Student Book

Written Assessment
AURETR010 Repair wiring harnesses and looms
Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017
Assessment – AURETR010
Page 3 of 22
 AURETR010 Repair wiring harnesses and looms

Date 5 Nov 2022 Date 6 Nov 2022

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010
Page 2 of 19

Context and Conditions of Assessment

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.
• This is an open book assessment and will be conducted at your designated campus / workshop / specialised lab.
• 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.
• Your Trainer / Assessor will inform you of the due date for this assessment task.
• Your Assessor will grade as either S – Satisfactory or NS – Not Satisfactory for the assessment. In all cases your
Assessor will provide you with feedback.
• Only when all assessment tasks have been graded as S – Satisfactory you will be deemed C – Competent in the final
result of the unit of competency; if you do not satisfactorily complete all the assessment tasks you
will be deemed NYC – Not Yet Competent.

Re-Assessment Conditions
 • If the evidence is graded as NS – Not Satisfactory you will be required to re-submit the evidence. In this case, you
will be provided with clear and constructive feedback based on the assessment decision so that they can improve
your skills / knowledge prior to reassessment.
• Where a ‘NS – Not Satisfactory’ judgement is made, you will be given guidance on steps to take to improve your
performance and provided the opportunity to resubmit evidence to demonstrate competence. The assessor will
determine and discuss the reasons for NS – Not satisfactory on any of the criteria and will assess you through a
different method of assessment e.g. verbal/oral questioning, problem solving exercises.
• You will be notified between 10-30 working days of undertaking an assessment of their result in achieving competency
o If a student does not complete the assessment, they should notify their trainer as to why they did not complete the
assessment and if due to illness, a medical certificate must be produced.
o In the above scenario, student will be given an opportunity for reassessment within 5 working days with no
reassessment fee charged.
o Students who are deemed to be Not Yet Competent (NYC) will be provided with information identifying the
areas in which they failed to achieve competency. Students will then have the opportunity to repeat the
assessment task within 5 working days of notification with no reassessment fee charged.
o If a student is deemed NYC in the reassessment or if the student did not approach the AIBT’s within five
working days with a valid reason for not availing themselves of the reassessment opportunity, then those
students will be given a final chance to re-sit the assessment and will be charged a reassessment fee as per
AIBT rule.
o After this no further reassessment attempt will be provided to the student and the student will be required to
repeat the whole unit with full fee for the unit. The student will be made aware of the impact of repeating the
unit may have on their student visa. o If a student is found to be cheating or plagiarising their assessment, a
reassessment fee will be charged for reassessing the assessment within 5 working days.
o If the student is found to be plagiarising or cheating again after conclusion of the Intervention meeting
with the Course Co-ordinator, the matter will be referred to the Academic Management Committee which
may result in the suspension or cancellation of their enrolment o
AIBT’s
has intervention strategies, including student support services available to enable students to complete
qualification in the expected time frame. Students at risk of not completing within this time
frame are identified as early as possible and an intervention strategy is put in place.

AIBT will ensure access to:

• automotive repair workplace or simulated workplace

• workplace instructions
• manufacturer machinery wiring specifications
• three (3) different vehicles, vessels or machinery requiring repairs to their wiring harnesses and looms

AURETR010 Repair wiring harnesses and looms

• tools, equipment and materials appropriate for repairing wiring harnesses and looms, including: o
multimeter o continuity tester o crimping tools o soldering equipment o heat gun o
terminals and connectors o wire and cabling.

Evidence to be submitted by the student: -

Completed written responses to the questions in the assessment task

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010
Page 5 of 22
Assessment Decision Making Rules

Your assessor will assess the evidence submitted for the following elements, performance criteria, performance
evidence and knowledge evidence to confirm that the student evidence submitted demonstrates validity, sufficiency,
authenticity and confirms current skills and knowledge relevant to the unit of competency. 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 repairing wiring
harnesses and looms, including procedures for:
o using safety data sheets (SDS) o selecting and using personal protective equipment (PPE) o
identifying firefighting equipment o safely handling hazardous materials and toxic substances o following
soldering equipment safe operating procedures
• environmental requirements, including procedures for trapping, storing and disposing of hazardous materials and toxic
substances released during repair processes
• location and content of workplace procedures and manufacturer specifications relating to wiring harnesses and looms
• types of wiring systems found in vehicles, including: o basic single wiring, including:
- trailer harness
- driving lights harness
- accessory wiring harness o complex multi-wiring with varying wire gauges o
controller area network databus (CAN-bus) wiring, including:
- twisted pair - shielded wiring
• testing procedures, including: o accessing electrical terminals and using test probes without damaging
connectors, fuse holders or wiring o testing wiring harnesses and looms, including resistance and voltage drop and
circuit performance checks o visual and functional assessments, including:
- component damage and wear
- component corrosion
- water and moisture ingress
- damaged insulation
- frayed wires
- burnt wiring
- terminal and connector damage
• removal procedures for wiring harnesses and looms, including: o accessing wiring and removing
panels and covers o removing and replacing components o disconnecting terminals from connectors
• repair procedures of wiring harnesses and looms, including:
o determining cable and terminal types and sizes according to circuit current draw

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010 Page 4 of 19

AURETR010 Repair wiring harnesses and looms

o wire soldering procedures o terminal crimping

o replacing male and female terminals within a
connector housing o protecting and routing harness
and loom
 • post-repair testing procedures of wiring harnesses and looms, including procedures for checking full operation
of associated electrical systems.

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010
Page 7 of 22
 AURETR010 Repair wiring harnesses and looms

Assessment 1 – Questioning

Written Assessment

1. Material safety data sheets (MSDS) or safety data sheets (SDS) contain important chemical information and must be
furnished to all employees annually. New employees should be exposed to the sheets as part of their job orientation.

True or False: True

2. Identify five (5) important items of personal protective equipment (PPE).

1 Gloves

2 Safety glasses and shoes

3 Earplugs and muffs

4 Respirators

5 Vest and full body suits

3. Which fire extinguisher below should you use on electrical fires?

A. Foam
B. Water
C. Carbon dioxide
D. None of these are correct

4. Complete the following statement about hazards involved in soldering using the following words.
Words: Check, Cleaners, Flick, Hands, Holder, Insulated, Iron, People, Sensitive, Temperature, Tools, Touch, Treated,
Yourself
 AURETR010 Repair wiring harnesses and looms

Although solder has a relatively low melting point this temperature is more than high enough to cause serious burns to
tools or objects. It is important to hold the soldering iron only by the flick handle, never touch the heating element or tip
when the soldering iron is on. The soldering iron will remain hot for some time after it is turned off so always touch that
it has cooled down before touching it, e.g. if changing the tip. When you are not soldering always keep the soldering
iron in a proper holder so that you don’t touch it accidently and it doesn’t heat or burn other objects such as the
benchtop. Don’t hold parts being soldered with your cleanser as these will also be heated when being soldered. Don’t
insulated molten solder from the soldering iron or wipe the tip on brass wool type tip holder.
If using a hot plate for surface mount soldering do not touch the hot plate. Use utensils such as pliers to place and
remove printed circuit boards (PCB’s) from the hotplate. If using hot air temperature for soldering, desoldering or
rework, do not direct the hot air stream onto yourself or other people. If using an oven allow the
PCB to cool before handling or use utensils. Don’t place hot PCB’s on temperature people surfaces. If burns occur,
they should be checked by holding under cold running water for several minutes and assistance sought if burns are
severe. Incidents should be reported.

5. Leaded solder contains lead which is a harmful material.

True or False: True

6. Solder flux creates fumes when heated during soldering which may be harmful if inhaled. Use a fume extractor
to avoid inhaling fumes.

True or False: True

7. Never use acid core solder. It creates corrosion and can damage electronic components.

True or False: True

8. Liquid solder flux, may generate a flammable vapour. Keep away from open flames and other sources of ignition.

True or False: True

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010
Page 9 of 22
 AURETR010 Repair wiring harnesses and looms

9. Soldering may result in the emission of hazardous metallic fumes and vapours from fluxes used. personnel should
position themselves so as to not directly inhale the fumes/vapours.

True or False: True

10. Flux is a chemical compound that when applied to the metals to be soldered prevents further oxidisation and assists in
the flow of solder onto the job.

True or False: True

11. Prepare a list of safety precautions that should be adhered to when soldering wires in the cabin of a vehicle. Your list
MUST include 5 different safety precautions.

1 Disconnect the battery terminal before soldering the wires-make sure disconnect the negative terminal first.

2 Make sure that the hot soldering iron does not get in contact with any of the vehicle parts other wise they wil l get

melted or burnt.

3 Make sure to wear proper PPE before conducting any soldering.

4 Use a non-flammable mat/cloth to protect carpets/seats from molten solder.

5 Make sure that the area you are working in his proper ventilation and opening doors and windows.

12. According to the SDS for CIGWELD Comweld 965 Soldering Flux, what container should NOT be used to trap and
store this flux during soft soldering activities?

Aluminium and galvanized containers should not be used.

13. Complete the following statement about disposing CIGWELD Comweld 965 Soldering Flux in soldering using the
following words.

Words: Chemical, Licensed, Neutralise, Material, Recycle, Supplier, Treatment, Waste

• Recycle wherever possible.
• Consult manufacturer for recycling options or consult local or regional waste management authority for disposal if

no suitable treatment or disposal facility can be identified.

• Treat and neutralize at an approved treatment plant. Treatment should involve: Neutralisation with sodaash or

soda-lime followed by: burial in a land-fill specifically liscenced to accept chemical and / or pharmaceutical

wastes or Incineration in a licensed apparatus (after admixture with suitable combustible material).
 AURETR010 Repair wiring harnesses and looms

• Containers may still present a chemical hazard/ danger when empty.

• Return to supplier for reuse/ recycling if possible.

14. A wiring diagram show the actual position of the part on a vehicle.

True or False: False

15. All the following information about the vehicle’s wiring can be found in the electrical schematics with the
exception of .

A. Wire colour
B. Wire size
C. Connector terminal designation
D. Component location on vehicle

16. When diagnosing wiring faults, you should use the electrical schematic diagram to trace the flow of current through
all the switches, wires, connectors, circuit protection devices, and grounds related to the problem before he begins
testing.

True or False: True

17. Where would you find the wiring diagram for the vehicle you are working on?

A. Internet
B. Workshop manual (WSM)
C. Automotive Technology Textbook
D. All these answers are correct

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010
Page 10 of 21

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010
Page 11 of 22
 AURETR010 Repair wiring harnesses and looms

18. Most automotive circuits contain five (5) basic parts.

1 Power sources, such as a battery

2 Conductors such as copper wires

3 Loads which are devices that use electricity to perform work

4 Controllers such as switches and relays

5 Circuit protection devices such as fuses and circuit breakers

19. Name the parts of the driving light wiring diagram below.

1. Driving Lamp

2. Brown Wire

3. 30A Fuse

4. Relay

5. Orange Wire

6. Black Wire .

Version: 1.0 Created Feb 2017

 AURETR010 Repair wiring harnesses and looms

Assessment 1 – Questioning – Written 11 of 21

Assessment – AURETR010

:
Page
20. Name the parts of the trailer wiring harness below.

1 Purple Wire (Back up) 2 Green Wire

3 Purple Wire 4 Red Wire
5 White Wire 6 White Wire (Ground)
7 Brown Wire (Tail) 8 Yellow Wire
9 Blue Wire ( Electric) 10 Red Wire ( Fused)

21. Name the function of which each wire of the trailer harness.

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010
Page 13 of 22
 AURETR010 Repair wiring harnesses and looms

Wire Function

Green Right turn

Yellow Left turn

White Ground

Brown Tail / Maker

Blue Brake

Red Battery

Purple Back-up

22. Name the parts of the vehicle instrument panel wiring diagram below.
 AURETR010 Repair wiring harnesses and looms

1 Indicates power circuit 7 Solid box indicates complete component

2 Indicates an internal splice 8 Indicates components is case grounded

3 Indicates splice 9 Indicates a body ground

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010
Page 15 of 22
 AURETR010 Repair wiring harnesses and looms

4 Indicates connector pin number 10 Indicates vehicle optional number

5 Indicates connector number 11 Indicates operating condition of component

6 Indicates inline connector number and 12 Dashed Box indicates component is not
Connector pin designation complete

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010 Page 12 of 19
23. Complete the following statement about complex multi-wiring using the following words

Words: Bent, Circuits, Complex, Components, Conduit, Engine, Harnesses, Heat, Joined, Multiple-pin, Nylon, Wire

Most manufacturers use wiring harnesses to reduce the number of loose wires hanging under the hood or dash of an
automobile. The wiring harness provides for a safe path for the wires of the vehicle’s lighting, engine, and accessory
Components. The wiring harness is made by grouping insulated wires and wrapping them together. The wires are
bundled into separate harness assemblies that are joined together by connector plugs. The multiple-pin connector plug
may have more than 60 individual wire terminals. There are several complex wiring harnesses in a vehicle, in addition
to the simple harnesses. The engine compartment harness and the under-dash harness are examples of complex
harnesses. A complex harness serves many circuits, while a simple harness services only a few multiple-pin.Some
individual circuit wires may branch out of a complex harness to other areas of the vehicle. Most wiring harnesses use a
flexible plastic or mesh circuits conduit to provide for quick wire installation. The Nylon has a seam that can be opened
to accommodate the installation or removal of wires from the harness. The seam will close once the wires are installed
and will remain closed even if the conduit is bent. In areas around the exhaust manifolds, the wires may be exposed to
excessive heat. To protect the wires of the harness, a special heat reflective conduit is typically used

24. A multiplex wiring system uses bus data links that connect different computers or control modules together.

True or False: True

25. Twisting together two (2) wires that carry data from one computer module to another increases the possibility that radio
waves and magnetic fields can interfere with data transmission.

True or False: True

26. The Society of Automotive Engineers (SAE) have classified the different communication protocols by their speed
and operation. Which communication protocol below would use shielded coaxial cable?
 AURETR010 Repair wiring harnesses and looms

A. Class A (Low-speed communication)

B. Class B (Medium-speed communication)
C. Class C (High-speed communication)
D. None of these answers are correct

27. Shielded coaxial cable or fibre optics may be used for less noise interference.

True or False: True

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010
Page 17 of 22
 AURETR010 Repair wiring harnesses and looms

28. Often testing electrical circuits requires the technician to use front-probing or back-probing tools to probe a
connector to allow a test lead to contact a terminal inside the connector. Why?

Because connector housings are so tight it is impossible to probe any other way. In addition

some connectors are watertight. So sometimes even that isn’t possible. It all depends on the

circumstances. Sometimes adapters are necessary with probe points such as on military type

connectors that are water tight.

29. A voltage drop test can find excessive resistance in a circuit that may not be detected using an ohmmeter.

True or False: True

30. A technician is testing a connector in a circuit with a voltmeter. With the power on in the circuit, the meter reads
12-volts when the leads are placed on each side of the connector. This indicates that the connector
.

A. Is shorted to ground
B. Is open
C. Is good
D. Has current flowing through it

31. A technician is checking a circuit with excessive resistance. The current flow through the circuit should be 10 amps,
but a check with an ammeter measures only 6 amps. The technician measures a voltage drop of 1.0 volts across the
switch terminals when the circuit is turned on. What is the resistance of the switch?

A. 1/60 ohm
B. 1/6 ohm
C. 6 ohms
D. 60 ohms

32. When testing resistance in a circuit with an ohmmeter, .

A. The ohmmeter is connected in parallel to the circuit and the circuit is turned on.
B. The ohmmeter is connected in series to the circuit and the circuit is turned on.
C. The circuit or component must first be disconnected from the power source, then the ohmmeter is
connected in parallel with the component being tested. D. All answers are correct.

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010
Page 18 of 22
 AURETR010 Repair wiring harnesses and looms

33. What faults should you visually inspect for on wiring and component connectors?

Wires:

Corroded terminals, frayed, broken wires

Connectors:

Make sure they are not corroded and damaged

34. If the wiring insulation was damaged, frayed or burnt, what kind of fault could this cause?

Live wires can cause shorts if they are damaged frayed or burnt

35. All the following information about the vehicle’s wiring can be found in the electrical schematics with the
exception of .

A. Wire colour
B. Wire size
C. Connector terminal designation
D. Component location on vehicle

36. When working with connectors, never pull on the wires to separate the connectors. This can create an intermittent
contact and an intermittent problem that can be very difficult to find later. Always use the special tools designed for
separating connectors to prevent this problem.

True or False: True

37. Which source of information will give you the most detail about accessing wiring, removing panels and covers and
removing and replacing components on the vehicle you are working on.

A. Workshop manual
B. Owner’s manual
C. Google
D. Textbooks
38. You are wiring a vehicle for a trailer hitch. The trailer will have eight parking lamps. Each parking lamp uses a 6-watt
light bulb. What size fuse should be used to supply power for the parking lamp circuit? [Assume that the normal
operating voltage is 14 volts.]

A. 5 amps
B. 10 amps

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010
Page 19 of 22
 AURETR010 Repair wiring harnesses and looms

C. 15 amps D. 20 amps

39. Always follow the manufacturer’s wiring and terminal repair procedures. On some components and circuits,
manufacturers recommend complete wiring harness replacement rather than making repairs to the wiring.

True or False: True

40. Complete the following statement about wire replacement using the following words.

Words: Amperage, Correct, Large, Small, Size,

All replacement wires should be of the same size or larger than the original. If adding an accessory, the new wire should

be large enough to ensure safe and reliable performance. However, overly large wires add weight and expense, and add

to the difficulty of splicing wires together. If the wire is too

small, an unwanted voltage drop can occur. The two factors that should always be considered when determining the
correct size of a wire are the total circuit Amperage and the total length of wire
(resistance increases with length) used in each circuit, including the ground.

41. Disconnect the fuse that powers the circuit being repaired. Note: If the circuit is not protected by a fuse,
disconnect the ground lead of the battery.

True or False: True

42. You should use a splice clip while soldering two wires together.

True or False: True

43. Twists the wire strands of the wire ends together before soldering.

True or False: True

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010
Page 20 of 22
 AURETR010 Repair wiring harnesses and looms

44. Rosin or resin-type flux core solder is used to repair electrical wiring.

True or False: True

45. Apply the tip flat of the soldering iron against the splice to hear it. At the same time, apply solder to the opening of the
clip. Do not apply solder to the iron. The iron should be 180 degrees away from the opening of the clip. As the splice
and wires heat, the solder will flow through the splice.

True or False: True

46. Terminal ends are replaced when they are damaged or to accommodate the use of a connector. The replacement
process must be done to provide for good continuity and to prevent electrical problems in the future. Describe the
procedure for replacing an electrical terminal.

The terminal strip makes the installation and connection of switchboards easier

In a practical manner, it can be said that it organizes the wiring and ensure the mechanical

and electrical safety of the panel. There are two acceptable methods for repairing wires and wiring

harnesses for automobiles. They are Soldering and using Heat Shrink Crimp Connectors.

Both can be permanent and reliable depending upon the skill of the technician making the repair.

Make sure you match the new plug with the type of cord you have. Get a 3-pronged plug for a 3-

pronged cord, and a 2-pronged plug for a 2-pronged cord. Check the instructions on any new plug

you get.

47. If there is damage to a terminal or connector, the wires and terminals need to be removed from the
connector. If the connector is a one-piece moulded type, what repairs can be carried out?

Replace both the male and female connector parts with the eight terminal part, transferring

the terminals from the old connectors to the new connector.

48. Hard shell connectors normally have a locking tab to retain the terminal. To remove the terminal, a connector pick is
used to depress the locking tab. After repairs are made, use the connector pick to bend the tang back to its original
shape before inserting it into the connector.

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010
Page 21 of 22
 AURETR010 Repair wiring harnesses and looms

True or False: True

49. Dielectric grease is used on wire terminals and connectors to prevent corrosion.

True or False: True

50. Dielectric grease reduces the resistance between the terminals.

True or False: False

51. You should always use heat shrink tubing to insulate and seal soldered wire connections.

True or False: True

52. You should always wrap the soldered connection with electrical tape.

True or False: T r u e

53. Never reroute wires when making repairs. Rerouting wires can result in induced voltages in nearby components.
Induced voltages produce unwanted signals through magnetism rather than from the components within the
circuit. These stray voltages can interfere with the function of electronic circuits.

True or False: True

54. Why is it important to verify that the vehicle you have repaired is operating correctly?

Properly maintaining your vehicle will not only ensure its safety and dependability, but may also

increase fuel efficiency as well as help maintain your vehicle's value. It is recommended to

consult your vehicle's owners manual and follow its preventive vehicle maintenance schedule.

Assessment 1 – Questioning – Written Version: 1.0 Created: Feb 2017

Assessment – AURETR010
Page 22 of 22