way through the front of the car to the radiator
through a rubber hose. And the heat produced is absorbed by the cylinder walls, the cylinder head and the
pistons, all of which are protected by the cooling system to avoid overheating.

Heat can be transferred in three ways:
Conduction: Move is transfer of heat over solids. In the refrigeration device heat is transferred from the combustion cham
Convection: Convection is transfer of heat by molecular motion and includes gases and liquids, not solids. As a liquid or g
Radiation: In space heat is described as rays of radiation. These are transformed into heat whenever a colder body is hit, th

Explain the operation of engine driven and electric cooling fansin about 100-150
12
words
Engine driven cooling fans
Engine powered fan uses a viscous coupler to connect the water pump pulley to the cooling ventilator. The
viscous coupler is called a fan clutch because it can hit, and disengage, the fan from the pulley. Typically the
fan clutch uses two disks that have closely spaced rings and grooves in between. It transmits, as viscous silicone
oil fills the tiny gaps between the rings and grooves.

Electric Fans
Electric ventilators use an electric motor to turn a wired fan. The electric fan is powered by two methods: a control module
a. List the different types of engine mounts used in the lightvehicles.

13
b. Explain the function of engine mounts in about 20 words.
The light vehicles mainly use two mounting styles. That is Rubber mounting type and the other is
hydraulic fluid filled mountings.
Mounting is intended mainly to reduce vibration and excessive noise at engine startup.

a. What is valve timing? 40-50 words.

14
b. Explain theoretical four stoke cycle engine valve timing in about 100 -150 words.
Valve timing
Valve timing is a very important valve operating sequence in a light-duty petrol engine. The movement of
valves according to the strokes is well controlled, allowing air and fuel mixture into the engine.
Power: All valves remain closed, and the ignition is prior to TDC. The exhaust valve opens in front of
BDC but a lot of energy from combustion is lost by this point.
Exhaust: After TDC the exhaust stroke is extended by opening and closing the exhaust valve before BDC.
Four stoke cycle engine valve timing

In the simple four-stroke engine, the valves are opened and closed in the Top Dead Center and Bottom Dead
Center as required to allow air-flow mixture into the cylinder and out of the exhaust gases of the cylinder. But
this is not happening right in an actual engine at TDC and BDC. Before or after those particular stages, valves
operate.
Intake: The intake valve opens and closes behind BDC before TDC. It increases the duration of the intake
stroke and allows more air and fuel mixture to get into the cylinder.
Compression: The valves are still closed after closing the intake valve after BDC and shortening the
compression stroke. Not impaired compression.
.

a. Explain the function of Variable valve timing in 60-80 words.

15 b. Explain the operation of variable valve timing in light vehicle petrol enginein about 100 -130
words.
In response to driving conditions, adjusting valve timing improves driving output and decreases fuel
consumption and emissions. On today's engines various variable valve timing systems are used. Some systems
differ the timing of intake and exhaust valves while others differ the timing of the two valves. Several may
differ in the intake or exhaust valve lifting and positioning, and others may vary in both positioning and lifting.
Depending on working conditions, an ECM carries forward or delays the valve timing. Including engine speed
and load.
Operation:
The VVT device is regulated by ECM. The ECM adjusts the valve timing depending on the volume of fuel,
the direction of the throttle and the temperature of the engine velocity intake. The ECM, in response to those
inputs, sends instructions to the camshaft timing oil control valve (OCV). The OCV directs the oil pressure to
the advance or retard leg of the VVT phaser. This magnetic field is opposed to a steady spring pressure in the
valve by the specific valve timing settings The VVT system relies on position sensors for the crankshaft and
camshaft position sensors to control camshaft positioning. The method therefore allows the valve overlap to
varying amounts.

Complete the following table with information about the types of noise, their characteristics
16
and causes. The first one has been done for you as an example.
Type Sound Mostly Heard During Possible Causes

Example: High-pitched rattle or Acceleration • Gloves used with pistons
Ring Noise clicking • Worn cylindrical walls
• Broken-piston ring lands
• Missing stress ring
Piston slap Hollow, bell-like Hot engine action and • Mannequins worn with
becomes louder during pistons
acceleration • Cylindrical walls put on
• Skirts with pistons dropped
• Misaligned repair rods
• Cast bearings
• Too much piston for wall
clearing
• Serious grease
Piston pin Sharp, metallic rap In idle, hot motor • Piston forged bolt
knock service • Boss wears sticker for pistons
• Used tweezers on piston
• Lubrication Defects
Main Dull, Steady knock Louder during  Wrought bearings.

bearing acceleration  Damaged pestle shaft.
noise
Rod bearing Light tap to heavy Idle speeds and low- • Cast bearings
noise knocking load higher speeds • Pestle shaft damaged
or • Crashed connecting rod
pounding • Lubrication Defects
Thrust Heavy thumping Irregular sound, that can only • Carry stress bearings
bearing be heard during acceleration • Pestle shaft damaged
noise • Wear motorized saddles
Tappet Light clicking regular Typically heard • Repair defective valve

noise during idle • Train with valve deactivated or
disabled
• The Disgusting Hydraulic Lifts
• Lubrication Defects
• Timing chain failed

Timing Severe knocking Increases with engine speed  Failed timing chain
chain noise rise
Detonation Pinging or banging At all times  Constructive mechanism to

ignite.
 Elevated mixed air fuel.
 No spark plugs.
 Fuel loss in combustion
chamber.
a) What could be the cause for loud knocking noise from engine? (30-40 words)
17
b) How would you locate the source of noise? (in about 50 -60 words)
a. A loud knocking noise may be from a bad main bearing or from connecting rod bearing because of a bent
out or rotating bearing. Typically a principal bearing sounds louder than a rod bearing. A main bearing is
often evenly spaced by a single knock, while a rod bearing normally makes a double knock.
b. Using a stethoscope with mechanics to detect the noise. Mechanical stethoscopes are the most common but
many electronic stethoscopes have settings that enhance selected frequencies of sound while filtering out
other frequencies of sound, making them very useful. Place the stethoscope against engine components and
listen to the sounds inside the engine in a variety of areas.

Customer concern is about a four cylinder petrol engine running rough and losing power (not
enough power). A visual inspection did not reveal any problems.
18
a. What test would you recommend to address the customerconcern?
b. Explain the testing procedure (in about 150-200 words)
Recommended test
When the engine runs rough or loses power, there might be one or more cylinders that lack the engine
compression. A compression check of the motor will detect internal damage to the engine.
Testing Procedure:
 Detach any wires or ignition coils that are directly connected to the spark plugs.
 Trigger the ignition mechanism by grounding or disconnecting the primary spindle wires.
 Disable fuel injectors or deactivate the fuse or relay device.
 They remove all spark plugs.
 Compression tester screw in the required fitting and tube (check the thread length and diameter for
proper fitting) if different, attach the tube to the compressor.
When any of the cylinders have low compressions, perform a wet test by placing a few squirts of clean engine
oil in the low cylinder and measuring the compression again. The piston rings are extracted as compression
pressure significantly increases. When the compression doesn't affect anything. A valve gets a leak at the
piston's head gasket or tip. Determine what action is required.

A customer complains of white smoke coming from the exhaust system. While diagnosing, the
technician observed bubbles appear when radiator cap is opened while engine is running at idle
19 conditions.
a. What test would you recommend to address the customer concern?
b. Explain the testing procedurein about 100 words.
The presence of bubbles may suggest a leak in the combustion chamber. The cylinder leakage test is
recommended to confirm the cylinder leakage.
Procedure for test:

 Ensure that the engine is in good order.
 The radiator cap, oil philtre cap, dipstick rim, air philtre cover and all spark plugs are removed.
 Push the Remote Start button to rotate the crankshaft so that the test cylinder piston is on its TDC
compression stroke. It means shutting the cylinder valves.
 Thread the threaded adapter at the end of the tester air pressure hose into the spark plug opening.
 Allowing compressed air to penetrate the container.
 Note the gauge read.
 Receive the source of every rain that falls, and experience it.

a. Identify 2 problemsthat arise because of low oil pressure.

20
b. Describe the oil pressure testing procedure in about 140-160 words.
Whenever oil pressure is low, the engine oil warning light pops up and the engine gets noisy.
Problems:
 The engine oil indicator light is shown all the time provided the full volume of oil.
 Where the engine is loud, the oil pressure can need to be checked to ensure proper operation
of the oil pump.
Oil Pressure Testing Procedure:

 Use the component locator to locate the oil pressure sensor that is often located on the cylinder block in
your service records.
 Put an oil drain tray under the engine to catch any oil, if you remove the oil pressure sensor.
 Remove the wire harness connector and detach the oil pressure sensor from the engine using the proper
system.
 Thread the adapter carefully into the motor, to ensure that the adapter is not cross- threaded.
 The oil pressure gauge is installed, then the engine starts and completely heats up.
 Compare the readings to the service specifications. The measurements can be at two separate velocities
of the engine. If so, you'll need to check for both speeds.
 Reinstall the oil sender unit and torque according to the specifications using thread sealant to remove
the manual pressure gauge and adaptor.
 Mount the cabling and boot the motor. Oil leakage inspection and proper use of pressure gauge.

Analyse the condition of the below given engine components and write down possible causes?
21
(at least 1 cause)
Surface torn and scoring marks on engine main  Crude shortfalls,

bearings  Insufficient room between the
bearings and the crankshafts.
Scuffed piston  Too little lubrication

 Combustion chamber overheats
 Engine Overheating
Scored piston Mechanical fault such as broken chain of pistons,

broken circlip, loose piston pin

Complete the table below with information about the types of diagnostic testing equipment required to
diagnose complex faults in light vehicle petrol engines, their functions, operation and limitations.
Criteria for answering this question:

22
 Functions; includes two (2) functions
 Operation; Explain the operation of the equipment
 Limitations; includes two (2) limitations
Basic code reader
Function Basic- Code reader connects to the car machine and sends Searches are performed on ABS, ESC
modules.
Operation- A simple code-reader tracks various sensor inputs and outputs. If the computer thinks something is
out of control, it will set a "trouble tag" that can be used in diagnostic procedures. -- code refers to a particular
fault and there are also different types of codes (i.e. hard, soft) that represent both ongoing and intermittent issues.
Limitations –
 Minimal Features.
 Connection to third party devices can be troublesome.
 Very little protection or support, either.

OBD 11 Scanners and Readers

Scan tool
Function – Diagnostic testing instruments are employed on-board. They interact with a "on board
diagnostic" system of a car to facilitate the diagnostic process. These are similar to those auto code readers.
Scan tools can read and display live data, display frozen frame data, view readiness status monitor, and reset
readiness monitor.
Also, scanning tools can graph data, send it to other devices such as a computer or telephone, provide
printable information and even read pending code.
Operation– The software which measures the diagnosis of the car takes inside the car regular readings of
different systems. It primarily focuses on the engine but the OBD-II provides sensors for the chassis, frame and
other parts of the vehicle. At each reading, the software records a particular acronym or code which represents
that device's functionality . Stored inside the OBD-II system, this information can be accessed by connecting the
port to a computer. The mechanic then downloads the codes and translates them to assess exactly what happened
at each point of inspection. It helps assess when a vehicle section suffered damage and how it occurred.
Limitations -
 OBD II Norm Restrictions
 Scanning tools usually attach to small display screens and slow sampling speeds of live scanning data.
 Connecting OBD port data (OBD connector) to ECU powertrain and emissions. Therefore it is not
possible to link to body safety data such as seat belt status, airbag status and more
 The data is accessible only via the query-response process.

Oscilloscope/ Lab scope
A visual voltmeter is a measuring instrument, or an oscilloscope.

It transforms electrical signal into a visual image which represents voltage changes over a given
period of time. It presents this information in the form of a continuous tension line called a
pattern or trace wave. Precise measurements can be achieved with an apparatus.
Operation – If an oscilloscope's probe is attached to a power source the device automatically shows the
waveform on the computer. The waveform is a visual representation of the signal summits and valleys. You can
easily calculate the frequency by watching the waveform in real time, and monitor the power source for dips and
spikes.
Limitations
 One drawback is that oscilloscopes, for example multimeters, cost more than other types of
electronic measuring devices.
 Replacing oscilloscopes is expensive too.
 They need a lot of practise to know how to manipulate controls through the oscilloscope to
get the strongest, highest quality signal from a circuit.
 Oscilloscopes may be too susceptible to interference from nearby circuits.

a) What are data trouble codes (DTCs)? (in about 50-60 words)
23 b) Briefly explain the procedure for interpreting DTCs and Scan Tool Data in about 60- 80 words.
DTC's are automotive computer codes which the onboard computer diagnostic system (OBD) stores in a car.
These codes tend to help determine the root cause of the failure. The diagnostic codes laid down by law on all
OBDII systems are standardised, and all vehicle manufacturers use the same basic code list.
Manufacturers can build their own DTCs for systems like ABS, and they are not required (though many do) to
provide code access to non-proprietary scanning tools.
Procedure for interpreting DTCs and Scan Tool Data

 Find the DLC connector, and attach to the scanner.
 Power the scanning unit, and turn the ignition on without running the engine.
 Repair vehicle communications by scanning tool.
 Sign in DTCs and register them.
 Look up the definitions of the DTCs in manufacturer's code books or service information.
 Display the results, and reference the manufacturer's service information.
 Also shut off the screen, delete the ignition and check too.
What would be the conditions for the running DTC P0103 Mass Air Flow Sensor Circuit High
23c
Frequency? 2 conditions
Condition for running the high frequency DTC P0103 Mass Air Flow Circuit
 Engine speed is greater than 300 RPM.
 Voltage is 8.0V higher than.

What would be the conditions for setting DTC P0103 Mass Air Flow Sensor Circuit High Frequency?
23d
2 conditions each
Condition for Setting the DTC P0103 Mass Air Flow Sensor Circuit High Frequency
 The MAF frequency crosses 14,00Hz.
 All conditions under 1 second have been fulfilled.
Briefly discuss the purpose and explain the procedure for accessing and interpreting the following
24
data in petrol engine management system using diagnostic tools
Live data: (70 – 90 words)

Live Data allows you to track vehicle sensors, switches, and relays inputs in real time while the vehicle is
moving. Knowledge about LIVE data helps identify the components of the issue for faster diagnosis.
 Find a Data Link (DLC) connector, and attach to the scanner.

 Power the scanning machine, and turn the engine-free ignition on.
 Set up vehicle communications scanning tool and select the live data alternative for a particular ECU
engine.
 Live until the data is submitted. Select the right PID values associated with a given DTC or
programme in real time.

Freeze frame data: (150-200 words)

Freeze frame data allows control of special generic parameter identification (PID) schemes for the management
of the petrol engines. Such values are stored in continuous memory when the diagnostic trouble code (DTC)
appropriate for the petrol engine control systems is stored. This offers a snapshot of the current circumstances at
the time the DTC was held. If one collection of freeze frame data is stored, even if another DTC petrol engine
management system is stored, the data will remain in memory. When the DTC-associated freeze frame data is
deleted or the DTCs are removed, new freeze frame data can be re- save.
 The camera-like icon will be shown when the freeze available for a DTC is shown. The icon is next to
the DTC post, its meaning and its status.
 To view the details press the Freeze Frame button. A window should open and will contain all the
usual paper controls and information.
 The Freeze Frame panel shows the Parameter ID (PID) values associated with a given DTC at the time
the DTC occurred. It will also give us a better picture of the situation the vehicle was in when the DTC
was being built.
 Open DTC Report – this opens the ALLDATA troubleshoot document mentioned in the DTC.
 Freeze Frame History display-showing past DTC Freeze frame info.
 Refresh the page with the latest Freeze frame data.
 Clear all active codes currently hold by the vehicle's ECU.
Waveforms: (80-100 words)

Waveforms are data in a voltage-overtime format. For sound, noise, temperature , light, and pulse, waveforms
may stand. Reading the information in a waveform lets you recognise the links between the signal and the
circuit, system and environment. When these occur a scope shows any voltage changes. An upward motion of
the voltage trace on an oscilloscope means an increase in voltage, and a downward motion of that trace
indicates a decrease in voltage. This represents a given period of time as the trace of voltage passes through an
oscilloscope tube.

Write the causes of failure of the following continuous and non-continuous monitoring
25 systems and classify it accordingly in the last column. First one is worked out as an example.
(Give at least 4 faults)
Continuous or non-
Monitoring system Reason of failure (4 reasons) continuous monitoring
system
 Contaminant fuels
 No exhaust leakage
 Mechanical Engine Issues Non-continuous
Catalyst monitor
 Oxygen sensor circuits defective Monitoring system
upstream or downstream
 Failing PCM
 A Detective pump for petrol.

 Anomalous HO2S signal Upstream. Continuous monitoring system
 Temperature sensor defects in engine.
 Failed catalytic converter.
Fuel  Faults linked to MAP or MAF.
system  Cooling system malfunctions.
monitor  EGR machine malfunctions.
 Faults with method for injecting gasoline.
 The Ignition System Defects.
 Vacuum-leakage.
 Worn out parts of the engine.
 Default value for EGR.
 Valves defective, or EGR routes. Non-continuous
 EGR solenoid cabling and/or loose or damaged connectors. monitoring system
 Impaired DPFE or VP EGR sensor.
 Disconnected or loose electrical connexions to DPFE or
EGR EGR VP sensors;
monitor
 The solenoid plug and/or cable links failed, broken, or

Non-continuous
loose.
monitoring system
 Leakage of hoses, tubes, or ties from EVAP system.
 Vacuum and/or venting hoses are misaligned to a canister
of solenoid and charcoal.
EVAP
 Threaded solenoid-purging hoses into the fuel canister.
monitor
 The Solenoid Purge Connectors were missing or damaged.
 Fuel tank cap not installed properly or missing.

 Too low amount of fuel during cycle of drive.

 Dirty fuel injector, or faulty.
 Muddy steam. Continuous monitoring system
 Faulty Fuel Pump.
Misfire
 Low Fuel Filter.
monitor
 EGR machine malfunctions.
 EVAP machine malfunctions.
 Limited-System failures.
 Faulty secondary ignition circuit.
 Weakened, loose, or resistant PCM power and/or
ground circuits.
 Malfunctions of the ascending and/or
downstream oxygen sensors.
 Heater malfunctions upstream or downstream of the
Oxygen oxygen sensor. Non-continuous monitoring
sensor  PCM defeated. system
 Inadequate cabling of and/or the sensors.
monitor
Describe the processes and methods for documenting and reporting diagnostic
26
findings and recommendations in about 70-90 words.
Even the information should be arranged so that anyone who looks at it can understand them. Relying on
memory is risky and conduct bad. It is important to write down the information, and not on a paper scrap
that can easily be lost or misplaced.
When a customer visits a business to be diagnosed with a disease, the majority of companies set up a work card
for that particular job. The Work Card is changed to a legal paper. The workshop keeps records of operation to
maintain the engine's service history, and for legal purposes.

27 Give four reasons why the diagnostic process must be documented.
1. The technician should keep an eye on the procedure and its progress, e.g. completed
tests.
2. The technician will see the build-up of information which will eventually enable them to locate the fault.
3. Before the repair is completed and paid for the company can communicate successfully with the
consumer at the start of the testing process.
4. A service record can be a helpful guide to future work.

Comments if the answer is not satisfactory

This form is completed by the assessor and used for comments if the answer is not satisfactory
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Based on the Comments above Please Redo / Rewrite those particular answers and resend
your Completed Reassessment for correction

Assessment Outcome – Assessment 1
Student name
Unit and Task

AURLTE004 – Diagnose complex faults in light vehicle petrol engines
being assessed
Course name and
AUR40216 - Certificate IV in Automotive Mechanical Diagnosis
title
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have provided appropriate feedback.
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Student Signature: Date: / /

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AUR40216

Harman Singh Bhullar

This is a summative assessment, which requires each

Assessment 1 Written Task

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No licensing, legislative, regulatory or certification requirements apply to this unit at the

Key 1. Identify and confirm the work requirement

Apply diagnostic skills to different vehicles.

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from manufacturer specifications.

Performance Evidence of the ability to:

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o abnormal noise analysis

Assessment Assessors must satisfy NVR/AQTF assessor requirements.

Assessment must include direct observation of tasks.

Where assessment of competency includes third-party evidence, individuals must provide

The following resources must be made available:

 automotive repair workplace or simulated workplace

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faults in light vehicle petrol engines

This unit is being offered as a part of Certificate IV in Light Vehicle Mechanical

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2 Demonstrati  Diagnose a complex fault in three

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For Assessor Only -ASSESSMENT COVER

Student’s Signature: Date: / /

Assessor: I declare that I have conducted a fair, valid, reliable and

Administrative use only

Entered onto Student

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USE FOR REASSESSMENT ONLY

Assessment Task No/s

Competent - C Not Competent - NC

Please provide general feedback on the Student’s performance.

Trainer/Assessor Signature Date

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Assessment 1 – Written Questions

Instructions for Students:

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 Requires the use of corresponding PPE security.

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Spark appears indicating there is no misfire at the moment.

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a. Describe four signs of a tank filled with contaminated or bad fuel.

DTCs that may pop are:

P0101-Mass Air Flow (MAF) sensor output.

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a. The Intake air system

b. Types of Intake Manifolds:

c. Variable intake manifold:

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