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AURLTE005
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Mechanical Engineering
Date
Dec 6, 2023
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61
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Student Name: Juan Pablo Velayos Garc
Unit: AURLTE005
Diagnose complex faults in light vehicle diesel engines
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y (NYS)
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Course Code
AUR40216
Course Name
Certificate IV in Automotive Mechanical
Diagnosis
Unit Code
AURLTE005
Unit Name
Diagnose complex faults in light vehicle diesel
engines
Due Date
________________
Assessment Name
Knowledge
Student No.
____193314______
Student Name
____juan pablo velayos garcia____
Student Phone
________________
Student Email
_____________________________
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Note: Filling out this coversheet as part of an electronic submission and approving the above information will operate in the same way as physically signing this cover sheet.
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Filling out the above Office Use Only section as part of an electronic submission will operate in the same way as physically signing this cover sheet. If not physically signed, Assessor must print their name in signature box.
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AURLTE005 Diagnose complex faults in
light vehicle diesel engines
autoassesstools.com
Knowledge Assessment
FILENAME \p \* MERGEFORMAT J:\VET\Automotive\AUR40216 - Cert IV in Automotive Mechanical Diagnosis\AURLTE005\STUDENT ASSESSMENT GUIDE\AURLTE005_Student
Assessment Tool:
Knowledge Assessment
Unit Code & Name
AURLTE005 Diagnose complex faults in light vehicle diesel engines
Purpose of Assessment: This unit describes the performance outcomes required to diagnose complex faults in light vehicle diesel 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 diesel 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. Target Group:
Student and those working in the automotive service and repair industry
. Exclusions or special conditions:
Some jurisdictions may require this qualification for licensing purposes. In addition, some units in
this qualification may have licensing or regulatory requirements, depending on the work context. Local regulations should be checked for details.
Student Assessment Information This unit describes the performance outcomes required to diagnose complex faults in light vehicle diesel 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 diesel engines include those of light vehicles or
light commercial vehicles.
The Knowledge Assessment must be completed successfully before Practical Assessment tasks are undertaken. These additional tasks will need to be completed before an assessor can determine you as competent for this unit. Knowledge Assessment (Student Guide for using the Knowledge Assessment) Knowledge Assessment
You are required to complete the Knowledge Assessment for this unit of competency. To complete this task, you will need to answer the 58 questions
in this Knowledge Assessment in your own handwriting.
After you have successfully completed the Knowledge Assessment you must present it to your assessor for correction. Conditions of Assessment: This Assessment is to be administered and monitored by the assessor to ensure currency and authenticity. ●
The Student will be provided with a limited number of attempts for each question. ●
Clarification for each question may be provided by the assessor to assist the Student J:\VET\Automotive\AUR40216 - Cert IV in Automotive Mechanical Diagnosis\AURLTE005 DIESEL\STUDENT ASSESSMENT GUIDE\AURLTE005_Student Assessment v1.2.docxPage 6
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in understanding the question. Duration of Knowledge Assessment: On average the Assessment should take a Student 8 hours to complete. Topics:
●
Identify and confirm the work requirement
●
Prepare to carry out diagnosis
●
Apply diagnostic procedures
●
Complete work processes
Decision Making Rule The trainer uses the following decision making rules to determine if a Student has answered all questions satisfactorily. ●
Questions relating to environmental and WHS/OHS = 100% ●
Questions relating to technical and other topics = 100% Marking Guide:
All questions must be answered correctly for Student to be deemed satisfactory in this Assessment task however assessors may ask questions to clarify understanding. A marking guide will not be provided, however on successful completion of Assessment the Student will be provided with a list of questions they have incorrectly answered Number of Attempts:
You will receive up to two (2) attempts at this Assessment task. Should your 1
st
attempt be unsatisfactory (U), your Trainer/Assessor will provide feedback and will arrange a date for your 2
nd
attempt. If your 2
nd
attempt is unsatisfactory (U), or you fail to attend of date scheduled for the
2
nd
attempt, you will receive an overall unsatisfactory result for this Assessment task. Only one re-Assessment attempt may be granted for each Assessment task
Learning Resources:
Learning Resources available to students include:
●
Automotive Mechanics (May & Simpson) 9
th
Edition
●
Automotive Technology (A System Approach) 6
th
Edition
●
Modern Diesel Technology: Light Duty Diesels 1
st
Edition
●
Internet ●
http://www.bp.com/content/dam/bp-country/en_au/media/fuel-news/winter-diesel-
problems.pdf
●
http://www.autotap.com/techlibrary/diagnosing_light_duty_diesels.asp
●
http://dfcdiesel.com/warranty-info/failure-analysis/
●
http://juchems.com/ServiceManuals/viewfilefcdc.pdf
●
http://share.qclt.com/
丰田
Toyota%20RAV4%20Repair%20Manual/2AZ-FE%20Engine
%20Control%20System/SFI%20System/0050023.pdf
●
http://gershon.ucoz.com/TOYOTA/m_05_0576.pdf
●
https://www.mazdabg.com/ftp-uploads/MAZDA%20material%20for%20technician/BT-
50_en.pdf
●
https://www.mazdabg.com/ftp-uploads/MAZDA%20material%20for%20technician/BT-
50_en.pdf
●
http://www.troublecodes.net/pcodes/p062d/
Plagiarism
By submitting this Assessment, I declare that this Assessment is original and has not been copied or taken from another source except where this work has been correctly acknowledged. Disclaimer This Assessment tool is correct and current at the time of publication, but does not give any warranty nor accept any liability in relation to the contents. Note:
This Assessment Tool was developed with reference to AUR Training Package Version 3 1.
Identify five (5) important items of personal safety.
1
Safety clothes
2
Safety glasse
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3
Safety boots
4
Safety gloves
5
Safety mask
2.
What safety precautions must be observed when working around engines?
Rotating engine components
Hot exhaust system
Hot engine oil
3.
What precautions are needed when draining the engine oil from an engine?
When draining the engine oil from an engine, care should be taken to avoid being burnt by hot engine oil.
4.
Describe the safety precaution that must be observed before removing the radiator cap
or disconnecting any component of a hot cooling system?
Never open the radiator cap while the engine is hot. Never pour cold water over the outside of the radiator. Always use a protective glove and rag when opening the radiator cap. Before remove any component of the cooling system wait until the engine is cold
5.
Explain the dangers which technicians should be aware of while working on cooling systems?
A sudden loss of pressure, from component failure or an open cap, can cause the hot liquid to boil instantly and be expelled through the opening. And hot radiators can be very dangerous. Cooling systems are pressurised to prevent boiling when the engine temperature exceeds 100°C
6.
What four (4) handling precautions with coolant containing corrosion inhibitors and Antifreeze/Anti-boil solutions?
1
Always wear proper clothing and eye protection
2
Always dispose the coolant fluid in an approved container
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3
Do not eat, drink or smoke when using coolant
4
do not split it. Always clean it with water 7.
What are the potential danger of working near electric thematically operated cooling fans? These fans can start at any time when the engine is hot. Some fans can keep running for a short time
after the engine is switched off.
8.
When handling, trapping, storing and disposing of new or waste oils and coolants, which document should you use to find this information?
Safety Data Sheet (SDS)
9.
How should waste engine oil and coolant be stored and disposed?
Waste oil and coolant should be correctly stored, labelled and removed by a licensed contractor.
10.
What is an intermittent fault?
An intermittent fault is a fault that comes and goes
11.
Complete the following statement about intermittent faults using the following words.
Words: Always, Carefully, Circuits, Component, Damaged, Diagnose, Diagram, Disconnected,
DTC, Electrical, Entire, Identify, Intermittent, Loose, MIL, Most, Possible, Problems, System, Terminals, Wire
An
intermittent
fault is a fault that is not always present. It may not activate the MIL
or cause
a DTC to be set. Therefore, intermittent problems
can be difficult to diagnose
. By studying the system
and the relationship of each component
to another, you should be able to create a list of possible
causes for the intermittent problem.
Most intermittent problems are caused by faulty electrical
connections or wiring. Refer to a wiring diagram
for each of the suspected circuits
or components. This will help identufy
all of the connections and components in that circuit. The entire
electrical system of the J:\VET\Automotive\AUR40216 - Cert IV in Automotive Mechanical Diagnosis\AURLTE005 DIESEL\STUDENT ASSESSMENT GUIDE\AURLTE005_Student Assessment v1.2.docxPage 9
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suspected circuit should be carefully and thoroughly inspected. Check for burnt or damaged
wire insulation, damaged terminals
at the connectors, corrosion at the connectors, loose
connectors, wire
terminals loose in the connector, and disconnected
or lose ground wire or straps.
12.
Which of the following diesel engine problems, may be indicated by good results from a compression test, and a good cylinder leakage test, but poor results from a cylinder power balance test?
A.
Incorrect valve timing
B.
Collapsed lifter
C.
Burnt intake valve
D.
Worn piston rings
13.
Name four (4) things that could cause unequal cylinder power balance on a diesel engine?
1
Leaking cylinder head gasket
2
Worn piston rings
3
Damaged piston
4
Broken valve spring
14.
Excessively advanced ignition timing on a diesel engine will usually cause what?
A.
Diesel knock
B.
Better fuel economy
C.
Improved starting ability
D.
All answers are correct
15.
What are some of the likely causes of engine overheating?
Engine overheating could be caused by lack of coolant, a blocked radiator core, coolant leaks, a loose
or broken fan belt, a defective thermostat, fan clutch faulty, electric fan inoperative, retarded ignition, clogged water-jackets, a defective radiator hose, a defective water pump, or insufficient engine oil.
16.
Which of the following is a function of the engine’s lubrication system?
A.
Holds an adequate supply of oil
B.
Removes contaminants from the oil
C.
Delivers oil to all necessary areas of the engine
D.
all answers are correct
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17.
What is the purpose of the cooling system?
A.
Remove heat from the engine
B.
Allow the engine to quickly warm up to a desired operating temperature C.
Keep it at the desired operating temperature regardless of operating conditions. D.
All answers are correct
18.
During engine warm-up, when the thermostat is closed __________?
A.
Coolant flows through the radiator
B.
Coolant flows through the bypass passage
C.
Both “coolant flows through the radiator” and “coolant flows through the bypass passage”
D.
Neither “coolant flows through the radiator” and “coolant flows through the bypass passage”
19.
Explain the purpose of the engine mounts of the engine?
Engine mounts are a flexible rubber portion that isolates much of the engine vibration from the vehicle
frame and passenger compartment.
20.
The cooling system pressure is regulated by the radiator cap.
True or False:
21.
Complete the following statement about diesel intake system using the following words.
Words: Air, Combustion, Cylinders, Diesel, Engine, Fuel, Intake, More, Operating, Scavenging, Designed , Aspirated .
The role of the intake
system in a diesel
engine is to supply a charge of air
or air/dead gas mixture to the engine
cylinders. This gas mixture is used for combustion
, cooling and cylinder scavenging
. Even when naturally aspirated
and especially when turbocharged, diesel engines are designed for lean-burn operation. This means that under most operating
phases, there is significantly more
air present in the engine cylinders
than that required to burn the fuel
.
22.
In a four-stroke diesel, scavenging is assisted by
:
A.
The inlet butterfly B.
The number of inlet ports C.
The port location D.
The valve overlap
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23.
Complete the following statement about diesel exhaust system using the following words.
Words: Cylinders, Diesel, Emissions, Engine, Exhaust, Fuel, Function, Intake, Pressurising, Waste, Work
The role of the exhaust
system is to minimise engine
noise while keeping harmful exhaust emissions
at a minimum. The turbocharger is common to both intake
and exhaust systems. Its function
is to use the exhaust system to recapture some waste
heat from the engine cylinders by prsssurising
the air delivered to the engine cylinders
from the intake system. diesel
intake and exhaust systems have to work
together to achieve the best fue
economy while minimising emissions. 24.
What is scavenging?
Scavenging is the action of clearing the cylinder of exhaust gases.
25.
What is meant by valve timing?
Valve timing means that the valves open and close at the correct times in relation to the piston movement.
26.
On a four-stroke diesel engine, both valves are closed on the __________ stroke.
A.
Power and exhaust
B.
Intake and exhaust
C.
Intake and compression
D.
Compression and power
27.
Which of the following is NOT a characteristic of a turbocharger?
A.
Is used to increase engine power by compressing the air that goes into the combustion chambers
B.
Is usually located close to the exhaust manifold
C.
Utilises an exhaust-driven turbine wheel
D.
Requires a mechanical connection between the engine and the pressurising pump to compress the intake air and fuel
28.
A turbocharged engine is running with 10psi (69kPa) of turbo boost. At what pressure is air being fed into the engine when the engine is operating at sea level?
A.
4.7psi (32kPa)
B.
10psi (69kPa)
C.
14.7psi (101kPa)
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D.
24.7psi (170kPa)
29.
What manages turbo output by controlling the amount of exhaust gas entering the turbine housing?
A.
Waste gate
B.
Turbine seal assembly
C.
Hot wheel
D.
Cold wheel
30.
Give some examples of abnormal engine noises, including a description of the sound, and their likely causes below. Type Sound
Mostly Heard During
Possible Causes
Ring noise high-pitched rattle or clicking
during acceleration
-worn piston rings
-worn cylinder walls
-broken piston ring lands
-insufficient ring tension
Piston slap or diesel knock
hollow, bell-like
cold engine operation and is louder during acceleration
-worn piston rings
-worn cylinder walls
-collapsed piston skirts
-misaligned piston rods
-worn bearings
-excessive piston to wall clearance
-lack of lubrication
Piston pin knock
sharp metallic rap
hot engine operation at idle
-worn piston pin
-worn piston pin boss
-worn piston pin bushing
-lack of lubrication
Main bearing
noise dull, steedy knock
louder during acceleration -worn bearings -worn crankshaft
Rod bearing noise light tap to heavy knocking or pounding
idle speed or low load higher speed
-worn bearings -worn crankshaft
-misaligned connecting rod
-lack of lubrication
Thrust irregular sound, -worn thrust bearing
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bearing noise heavy thumping
may be heard only during acceleration
-worn crankshaft
-worn engine saddles
Tappet noise light regular clicking
mostly heard during idle
-improper valve adjustment
-worn or damaged valve train
-dirty hydraulic lifters
-lack of lubrication
Timing chain noise severe knocking
increases with increase the engine speed
-loose timing chain
31.
A wet compression test is performed on an engine after a dry compression test revealed low compression on one cylinder. If the compression on the low cylinder rises, it indicates __________?
A.
Leaking valves
B.
Worn rings
C.
Worn camshaft
D.
All answers are correct
32.
How is a compression test carried out on a diesel engine?
A compression test is carried out firstly consulting the workshop manual then by screwing or bolting a special compression gauge into the glow plug or injector hole.
33.
Complete the following statement about compression testing using the following words.
Words: All, Batteries, Cranking, Cylinders, Diesel, Engine, Gauge, Injectors, Manufacturer’s, Parameters, Removed, Rotations, Sequentially, Specifications, Temperature, Test, Within
In diesel
engines, the compression
test
should be performed when the engine is close to operating temperature
by first removing all the injectors
, fitting the compression test gauge to the injector bore in one of the cylinder
, and then cranking through five rotations
. The batteries
should be fully charged during this test because crancking
velocity should exceed 250 rpm; therefore, all
the injectors should be removed
. Test each cylinder sequentially
and match the test results to specifications
. The results should be within the engine manufacture’s
cylinder compression parameters
and normally within 10 percent of each other.
34.
A zero reading means there is no leakage in the cylinder. Readings of __________ indicate that the cylinder will not hold any pressure.
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A.
10%
B.
20%
C.
50%
D.
100%
35.
Complete the following statement about cylinder leakage testing using the following words.
Words: Controlled, Cylinder, Engines, Leaks, Leakage, Operating, Percentage, Piston, Pressure, Rings, TDC, Test, Water
In diesel engines
, the engine should be close to its operating
temperature at the beginning of the test
. The test is performed with the piston
in the cylinder to be tested at TDC
, and regulated air pressure
is delivered to the cylinder
. The test may indicate valve seal leaks
, head gasket leaks, leaks to the water
jacket, leaking piston rings
, and defective pistons. The cylinder leakage
test regulator delivers air at a controlled
volume and pressure, then measures the percentage
of leakage. 36.
Engine oil pressure testing should be tested with the engine cold?
True or False
:
37.
An oil pressure test is used to determine the wear of an engine’s parts
.
True
or False:
38.
Complete the following statement about oil pressure testing using the following words.
Words: Adapters, Clearances, Contaminated, Faulty, Engine, Gauge, High-pressure, Hose, kPa, Low, Manufacturer’s, Much, Oil, Operating, Pressure, Problems, psi, Reading, Relief, Run, Running, Screen, Sensor, Test, Viscosity, An oil pressure
tester is a gauge with a high-pressure
hose attached to it. The scale of the gauge
typically reads from 0 to 100 psi
(0 to 690 kPa
). Using the correct fittings and adapters
, the hose is connected to an oil
passage in the engine
block. The test
normally includes the following steps: 1
Remove the oil pressure sensor
and tighten the threaded end of the gauge’s hose
into that bore.
2
Run
the engine until it reaches normal operating
temperature.
3
Observe the gauge reading
while the engine is running
at about 1,000 rpm and at 2,500 rpm (or the specified engine speed). 4
Compare the readings to the manufacture
’s
specifications. Excessive bearing clearances
are not the only possible causes for low
oil pressure readings;
others are oil pump-related problems
, a plugged oil pickup screen
, weak or broken oil J:\VET\Automotive\AUR40216 - Cert IV in Automotive Mechanical Diagnosis\AURLTE005 DIESEL\STUDENT ASSESSMENT GUIDE\AURLTE005_Student Assessment v1.2.docxPage 15
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pressure relief
valve, low oil level, _
contaminated
oil, or low oil viscosity. Higher than normal readings can be caused by too much
oil, cold oil, high oil viscosity
, restricted oil passages, and a faulty
pressure regulator. 39.
What is an interference engine?
In an interference engine, the valve will hit the pistons if the timing belt/chain breaks, slips or skips. The valves will be bent, piston may be damaged, and extensive engine damage may also occur.
40.
A good technician should not limit his action only to the exchange of parts, but they should also diagnose the cause of the failure. Diagnose the following engine component failures
.
Melted piston:
Crown damage by erosion is
described as having the piston crown
eroded, due to mechanical overloads and
thermal disintegration
Hole in piston:
Temperatures present in the
flame front are much higher than the melting
temperature of an aluminium piston
Dusting:
The ingress of dirt allows for the
piston ring to be worn on the running
surfaces and edges, so they can no longer
seal the cylinder sufficiently and can
therefore no longer prevent oil from passing
into the combustion chamber
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Hot short:
A loss or lack of proper
lubrication is created when the oil film
present during operation is inadequate,
either in quantity or quality, to support the
loads placed upon it.
Bent connecting rod:
Since most common
liquids are incompressible the piston cannot
complete its travel; either the engine must
stop rotating or a mechanical failure must
occur.
Hole in the block:
Catastrophic bearing
failure can be as a result of both isolated and
progressive bearing wear and/or
contamination
lack of maintenance
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Cylinder washing:
Dry running damage from
fuel flooding happens when unburned fuel is
wetting the cylinder running surface and
has
washed off the load bearing oil film
Lifter failure
Head gasket failure
Cracked piston
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Failed thrust bearing
41.
Complete the following statement about scan tools using the following words.
Words: Compatible, Diagnose, Engine, Entry, Information, Manufacturer, Most, Systems, Tools, Use, Varies
Scan tools
are available to diagnose
nearly all engine
control systems. When using a scan tool on these early system
, make sure it is compatible
with the system. Often, a manufacturer
specific scan tool is required. The use
of a scan tool varies with the make of the tool, but most
require an initial entry
of vehicle information
, including the VIN. 42.
Scan tools can be used to cycle on and off some actuators such as injectors, solenoids, idle air control motors and the like.
True
or False:
43.
On an OBD-II vehicle, the DLC connector is located?
A.
Under the bonnet, on the left side inner guard
B.
Under the bonnet, on the right side inner guard
C.
Under the bonnet, in the fuse/relay box
D.
Under the dashboard, within arm’s reach of the driver
To answer the following questions, you will need to go to the following link below
http://share.qclt.com/
丰田
Toyota%20RAV4%20Repair%20Manual/2AZ-FE%20Engine%20Control
%20System/SFI%20System/0050023.pdf
http://gershon.ucoz.com/TOYOTA/m_05_0576.pdf
44.
On a Toyota Land Cruiser, what would be the two (2) conditions that DTC P0116 Engine
Coolant Temperature Circuit Range/Performance Problem can be logged as a fault in the diesel engine system?
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When a cold engine start is performed and then the engine is warmed up, if the ECT sensor value does not change, it is determined that a malfunction has occurred. If this is detected in 2 consecutive
driving cycles, the MIL is illuminated and a DTC is set. After a warmed up engine is started, if the ECT sensor value does not change when the engine is stopped and then the next cold engine start is
performed, it is determined that a malfunction has occurred. If this is detected in 2 consecutive driving cycles, the MIL is illuminated and a DTC is set.
45.
On a Toyota Land Cruiser, what are the conditions for running DTC P0488 Exhaust Gas
Recirculation Throttle Position Control Range/Performance Problem?
This DTC will be set if the actual opening angle of the intake shutter valve varies from the target opening angle. The ECM forces the valve to fully open within 2 to 3 seconds after the engine switch is
turned ON (IG), and then checks if the intake shutter valve fully opened switch is turned ON. In addition, the ECM also forces the valve to fully open when accelerating the engine (high engine load) and checks if the switch is turned ON. When starting and/or accelerating the engine, the ECM sets this DTC if the switch is not turned ON. If the DTC is set, the ECM enters fail - safe mode and limits the engine power. The fail safe mode continues until the engine switch is turned OFF
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To answer the following questions, you will need to go to the following link below https://www.mazdabg.com/ftp-uploads/MAZDA%20material%20for%20technician/BT-50_en.pdf
46.
With the PID/data monitor function, input/output signal monitor items set in the diesel engine control module can be selected and read out in real-time. Answer the following PID monitored data below.
.
PID
Definition
Unit / Condition
AAT
Ambient air temperature O
C
AC_REQ
A/C request signal OFF / ON
ACCS
A/C relay OFF / ON
APP
Accelerator pedal position %
APP1
Accelerator pedal position sensor no.1 % / V
APP2
Accelerator pedal position sensor no.2
% / V
ARPMDES
Target engine speed RPM
BARO
Barometric pressure Pa / V
BOO
Brake switch OFF / ON
CPP
Clutch pedal position switch OFF / ON
DTCCNT
DTC count -
ECT
Engine coolant temperature O
C / V
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EGRV2
EGR control solenoid valve OFF / ON
FIP_FL
High-pressure pump flow control A / %
FIP_SCV
Fuel metering valve A
FLT
Fuel temperature O
C
FRP
Fuel rail pressure Pa
GP_LMP
Glow indicator light OFF / ON
GPC
Glow plug relay OFF / ON
IASV
ISV solenoid valve (half) OFF / ON
IASV2
ISV solenoid valve (FULL) OFF / ON
IAT
Intake air temperature (IAT sensor no.1) O
C / V
INGEAR
Load / no load condition OFF / ON
IVS
Idle switch OFF Idle / Idle
LOAD
Engine load %
MAF
Mass airflow g/s / V
MAP
Manifold absolute pressure Pa / V
MIL
Malfunction indicator lamp OFF / ON
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MIL_DIS
Distance travelled since the MIL was activated km
RPM
Engine speed Rpm
SEGRP DSD
Desired EGR valve position %
SELTESTDTC
Diagnostic trouble codes -
VBCV
VBC solenoid valve %
VPWR
Module supply voltage V
VSS
Vehicle speed km/h
WARMSW
Warm-up switch OFF / ON
WARMSOL
Exhaust solenoid valve shutter valve OFF / ON
To answer the following questions, you will need to go to the following link below and watch the video Ford 6.7 Powerstroke Diesel Freeze Frame Data.
https://www.youtube.com/watch?v=GZnbbKo-VK8
47.
Answer the following ‘Freeze Frame Data Items’ for the diesel engine control system below
EGRTP_CMD
0%
EGRT11
415.4
O
F
EGRT12
419
O
F
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FRP_A
24188.9psi
FRP_A_CMD
24199.05psi
FRT_A
131
O
F
VGT_A_CMD
36.08%
EBP1
36.975psi
CACT11
131
O
F
CACT12
131
O
F
EGT11
726.8
O
F
EGT12
743
O
F
EGT13
726.8
O
F
EGT14
1.98k
O
F
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48.
Explain how to access the “PID Data” list in question 46 using the scan tool?
Toolbox / Data Logger / Modules / PCM.
49.
How does the ECM records engine condition freeze frame data? Follow the link below to answer this question.
http://juchems.com/ServiceManuals/viewfilefcdc.pdf
Freeze frame data allows access to emission-related values from specific generic parameter identification (PIDs). These values are stored when an emission-related diagnostic trouble code (DTC) is stored in contiguous memory. This provides a snapshot of the conditions that were present when the DTC was stored.
Once one set of freeze frame data is stored, this data remains in memory even if another emission- related DTC is stored, with the exception of misfire or fuel system DTCs. Once freeze frame data for a misfire or fuel
system DTC is stored, it overwrites any previous data, and freeze frame data is no longer overwritten. When a DTC associated with the freeze frame data is erased or the DTCs are cleared, new freeze frame data can be stored again. In the event of multiple emission-related DTCs in memory, always note the DTC for the freeze frame data.
50.
From the Freeze Frame Data in question 47, what is causing DTC P200C Ford 6.7 Powerstroke Diesel?
A.
EGRT 11
B.
EGT14
C.
ETG13
D.
CACT 1
51.
Erasing the DTC with a scan tool will erase the corresponding freeze frame data.
True
or False:
52.
The freeze frame data is the sensor and output status data at the instant the DTC was set.
True or False:
53.
A PCM that can learn the normal range of inputs and outputs by monitoring them over a long period is said to be using adaptive strategy.
True
or False:
54.
The monitor that continuously looks at all the major engine sensors and actuators that can affect emission levels is called the comprehensive component monitor.
True
or False:
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55.
On the Toyota Land Cruiser, if DTC P062D Fuel Injector Driver Circuit Performance (Bank 1) or P062E Fuel Injector Driver Circuit Performance (Bank 2) were to log as a fault and you were to check the waveform on the oscilloscope, how should the injector command and confirmation signals look like? Draw them below. Follow the link below to answer this question
http://www.troublecodes.net/pcodes/p062d/
56.
Complete the following statement about documenting your diagnostic findings on the job card using the following words.
Words: Clear, Defective, Diagnostic, Documentation, Equipment, Found, Job, Operations, Pressure,
Problem, Sensor, Technician, Trouble, Write, The service technician
must document the job
card. This means that the service technician must write
(or type) what all was done to the vehicle including documenting defective
components or conditions that were found
in the course of the diagnostic
. The documentation
is often called “telling the story” and should include the following:
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●
The test equipment
used to diagnose the problem
. For example: Used a scan tool to retrieve P0046 Turbocharger/Supercharger Boost Control Solenoid Circuit Range/performance trouble
code. ●
Used an oil pressure
tester to determine the engine lubrication system was defective.
●
List what parts or service operations
were performed. For example: Replaced the Turbocharger. Used a scan tool to clear
the diagnostic trouble codes and verify that the system operated correctly. 57.
Why is it very important that the Job Card is completed correctly?
The Job Card becomes a legal document. Service records are kept by the workshop to maintain the vehicle's service history and for legal purposes
58.
When retuning a vehicle to the customer the vehicle should?
A.
Be cleaned.
B.
Have documentation completed.
C.
Post repair test completed.
D.
All answers are correct.
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Manual to assist with Q46
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FREEZE FRAME DATA DIESELS 1.
On a Toyota Land Cruiser, what are the conditions for running DTC P0488 Exhaust Gas Recirculation Throttle Position Control Range/Performance Problem?
This DTC will be set if the actual opening angle of the intake shutter valve varies from the target opening angle. The ECM forces the valve to fully open within 2 to 3 seconds after the engine switch is turned ON (IG), and then checks if the intake shutter valve fully opened switch is turned ON. In addition, the ECM also forces the valve to fully open when accelerating the engine (high engine load) and checks if the switch is turned ON. When starting and/or accelerating the engine, the ECM sets this DTC if the switch is not turned ON. If the DTC is set, the ECM enters fail–safe mode and limits the engine power. The fail–safe mode continues until the engine switch is turned OFF. J:\VET\Automotive\AUR40216 - Cert IV in Automotive Mechanical Diagnosis\AURLTE005 DIESEL\STUDENT ASSESSMENT GUIDE\AURLTE005_Student Assessment v1.2.docxPage 29
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To answer the following questions, you will need to go to the following link below https://www.mazdabg.com/ftp-uploads/MAZDA%20material%20for%20technician/BT-50_en.pdf
2.
With the PID/data monitor function, input/output signal monitor items set in the diesel engine control module can be selected and read out in real-time. Answer the following PID monitored data below.
PID
Definition
Unit / Condition
AAT
Ambient air temperature O
C
AC_REQ
A/C request signal OFF / ON
ACCS
A/C relay OFF / ON
APP
Accelerator pedal position %
APP1
Accelerator pedal position sensor no.1 % / V
APP2
Accelerator pedal position sensor no.2
% / V
ARPMDES
Target engine speed RPM
BARO
Barometric pressure Pa / V
BOO
Brake switch OFF / ON
CPP
Clutch pedal position switch OFF / ON
DTCCNT
DTC count -
ECT
Engine coolant temperature O
C / V
EGRV2
EGR control solenoid valve OFF / ON
FIP_FL
High-pressure pump flow control A / %
FIP_SCV
Fuel metering valve A
FLT
Fuel temperature O
C
FRP
Fuel rail pressure Pa
GP_LMP
Glow indicator light OFF / ON
GPC
Glow plug relay OFF / ON
IASV
ISV solenoid valve (half) OFF / ON
IASV2
ISV solenoid valve (FULL) OFF / ON
IAT
Intake air temperature (IAT sensor no.1) O
C / V
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INGEAR
Load / no load condition OFF / ON
IVS
Idle switch OFF Idle / Idle
LOAD
Engine load %
MAF
Mass airflow g/s / V
MAP
Manifold absolute pressure Pa / V
MIL
Malfunction indicator lamp OFF / ON
MIL_DIS
Distance travelled since the MIL was activated km
RPM
Engine speed Rpm
SEGRP DSD
Desired EGR valve position %
SELTESTDTC
Diagnostic trouble codes -
VBCV
VBC solenoid valve %
VPWR
Module supply voltage V
VSS
Vehicle speed km/h
WARMSW
Warm-up switch OFF / ON
WARMSOL
Exhaust solenoid valve shutter valve OFF / ON
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To answer the following questions, you will need to go to the following link below and watch the video Ford 6.7 Powerstroke Diesel Freeze Frame Data.
https://www.youtube.com/watch?v=GZnbbKo-VK8
3.
Answer the following ‘Freeze Frame Data Items’ for the diesel engine control system below
EGRTP_CMD
0%
EGRT11
415.4
O
F
EGRT12
419
O
F
FRP_A
24188.9psi
FRP_A_CMD
24199.05psi
FRT_A
131
O
F
VGT_A_CMD
36.08%
EBP1
36.975psi
CACT11
131
O
F
CACT12
131
O
F
EGT11
726.8
O
F
EGT12
743
O
F
EGT13
726.8
O
F
EGT14
1.98k
O
F
Decision Making Rules:
All tasks must
be performed correctly to be deemed satisfactory for this assessment activity.
Unit Code/s & Name/s
AURLTE005 Diagnose complex faults in light vehicle diesel engines
Student Name:
Student ID
Student Knowledge Was: 1
st
Attempt
◻
Satisfactory
◻
Not Yet Satisfactory
Student Knowledge Was: 2
nd
Attempt
◻
Satisfactory
◻
Not Yet Satisfactory
Comment(s)
A comment must be recorded if a NO is ticked in any of the tasks or NYS has J:\VET\Automotive\AUR40216 - Cert IV in Automotive Mechanical Diagnosis\AURLTE005 DIESEL\STUDENT ASSESSMENT GUIDE\AURLTE005_Student Assessment v1.2.docxPage 32
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been indicated
Student Declaration
I declare that I have been assessed in this unit, and I have been advised of my result. I also am aware of my appeal rights.
Signed by the Student:
Date
Assessor Declaration
I confirm that I have observed the student demonstrate the skills associated with the elements and performance criteria for assessment and required skill for this unit of competencies.
Signed by the Assessor:
Date
Note to Assessor: Please record any reasonable adjustment that has occurred to this assessment
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Course Code
AUR40216
Course Name
Certificate IV in Automotive Mechanical Diagnosis
Unit Code
AURLTE005
Unit Name
Diagnose complex faults in light vehicle diesel engines
Due Date
________________
Assessment Name
Practical
Student No.
________________
Student Name
_____________________________
Student Phone
________________
Student Email
_____________________________
Student Declaration
I declare that this assessment is my own work and where my work is supported by documents from my workplace placement/employer permission has been granted.
Note: This assessment will not be accepted unless all sections have been completed and the front cover has been signed and dated.
Student Signature
_________________________ Date:
_____________________________
Office Use Only
Date/s Received:
___/___/___
___/___/___
___/___/___
Date/s Assessed:
___/___/___
___/___/___
___/___/___
Result of Assessment:
___________
___________
___________
Entered on Training Plan
Moderation
Signature
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Imagine Education
Student Assessment Cover Sheet
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AURLTE005 Diagnose complex faults in
light vehicle diesel engines
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Assessment Tool:
Practical Assessment
Unit Code & Name
AURLTE005 Diagnose complex faults in light vehicle diesel engines
Purpose of Assessment: This unit describes the performance outcomes required to diagnose complex faults in light vehicle diesel 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 diesel 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. Target Group:
Student and those working in the automotive service and repair industry
. Exclusions or special conditions:
Some jurisdictions may require this qualification for licensing purposes. In addition, some units in this qualification may have licensing or regulatory requirements, depending on the work context. Local regulations should be checked for details.
Student Assessment Information This unit describes the performance outcomes required to diagnose complex faults in light vehicle diesel 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 diesel engines include those of light vehicles or
light commercial vehicles.
The Knowledge Assessment must be completed successfully before Practical Assessment tasks are undertaken. These additional tasks will need to be completed before an assessor can determine you as competent for this unit.
Practical Assessment (Student Guide for using the Practical Assessment) Practical Assessment
You are required to complete the Practical Assessment for this unit of competency.
Before being assessed, complete the Knowledge Assessment of this unit and show a copy of your Assessment result to the assessor/trainer, together with your results of other prerequisite Practical Assessments.
Practice the tasks a number of times as you can before asking for Assessment so that you are confident of meeting all the Assessment requirements.
Carry out the steps described in the Practical Assessments under supervision of a recognised assessor.
Conditions of Assessment: Assessors must satisfy SNR/AQTF assessor requirements. 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 having followed safe work practices while working in an automotive workplace, e.g. documented hazard inspection or incident report. Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application. Materials and equipment to be supplied by the ●
PPE
●
Safety goggles or glasses with side shields J:\VET\Automotive\AUR40216 - Cert IV in Automotive Mechanical Diagnosis\AURLTE005 DIESEL\STUDENT ASSESSMENT GUIDE\AURLTE005_Student Assessment v1.2.docxPage 36
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autoassesstools.com
Practical Assessment
FILENAME \p \* MERGEFORMAT J:\VET\Automotive\AUR40216 - Cert IV in Automotive Mechanical Diagnosis\AURLTE005 DIESEL\STUDENT ASSESSMENT GUIDE\AURLTE005_Practical Assessment v1.1.docx
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Student:
●
Steel-toed shoes
●
Pen
Work, Health and Safety: Students must wear PPE at all times during all practical activities
Resources Required: The following resources must be made available:
●
automotive repair workplace or simulated workplace
●
workplace instructions
●
manufacturer light vehicle diesel engine specifications
●
three different light vehicles with complex faults in their diesel engines
●
light vehicle engine diagnostic equipment, including:
−
compression gauge
−
vacuum gauge
−
cylinder leak-down gauge
−
oil pressure gauge
●
tools, equipment and materials appropriate for diagnosing complex faults in light vehicle diesel engines.
Demonstration Requirements:
Student is to demonstrate: Diagnose complex faults in light vehicle diesel engines
The demonstration will include the following – ●
diagnose a complex fault in three different light vehicle diesel engines
●
the above diagnosis must involve two of the following types of complex faults:
−
an intermittent fault
−
a fault that affects more than one system
−
a fault introduced as a result of a system repair
−
an indirect fault caused by the influence of external systems.
Number of Attempts:
You will receive up to two (2) attempts at this Assessment task. Should your 1
st
attempt be unsatisfactory (U), your Trainer/Assessor will provide feedback and will arrange a date for your 2
nd
attempt. If your 2
nd
attempt is unsatisfactory (U), or you fail to attend of date scheduled for the 2
nd
attempt, you will receive an overall unsatisfactory result for this Assessment task. Only one reassessment attempt may be granted for each Assessment task
Time Allowed:
16 Hours
Plagiarism
By submitting this Assessment, I declare that this Assessment is original and has not been copied or taken from another source except where this work has been correctly acknowledged. Trainer/Assessor Information
Demonstration Requirements:
Student is to demonstrate: Diagnose complex faults in light vehicle diesel engines
The demonstration will include the following – ●
diagnose a complex fault in three different light vehicle diesel engines
●
the above diagnosis must involve two of the following types of complex faults:
−
an intermittent fault
−
a fault that affects more than one system
−
a fault introduced as a result of a system repair
−
an indirect fault caused by the influence of external systems.
Oral Questions ●
Questions must be asked while the demonstration is taking place or if appropriate directly after the task/s have been completed ●
Access to required materials (e.g. reference materials, policy documents, workplace documents) during oral questioning may be provided. Learning Resources:
Learning Resources available to students include:
●
Automotive Mechanics (May & Simpson) 9
th
Edition
●
Automotive Technology (A System Approach) 6
th
Edition ●
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Disclaimer This Assessment tool is correct and current at the time of publication, but does not give any warranty nor accept any liability in relation to the contents. RTO’s are reminded they are responsible for ensuring that any learning and Assessment strategies
used for Assessment of an individual meet all regulatory requirements relevant to the role of an RTO Note:
This Assessment Tool was developed with reference to AUR Training Package Version 3 J:\VET\Automotive\AUR40216 - Cert IV in Automotive Mechanical Diagnosis\AURLTE005 DIESEL\STUDENT ASSESSMENT GUIDE\AURLTE005_Student Assessment v1.2.docxPage 38
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Task 1
This task is designed to develop your skill in Identify WH&S issues relating to diagnosing complex faults in light vehicle diesel engines.
Resources ●
Job Safety & Environmental Analysis (JSEA) form
Procedure 1.
Conducted/participated in a risk assessment (e.g. JSEA) using the JSEA form.
2.
Complete the JSEA form and 3.
Record the level of risk as E (Extreme) H (High) M (Medium) or L (Low).
4.
Use the Risk Matrix below to determine the level of risk.
Protective Clothing
●
PPE
●
Safety goggles or glasses with side shields ●
Steel-toed shoes
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Job Safety & Environmental Analysis (JSEA) Form Students Name:
Students ID No:
Location of the Job
Unit Code
AURLTE005
Unit Name
Diagnose complex faults in light vehicle diesel engines
Date Activity
List the tasks required to perform this activity Hazards
Against each task, list the hazards that could cause injury when the task is performed
Risk Rating
Risk Matrix – likelihood and consequence
Risk Control Measures
List the control measures required to eliminate or minimise the risk of injury arising from the identified hazard
Like
Con
Risk
Example: Lifting vehicle on hoist
Vehicle may fall off hoist
Unlikely
Major
Medium
Control evaluation and monitoring should occur
1
2
3
4
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Task 2: Diagnose complex faults in light vehicle diesel engines
Upon completion of this task, you should be able to demonstrate how to diagnose complex faults in light vehicle diesel engines.
Student instructions:
You MUST
diagnose complex faults in light vehicle diesel engines in three (3) different vehicles that you have been given to by your Trainer/Assessor. The above diagnosis MUST
also include two (2) of the following complex faults:
●
an intermittent fault
●
a fault that affects more than one (1) system
●
a fault introduced as a result of a system repair
●
an indirect fault caused by the influence of external systems
Tools and Materials 1.
Three (3) different light vehicles
2.
Workshop manuals (WSM) for vehicles (
MUST
be used)
3.
Workshop hand tools
4.
Micrometers
5.
Scan tool (
MUST
be used)
6.
Compression gauge (
MUST
be used)
7.
Vacuum gauge (
MUST
be used)
8.
Cylinder leak-down gauge (
MUST
be used)
9.
Oil pressure gauge (
MUST
be used)
10.
Inspection light
Protective Clothing:
●
PPE
●
Safety goggles or glasses with side shields ●
Steel-toed shoes
●
Vehicle protection
Trainer / Assessor Notes:
1.
The Student MUST
diagnose complex faults in light vehicle diesel engines in three (3) different vehicles that you have given the Student. The above diagnosis MUST
also include two (2) of the following complex faults:
●
an intermittent fault
●
a fault that affects more than one (1) system
●
a fault introduced as a result of a system repair
●
an indirect fault caused by the influence of external systems
2.
Trainer / Assessors MUST
verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application. 3.
The Student MUST
use the following tools and equipment during the diagnosis complex faults in light vehicle diesel engines:
1
Vehicle Workshop Manual 4 Scan tool 5 compression gauge 6 vacuum gauge
2
cylinder leak-down gauge
3
oil pressure gauge
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Job Card 1: Diagnose complex faults in light vehicle diesel engines
Job Details: Upon completion of this task, you should be able to demonstrate how to diagnose complex faults in light vehicle diesel engines.
Tool and Materials:
1.
One (1) light vehicle
2.
Workshop manuals (WSM) for vehicles (
MUST
be used)
3.
Workshop hand tools
4.
Micrometers
5.
Scan tool (
MUST
be used)
6.
Compression gauge (
MUST
be used)
7.
Vacuum gauge (
MUST
be used)
8.
Cylinder leak-down gauge (
MUST
be used)
9.
Oil pressure gauge (
MUST
be used)
10.
Inspection light
Protective Clothing:
●
PPE
●
Safety goggles or glasses with side shields ●
Steel-toed shoes
●
Vehicle protection
Procedure:
1.
Obtain tools and equipment from your trainer. 2.
Ask your Trainer/Assessor to direct you to a vehicle to work on.
3.
Identify the nature of the fault or problem. Your Trainer/Assessor will pick a fault from the customer compliant list below and write the fault on the front of the Job Card. You must carry out your diagnosis on that fault using the diagnosis as specified in the vehicles workshop manual.
4.
Report the fault. You must report your findings to the customer by filling in the Recommendations for the repair of the vehicle on the back of the Job Card. The customer can be your Trainer/Assessor, record the conversation with the customer on the back of the Job Card.
5.
Clean-up work area, tools and equipment are stowed in their appropriate area and finalise Job Card documentation by filling in the Customers Fault, the Cause of the Fault, the Rectification to repair the vehicle and the Parts used on the back of the Job Card.
Customer Complaint: Symptom(s):
Fault
must include one (1) of the following (Trainer to choose one)
1
Engine oil light on and engine noisy
2
Excessive oil consumption
3
Engine has no power intermittently
4
Excessive engine detonation after service
5
Severe engine knock after timing chain replaced last week
6
Engine overheating when stopped
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Job Card 1
Customer Details
Customer: John Smith
Contact Details:
(H) 03 9 123 4567
(M) 0401 234 567
Address:
101010 Melbourne Street
City
: Melbourne
State:
Victoria
Post code:
3000
Vehicle Details (Must
fill in the vehicle details
) If simulated vehicle used please tick ◻
Make:
Model
:
Colour:
License No:
VIN No:
Odometer Reading:
Engine No:
Engine Type:
Trans Type:
Customer Concern Labour Cost:
Cost of Parts:
Total Cost to Customer:
Declaration By The Customer
Please execute at my cost and as soon as you conveniently can repair the listed items above, and also any work considered essential. The vehicle, its accessories and contents are at my risk entirely whether theft or loss thereof or damaged thereto arises from any want of care on the part of yourself or your contractors or servants or from any cause whatsoever. Any claims for faulty workmanship is to be raised within seven (7) working days after the vehicle is returned to me. I agree such claim is limited solely to the rectification free of cost of the faulty work. No claim for loss consequential or otherwise being admissible.
X
J Smith / / 20 Signature of Owner Date (Fill in the date)
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Fault:
Record of Conversation with Customer:
Date:
Time:
Service Advisor:
Conversation:
Cause:
Rectification:
Parts Used
Recommendations:
Sublet Repairs
Order No
Fluids
QT
Y
Tyre Report
Tech #
Job #
Time
Clock Record
Gear Oil
L/H/F
R/H/F
ON
Auto Oil
mm
mm
OFF
Engine Oil
L/H/R
R/H/R
ON
Diff Oil
mm
mm
OFF
Coolant
Brake Report
ON
P/S Oil
L/H/F
R/H/F
OFF
Brake Fluid
mm
mm
ON
Other
L/H/R
R/H/R
OFF
mm
mm
ON
OFF
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Job Card 2: Diagnose complex faults in light vehicle diesel engines
Job Details: Upon completion of this task, you should be able to demonstrate how to diagnose complex faults in light vehicle diesel engines.
Tool and Materials:
1.
One (1) light vehicle
2.
Workshop manuals (WSM) for vehicles (
MUST
be used)
3.
Workshop hand tools
4.
Micrometers
5.
Scan tool (
MUST
be used)
6.
Compression gauge (
MUST
be used)
7.
Vacuum gauge (
MUST
be used)
8.
Cylinder leak-down gauge (
MUST
be used)
9.
Oil pressure gauge (
MUST
be used)
10.
Inspection light
Protective Clothing:
●
PPE
●
Safety goggles or glasses with side shields ●
Steel-toed shoes
●
Vehicle protection
Procedure:
1.
Obtain tools and equipment from your trainer. 2.
Ask your Trainer/Assessor to direct you to a vehicle to work on.
3.
Identify the nature of the fault or problem. Your Trainer/Assessor will pick a fault from the customer compliant list below and write the fault on the front of the Job Card. You must carry out your diagnosis on that fault using the diagnosis as specified in the vehicles workshop manual.
4.
Report the fault. You must report your findings to the customer by filling in the Recommendations for the repair of the vehicle on the back of the Job Card. The customer can be your Trainer/Assessor, record the conversation with the customer on the back of the Job Card.
5.
Clean-up work area, tools and equipment are stowed in their appropriate area and finalise Job Card documentation by filling in the Customers Fault, the Cause of the Fault, the Rectification to repair the vehicle and the Parts used on the back of the Job Card.
Customer Complaint: Symptom(s):
Fault
must include one (1) of the following (Trainer to choose one) (
MUST
be different to Job Card 1)
1
Engine oil light on and engine noisy
2
Excessive oil consumption
3
Engine has no power intermittently
4
Excessive engine detonation after service
5
Severe engine knock after timing chain replaced last week
6
Engine overheating when stopped
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Job Card 2
Customer Details
Customer: John Smith
Contact Details:
(H) 03 9 123 4567
(M) 0401 234 567
Address:
101010 Melbourne Street
City
: Melbourne
State:
Victoria
Post code:
3000
Vehicle Details (Must
fill in the vehicle details
) If simulated vehicle used please tick ◻
Make:
Model
:
Colour:
License No:
VIN No:
Odometer Reading:
Engine No:
Engine Type:
Trans Type:
Customer Concern Labour Cost:
Cost of Parts:
Total Cost to Customer:
Declaration By The Customer
Please execute at my cost and as soon as you conveniently can repair the listed items above, and also any work considered essential. The vehicle, its accessories and contents are at my risk entirely whether theft or loss thereof or damaged thereto arises from any want of care on the part of yourself or your contractors or servants or from any cause whatsoever. Any claims for faulty workmanship is to be raised within seven (7) working days after the vehicle is returned to me. I agree such claim is limited solely to the rectification free of cost of the faulty work. No claim for loss consequential or otherwise being admissible.
X
J Smith / / 20 Signature of Owner Date (Fill in the date)
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Fault:
Record of Conversation with Customer:
Date:
Time:
Service Advisor:
Conversation:
Cause:
Rectification:
Parts Used
Recommendations:
Sublet Repairs
Order No
Fluids
QT
Y
Tyre Report
Tech #
Job #
Time
Clock Record
Gear Oil
L/H/F
R/H/F
ON
Auto Oil
mm
mm
OFF
Engine Oil
L/H/R
R/H/R
ON
Diff Oil
mm
mm
OFF
Coolant
Brake Report
ON
P/S Oil
L/H/F
R/H/F
OFF
Brake Fluid
mm
mm
ON
Other
L/H/R
R/H/R
OFF
mm
mm
ON
OFF
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Job Card 3: Diagnose complex faults in light vehicle diesel engines
Job Details: Upon completion of this task, you should be able to demonstrate how to diagnose complex faults in light vehicle diesel engines.
Tool and Materials:
1.
One (1) light vehicle
2.
Workshop manuals (WSM) for vehicles (
MUST
be used)
3.
Workshop hand tools
4.
Micrometers
5.
Scan tool (
MUST
be used)
6.
Compression gauge (
MUST
be used)
7.
Vacuum gauge (
MUST
be used)
8.
Cylinder leak-down gauge (
MUST
be used)
9.
Oil pressure gauge (
MUST
be used)
10.
Inspection light
Protective Clothing:
●
PPE
●
Safety goggles or glasses with side shields ●
Steel-toed shoes
●
Vehicle protection
Procedure:
1.
Obtain tools and equipment from your trainer. 2.
Ask your Trainer/Assessor to direct you to a vehicle to work on.
3.
Identify the nature of the fault or problem. Your Trainer/Assessor will pick a fault from the customer compliant list below and write the fault on the front of the Job Card. You must carry out your diagnosis on that fault using the diagnosis as specified in the vehicles workshop manual.
4.
Report the fault. You must report your findings to the customer by filling in the Recommendations for the repair of the vehicle on the back of the Job Card. The customer can be your Trainer/Assessor, record the conversation with the customer on the back of the Job Card.
5.
Clean-up work area, tools and equipment are stowed in their appropriate area and finalise Job Card documentation by filling in the Customers Fault, the Cause of the Fault, the Rectification to repair the vehicle and the Parts used on the back of the Job Card.
Customer Complaint: Symptom(s):
Fault
must include one (1) of the following (Trainer to choose one) (
MUST
be different to Job Card 1 and 2)
1
Engine oil light on and engine noisy
2
Excessive oil consumption
3
Engine has no power intermittently
4
Excessive engine detonation after service
5
Severe engine knock after timing chain replaced last week
6
Engine overheating when stopped
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Job Card 3
Customer Details
Customer: John Smith
Contact Details:
(H) 03 9 123 4567
(M) 0401 234 567
Address:
101010 Melbourne Street
City
: Melbourne
State:
Victoria
Post code:
3000
Vehicle Details (Must
fill in the vehicle details
) If simulated vehicle used please tick ◻
Make:
Model
:
Colour:
License No:
VIN No:
Odometer Reading:
Engine No:
Engine Type:
Trans Type:
Customer Concern Labour Cost:
Cost of Parts:
Total Cost to Customer:
Declaration By The Customer
Please execute at my cost and as soon as you conveniently can repair the listed items above, and also any work considered essential. The vehicle, its accessories and contents are at my risk entirely whether theft or loss thereof or damaged thereto arises from any want of care on the part of yourself or your contractors or servants or from any cause whatsoever. Any claims for faulty workmanship is to be raised within seven (7) working days after the vehicle is returned to me. I agree such claim is limited solely to the rectification free of cost of the faulty work. No claim for loss consequential or otherwise being admissible.
X
J Smith / / 20 Signature of Owner Date (Fill in the date)
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Fault:
Record of Conversation with Customer:
Date:
Time:
Service Advisor:
Conversation:
Cause:
Rectification:
Parts Used
Recommendations:
Sublet Repairs
Order No
Fluids
QT
Y
Tyre Report
Tech #
Job #
Time
Clock Record
Gear Oil
L/H/F
R/H/F
ON
Auto Oil
mm
mm
OFF
Engine Oil
L/H/R
R/H/R
ON
Diff Oil
mm
mm
OFF
Coolant
Brake Report
ON
P/S Oil
L/H/F
R/H/F
OFF
Brake Fluid
mm
mm
ON
Other
L/H/R
R/H/R
OFF
mm
mm
ON
OFF
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Practical Observation
Students Name:
Students ID No:
autoassesstools.com
AURLTE005 Diagnose complex faults in
light vehicle diesel engines
FILENAME \p \* MERGEFORMAT J:\VET\Automotive\AUR40216 - Cert IV in Automotive Mechanical Diagnosis\AURLTE005\STUDENT ASSESSMENT GUIDE\AURLTE005_Practical Observation v1.0.docx
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Decision Making Rules:
All tasks must
be performed correctly to be deemed satisfactory for this assessment activity
Unit Code/s & Name/s
AURLTE005 Diagnose complex faults in light vehicle diesel engines
Student Name:
Student ID
Student Performance
Was: 1
st
Attempt
◻
Satisfactory
◻
Not Yet Satisfactory
Student Performance
Was: 2
nd
Attempt
◻
Satisfactory
◻
Not Yet Satisfactory
Comment(s)
A comment must be recorded if a NO is ticked in any of the tasks or NYS has been indicated
Student Declaration
I declare that I have been assessed in this unit, and I have been advised of my result. I also am aware of my appeal rights.
Signed by the Student:
Date
Assessor Declaration
I confirm that I have observed the student demonstrate the skills associated with the elements and performance criteria for assessment and required skill for this unit of competencies.
Signed by the Assessor:
Date
Note to Assessor: Please record any reasonable adjustment that has occurred to this assessment
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Trainer/Assessor Observation Students Name:
Students ID No:
Assessment Type
☐
Workplace ☐
Simulated Workplace
Unit Code
AURLTE005
Unit Name
Diagnose complex faults in light vehicle diesel engines
Date of Assessment
The evidence required to demonstrate competency in this unit must be relevant to workplace operations and satisfy all of the requirements of the performance criteria, required skills and knowledge.
Trainer/Assessors Name:
1
st
Attempt
2
nd
Attempt
During the demonstration of skills, did the student satisfactorily?
Evidence needs to be gathered that the student employs a systematic approach to diagnose complex faults in light vehicle diesel engines.
Yes
No
Yes
No
Safety
1.
Safely used appropriate hand and power tools and equipment
☐
☐
☐
☐
2.
Completed work safely, efficiently and within acceptable timeframes
☐
☐
☐
☐
3.
Observed all safety, PPE, environmental and workplace policies throughout the work including correct manual handling techniques
☐
☐
☐
☐
4.
Safely use relevant tooling and equipment to the level required by industry ☐
☐
☐
☐
Setup / preparation
5.
Accessed and used materials in a cost effective way, reducing wastage and using sustainability principles
☐
☐
☐
☐
6.
Accessed a range of information sources, seeks assistance and used a range of strategies for learning and self-improvement
☐
☐
☐
☐
7.
Attended at times required and was prepared for work ☐
☐
☐
☐
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Generic skills
8.
Followed task and job instructions and specifications including correct tool and equipment identification and testing in a safe and efficient manner
☐
☐
☐
☐
9.
Used technology such as diagnostic equipment without causing damage to components or systems
☐
☐
☐
☐
10.
Conducted/participated in a risk assessment (e.g. JSEA) – attach a copy
☐
☐
☐
☐
11.
Used manufacturer’s workshop manual/publication/database to access, interpret and apply information, safely making adjustments where necessary
☐
☐
☐
☐
12.
Communicated respectfully and inclusively with teachers and others
☐
☐
☐
☐
13.
Adapted to changes in workshop environment
☐
☐
☐
☐
14.
Solved problems using analytical skills and sought assistance as required
☐
☐
☐
☐
15.
Worked consistently on tasks and managed time efficiently and effectively
☐
☐
☐
☐
16.
Worked well in a team environment and resolved conflict and differences
☐
☐
☐
☐
17.
Displayed appropriate numeracy skills for the task at hand
☐
☐
☐
☐
Specific task skills
18.
Task 1: Complete a JSEA Form
☐
☐
☐
☐
19.
Task 2: Job Card 1: Diagnose complex faults in light vehicle diesel engines
☐
☐
☐
☐
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20.
Task 2: Job Card 2: Diagnose complex faults in light vehicle diesel engines
☐
☐
☐
☐
21.
Task 2: Job Card 3: Diagnose complex faults in light vehicle diesel engines
☐
☐
☐
☐
Clean up/ reporting
22.
Completed documentation (e.g. job card) to workplace standard
☐
☐
☐
☐
23.
Checked and stowed tools and equipment correctly; identified and reported any broken or faulty items for repair or replacement
☐
☐
☐
☐
24.
Kept work area clean ensuring all waste is scrapped and/or recycled ☐
☐
☐
☐
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Observation Questions
This answer sheet is for use by the assessor and is one form of evidence of Assessment. Do Not
give to student before assessment
. Use this answer sheet as a guide to assessing verbal questions and providing feedback to student.
1
st
Attempt
2
nd
Attempt
Yes
No
Yes
No
Q1. What safety precautions must be observed when working around engines?
☐
☐
☐
☐
(Students Comments / Responses):
Q2. Identify various causes of intermittent diesel engine electrical faults?
☐
☐
☐
☐
(Students Comments / Responses):
Q3. Excessively advanced ignition timing will usually cause what?
☐
☐
☐
☐
(Students Comments / Responses):
Q4. A wet compression test is performed on an engine after a dry compression test revealed low compression on one cylinder. If the compression on the low cylinder rises, it indicates?
☐
☐
☐
☐
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(Students Comments / Responses):
Q5. Why is it very important that the Job Card is completed correctly?
☐
☐
☐
☐
(Students Comments / Responses):
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Imagine Education Australia Automotive Workshop Job Card:
Date:
Student Name:
Customer Name:
Car Rego:
Address: Car Make:
Car Model:
Car Year:
Kms:
Contact Phone:
VIN:
Engine No.:
Customer Requests:
Diagnosis: Parts Required and Cost of Parts: Cost $
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Repairs Made/Equipment Used incl Measuring, Hand and Power Tools: Calculations Time Taken: hrs min Labour Rate @ $75.00 ph
Student Signature:
Trainer/ Assessor Signature:
Related to the following Units of Competency
Imagine Education Australia Automotive Workshop Job Card:
Date:
Student Name:
Customer Name:
Car Rego:
Address: Car Make:
Car Model:
Car Year:
Kms:
Contact Phone:
VIN:
Engine No.:
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Customer Requests:
Diagnosis: Parts Required and Cost of Parts: Cost $
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- Automotive Technology: A Systems Approach (MindTa...Mechanical EngineeringISBN:9781133612315Author:Jack Erjavec, Rob ThompsonPublisher:Cengage Learning
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