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AURAFA103_ Communicate effectively in an automotive workplace

Trinity College
Australia
Practical

Assessment 2 Practical

Student Name Aditya Khattar Student ID Number 20230880

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 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: Assessor’s Name:

Student Signature Date Assessor Signature Date


Document Name: Student Written Knowledge Assessment – AURTTA105 Created Date: 01st Dec 2020
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AURAFA103_ Communicate effectively in an automotive workplace
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Practical

Student Guide for Written Knowledge Assessment


Overview of This is a written assessment task you will be assess on your knowledge of selecting and
Assessment using bearings, seals, gaskets, sealants and adhesives.
The topics that will be covered in the assessment are:
1. Prepare to select and use bearings, seals, gaskets, sealants and adhesives
2. Install bearings, seals and gaskets
3. 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 56 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 4 – 6 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
rules answer 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: -
 Methods to locate and interpret information required to select and use bearings,
seals, gaskets, sealants and adhesives:
o Manufacturer specifications, procedures and supporting information for
preparing, inspecting and installing sealants and adhesives
o Manufacturer specifications, procedures and supporting information for
preparing, inspecting and installing bearings, seals and gaskets
 Workplace procedures required to select and use bearings, seals, gaskets, sealants
and adhesives, including:
o Establishing the serviceability of tools and equipment
o Documentation procedures
o Housekeeping procedures, including:
- Examination of tools and equipment
- Storage of equipment
- Identification, tagging and isolation of faulty equipment
- Disposal of excess materials

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Trinity College
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Practical

- Recycling procedures
 Workplace health and safety (WHS) requirements relating to selecting and using
bearings, seals, gaskets, sealants and adhesives, including:
o Procedures for working safely with sealants and adhesives, lubricants and
greases
 Environmental requirements relating to selecting and using bearings, seals,
gaskets, sealants and adhesives, including:
o Procedures for trapping, storing and disposing of excess materials
produced when applying sealants and adhesives
o Procedures for trapping, storing and disposing of lubricants and greases
released during work processes
 Identification and function of:
o Bearings, including:
- Ball
- Roller
- Plain
o Seals, including:
- Lip
- Face
- O-Ring
- Square section ring
- Metal surface
o Gaskets, including:
- Treated paper
- Cork
- Composite materials
- Metal, synthetic, rubber, fibre, and nylon
 Types, characteristics, uses and limitations of sealants and adhesives, including
application techniques
 Inspection, service, installation and adjustment procedures, including:
o Bearings, including:
- Roller types
- Ball types
- Plain types
o Seals and sealing surface condition
o Gaskets
 Types and applications of bearing lubricants and greases

Assessment Competency is to be assessed in the workplace or a simulated environment that accurately


conditions 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 bearings, seals, gaskets, sealants and adhesives they have
selected and used, 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 specifications relating to bearings, seals, gaskets, sealants and
adhesives

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 Vehicle or equipment requiring the application of bearings, seals, gaskets, sealants


and adhesives
 Bearings, seals, gaskets, sealants and adhesives as specified in the performance
evidence
 Tools, equipment and material appropriate for installing bearings, seals and
gaskets.
Assessors of this unit MUST satisfy the requirements for assessors in applicable vocational
education and training legislation, frameworks and/or standards.

Resources required Learning Resources available to students include:


 Automotive Technology (A System Approach) 7th Edition – Chapters 2, 5, 7, 8, 11,
13 & 45
 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.

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Assessment 1 – Questioning

Written Assessment

1. Identify five (5) important items of personal safety when working with bearings, seals, gaskets, sealants,
adhesives lubricants and greases.

1 Ear Protection

2 Skin Protection

3 Clothing

4 Footwear

5 Safety glasses and shields.

True or False question


2. Do not use sealants or adhesive on rubber gaskets; they can prevent the gasket from sealing.

✘ True or False

True or False question


3. Always refer to the specific engine and engine part section of the service information for the recommended
procedures for using sealants.

✘ True or False

True or False question


4. Never use a sealant or liquid gasket material on exhaust manifolds.

✘ True or False

True or False question


5. Make sure every sealant used is oxygen sensor safe.

✘ True or False

True or False question


6. Be careful not to use excessive amounts of RTV. If too much is applied, it can loosen up and get into the oil
system where it can block an oil passage and cause severe engine damage.

✘ True or False

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True or False question


7. The uncured rubber contained in RTV silicone gasketing irritates the eyes. If any gets in your eyes,
immediately flush with clean water or eyewash. If the irritation continues, see a doctor.

✘ True or False

8. Referring to the LOCTITE® SUPERFLEX® Blue RTV Silicone Adhesive Sealant Safety Data Sheet (SDS),
how should this sealant be trapped, stored and disposed of?

Trapped: Keep the product away from waterways and sewage systems.
As much garbage as you can assemble. For significant spills, have great ventilation going.
Scrap material must be placed in a well-ventilated environment to cure into rubber.

Stored: Close the container tightly while storing it.


Store at or below 32 °C (89.6 °F) for safe keeping

Disposed: According to EPA and municipal rules, cured rubber may be burned or dumped in a landfill.
Observe the disposal requirements of all municipal, state, federal, and provincial legislation.

9. How should waste lubricants and grease be stored and disposed?


An authorised contractor is required to properly label, store, and remove spent lubricants.

Multiple choice. Circle all the correct answer


10. When replacing a leaking engine oil seal, what should you use to catch the any leaking waste oil?

A. Drain pan.
B. Mop bucket.
C. Storm water drain.
D. Funnel.

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11. When handling, trapping, storing and disposing of new or waste lubricants, grease or sealants and adhesives,
which document should you use to find this information?
Safety Data Sheet (SDS)

12. Describe what is a plan bearing?


Casting drillings, sleeves, or bushes are all examples of plain bearings. They can be divided or solid, and they can
sustain a range of weights.

13. Name four (4) types of roller bearings.

1 Needle thrust

2 Straight assembly

3 Loose needle

4 Caged needle

14. Explain what are loose needle roller bearings?


When many rollers have been inserted into the bore of a gear to serve as a bearing, needle rollers can be utilised in
their position without a retainer. A shaft that has been hardened is right beneath the rollers as they move.

15. What are the advantages of double-row ball bearings?


. They are capable of transporting heavy loads and can bear slight thrust forces in either direction.

Multiple choice. Circle all the correct answer


16. Which of the following bearing types will not accept radial loads?

A. Single-row ball bearings.


B. Double-row ball bearings.
C. Thrust bearings.
D. Cup-and-cone bearings.

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17. What is a thrust bearing?


Loads are applied to the shaft longitudinally by thrust bearings.

18. Explain what are antifriction bearings?


Ball and roller bearings of various sorts are considered antifriction bearings.

19. Why are sealed bearings used?


The use of sealed bearings prevents lubricant from flowing too freely and keeps out debris.

20. Name the ten [10] engine assembly gaskets, seals and grommets below.

1 PCV valve grommet

2 Thermostat housing gasket

3 Intake manifold gasket

4 Intake manifold end seals

5 Cylinder head gasket

6 Valve cover gasket

7 Oil pan gasket

8 Timing cover gasket

9 Front crankshaft seal

10 Water pump gasket

21. Why are oil seals used?


To stop oil, grease, or dirt from seeping out or entering, oil seals are employed between a shaft and housing.

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Multiple choice. Select the correct answer


22. The lip on lip-type seal faces ________.

A. Toward the front of the engine.


B. Toward the rear of the engine.
C. Away from the fluid it is sealing.
D. Toward the fluid that it is sealing.

Multiple choice. Select the correct answer


23. What type of seal is the one below?

A. Double-lip seal.
B. Lip-type seal.
C. Metal face seal.
D. Flat seal.

Multiple choice. Select the correct answer


24. ________ are synthetic rubber rings that fit into grooves that have been machined in shafts and other
components.

A. Lip seals.
B. Face seals.
C. O-rings.
D. Square section ring.

25. What is a square-section ring?


A square-ring is a type of sealing tool with a torus shape and a square cross section.

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26. Why use a metal seal?

When the application circumstances exceed the polymer seal's predefined bounds, a metal seal is utilised. The
pressure is the same and the temperature is either too high or too low.

Multiple choice. Select the correct answer


27. When the O-ring is installed into its groove, it protrudes above the shaft. When the shaft and its mating part
are assembled, the O-ring is ________ slightly, forming a seal between the two parts.

A. Compressed.
B. Enlarged.
C. Sealed.
D. Friction.

Fill in the Missing Word


28. Place the missing word to complete the following statement about oil scroll using the following words.

Missing Words: oil, rotation, scroll, shaft, winds, wound

An oil scroll is a spiral groove that is machined in a shaft. The scroll is not the main seal, but it is used to
reduce the amount of oil that reaches the main seal.
The scroll winds in a direction opposite to the shaft rotation. Oil that is carried along the shaft to the scroll
tends to be wound back along the shaft and so retained in the housing.

Fill in the Missing Word


29. Place the missing word to complete the following statement about oil slinger using the following words.

Missing Words: housing, oil, seal, slinger, thrown, washer

This is a dished washer that is sometimes used on a shaft where it fits through a housing. Oil reaching the
slinger tends to work outward to the edge of the slinger and is then thrown back away from the shaft.
This is also a supplementary seal and not a main seal. It reduces the quantity of oil that reaches the main
seal.

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Multiple choice. Circle all the correct answer


30. Gaskets are made from.

A. Cork and cork composition.


B. Special jointing materials.
C. Fibre and nylon.
D. Synthetic rubbers.
E. Steel core and composition.
F. Metal gaskets.
G. All answers are correct.

31. Why are gaskets needed?


Gaskets are needed to seal seams and stop leaks, gaskets are necessary.

32. Describe the following basic types of gasket construction.

Plain gaskets:
These gaskets are made of cork, special jointing sheets, cork, synthetic rubber, and other sheet materials.

Layered gaskets:
These are constructed from two thin sheets of steel and a layer of composition material.

For reinforcing, the metal is rolled over the perforations.

Bonded gaskets:
The gaskets that are affixed to the perforated metal core are made from composition materials. Typically, metal
ferrules are used to strengthen the holes in the gasket.

Embossed (corrugated) steel gaskets:


The corrugated (embossed) steel gaskets are constructed from strong steel. To help with sealing, corrugations or
beads are pushed into the steel surrounding the perforations.

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33. Name five (5) different grades of sealants or sealing compounds.

1 Thread sealants

2 Thread lock compound

3 Gasket sealants

4 RTV silicone sealants

5 Retaining compound

Fill in the Missing Word


34. Place the missing word to complete the following statement about sealants and sealing compounds uses and
limitations using the following words.

Missing Words: air, assembly, bearing, bolts, component, cylinder, fluid, gasket, leaking, liquids, loose, rocker,
sealant, silicone, strengths, threads, wear

1 Thread sealants. Sealants are applied to threads to prevent fluid under pressure from leaking past the
thread. They are commonly used on bolts that come into contact with the cooling system, such as cylinder
head bolts.
2 Thread lock compounds. These prevent nuts, bolts and studs from coming loose and are available in
various grades or strengths. They work by filling in the small gaps between the threads with a fluid that
cures or ‘sets’ in the absence of air. This is known as anaerobic cure. They are useful for fasteners that
cannot be checked after assembly, such as flywheel bolts.
3 Gasket sealants. Some gaskets are coated with a sealant just prior to assembly. This fills the small
spaces between the component and the gasket. The sealant is normally applied to the removable part, for
example, between the rocker cover and the gasket. They also help to keep the gasket in place during
assembly.
4 RTV silicone sealants. These silicone sealants cure or vulcanise at room temperature (RTV). They can be
used in place of a gasket to produce formed-in-place gaskets.
5 Retaining compounds. These are anaerobic liquids that can be used for applications such as between the
inner race of a bearing and its shaft, or between the outer race of the bearing and its housing. This
secures the bearing in place and compensates for any minor wear in the parts. Catalytic action between
the parts assists with curing.

True or False question


35. A gasket adhesive does not add to the gasket’s sealing ability.

✘ True or False

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Fill in the Missing Word


36. Place the missing word to complete the following statement about gasket adhesives using the following
words.

Missing Words: Adhesives, bond, components, during, gasket

Gasket adhesives form a tough bond when used on clean, dry surfaces. Adhesives do not aid the sealing
ability of the gasket. They are meant only to hold gaskets in place during assembly. Use small dabs. Do not
assemble components until the adhesive is completely dry.

37. Explain the four (4) steps needed to clean and check a ball or roller bearing assembly?

1 Use a solvent to clean the bearings, then allow them to air dry. It could be necessary to soak oily bearings.

2 After cleaning, lubricate the bearings.

3 Slowly rotate the bearing by hand to inspect it for any irregularities. Put force in the thrust direction by using
thrust bearings.

4 Check for flaws in the bearing surfaces, balls, and rollers. Rotate the bearing carefully inspecting each
surface as you go.

38. What is meant by bearing preload?


Preload is the first weight applied to a bearing.

39. Describe briefly how front-wheel bearings of a rear wheel-drive vehicle would be adjusted.
Once completely tightened, the nut is backed off by about a sixth of a turn.

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True or False question


40. You should use fine emery cloth to polish and repair minor scratches on the seal surface of a camshaft or
crankshaft.

✘ True or False

True or False question


41. Whenever installing an oil seal, make sure its lip seal is lubricated with a light coating of oil. Also, make sure
the lip of the seal is facing the direction that oil is coming against.

✘ True or False

Multiple choice. Select the correct answer


42. Some important points for the installation of new gaskets are EXPECT.

A. Treat gaskets with care to avoid damage; carelessness can ruin a new gasket before it is used.
B. The surfaces of the parts against which the gasket seats should be clean, with all traces of the old gasket
removed.
C. Cast-iron and aluminium alloy surfaces can be checked for flatness, and burrs can be removed by lightly
draw-filing them with a smooth flat file or carefully rubbing them with fine-grade wet and dry sandpaper.
D. Where a gasket is fitted between two parts, the bolts that hold the parts should be tightened one at a time.
A torque wrench should be not used to tighten the bolts.

Fill in the Missing Words


43. Place the missing word to complete the following statement about wheel bearing grease specification using
the following words.

Missing Words: corrosion, damage, grease, lithium, lube, materials, petroleum, soaps

The grease for wheel bearings should be smooth textured, consist of soaps and oils, and be free of filler and
abrasives. Recommended are lithium complex (or equivalent) soaps, or solvent-refined petroleum oils.
Additives could be added to inhibit corrosion and oxidation. The grease should be noncorrosive to bearing
materials with no chance of separating during storage or use.
Using the correct amount of lube is also essential. Failure to maintain proper lubrication might result in
bearing damage, causing a wheel to lock.

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True and False


44. An automotive technician must adhere to workshop safety guidelines and procedures when using all tools and
equipment to service vehicles.

✘ True or False

True and False


45. An automotive technician is required to document the work that was performed on a vehicle. Writing or typing
in the description of the steps performed during the service or repair of the vehicle, parts and lubricants used
should be worded as if the technician is talking to the customer.

✘ True or False

True and False


46. Inspect your tools for cracks, broken parts, or other dangerous conditions before you use them. Never use
broken or damaged tools.

✘ True or False

True and False


47. For best results and long tool life, each tool used must be cleaned and checked before placing it back into the
toolbox or tool storage room.

✘ True or False

Multiple Choice question. Select the correct answer.


48. Lockout/tagout practices and procedures are intended to reduce the risk of automotive technicians’
inadvertently using service tools, equipment or materials that have been determined to?

A. Be unsafe or potentially unsafe.


B. That are in the process of being serviced.
C. Both “Be unsafe or potentially unsafe” and “That are in the process of being serviced”.
D. Neither “Be unsafe or potentially unsafe” and “That are in the process of being serviced”.

True and False


49. Disposing of excess silicone firstly, the silicone must be cured, then can be incinerated or landfilled following
EPA and local regulations.

✘ True or False

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Multiple Choice question. Select the correct answer.


50. Metal bearings such as ________, which should be stored in a secure container for collection by a metal
recycler?

A. Copper.
B. Steel.
C. Both “Copper” and “Steel”.
D. Neither “Copper” and “Steel”.

True and False


51. An automotive technician must adhere to workshop safety guidelines and procedures and follow the
manufactures procedures in the workshop manual for servicing vehicles.

✘ True or False

52. You are refitting the engine oil pan sub-assembly on a 2007 FJ Cruiser. Referring to the 2007 FJ Cruiser
Engine Mechanical Workshop manual, locate and interpret the sealant type recommended by Toyota, and
sealant application and width instructions, including the time engine oil pan sub-assembly MUST be fitted
within.
Sealant type recommended by Toyota: Toyota Genuine Seal Packing Black, Three Bond 1207B or the equivalent

Sealant application and width instructions: Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12
to0.16 in.)) to the oil pan

Sealant instructions: Three minutes after applying the seal packing, install the oil pan. Tighten the bolts and nuts
within 15 minutes of installing the oil pan. If not, the seal packing must be removed and then reapplied.

53. You are refitting the engine cylinder head after replacing the head gasket on a 2007 FJ Cruiser. Referring to
the 2007 FJ Cruiser Engine Mechanical Workshop manual, locate and interpret the cylinder head bolt torque
specifications.
1st 36Nm, 367kgf*cm or 27ft*lbf

2nd Turn 180°

Document Name: Student Written Knowledge Assessment – AURTTA105 Created Date: 01st Dec 2020
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AURAFA103_ Communicate effectively in an automotive workplace
Trinity College
Australia
Practical

54. You are refitting the engine cylinder head after replacing the head gasket on a 2007 FJ Cruiser and you need
to refit cooling system unions. Referring to the 2007 FJ Cruiser Engine Mechanical Workshop manual, locate
and interpret the cooling system unions adhesive type recommended by Toyota application and width
instructions specifications.
Adhesive type recommended by Toyota: Toyota Genuine Adhesive 1324, Three Bond 1324 or the equivalent

Sealant application and width instructions: Apply adhesive to 2 to 3 threads of the bolts end.

55. You are refitting the engine crankshaft pulley after replacing the timing gear case oil seal on a 2007 FJ
Cruiser. Referring to the 2007 FJ Cruiser Engine Mechanical Workshop manual, locate and interpret the
crankshaft pulley bolt torque specifications.
250Nm, 2,549kgf*cm or 184ft*lbf

56. You are refitting the rebuilding the engine on a 2007 FJ Cruiser and have replaced connecting rod big end
bearings. Referring to the 2007 FJ Cruiser Engine Mechanical Workshop manual, locate and interpret the
connecting rod end cap bolt torque specifications.
1st 25Nm, 259kgf*cm or 18ft*lbf

2nd Turn 90°

Document Name: Student Written Knowledge Assessment – AURTTA105 Created Date: 01st Dec 2020
Document No: Gills College Australia – AURTTA105 Version No: 1.0 Last Modified 2nd Feb 2023
Date:
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