Highlights
Task:
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.
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 in understanding the question.
• This is an open book assessment and you may reference your learning material to assist you in this task.
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.
1. Identify five (5) important items of personal safety.
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2. What safety precautions must be observed when working around engines?
3. What precautions are needed when draining the engine oil from an engine?
4. Describe the safety precaution that must be observed before removing the radiator cap or disconnecting any component of a hot cooling system?
5. Explain the dangers which technicians should be aware of while working on cooling systems?
6. What four (4) handling precautions with coolant containing corrosion inhibitors and Antifreeze/Anti-boil solutions?
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7. What are the potential danger of working near electric thematically operated cooling fans?
8. When handling, trapping, storing and disposing of new or waste oils and coolants, which document should you use to find this information?
9. How should waste engine oil and coolant be stored and disposed?
10. What is an intermittent fault?
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 __________ fault is a fault that is not __________ present. It may not activate the __________ or cause a __________ to be set. Therefore, intermittent __________ can be difficult to __________. By studying the __________ and the relationship of each __________ to another, you should be able to create a list of __________ causes for the intermittent problem. __________ intermittent problems are caused by faulty __________ connections or wiring. Refer to a wiring __________ for each of the suspected __________ or components. This will help __________ all of the connections and components in that circuit. The __________electrical system of the suspected circuit should be __________ and thoroughly inspected. Check for burnt or __________ wire insulation, damaged __________ at the connectors, corrosion at the connectors, __________ connectors, __________ terminals loose in the connector, and __________ 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?
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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?
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
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?
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,
The role of the __________ system in a __________ engine is to supply a charge of __________ or air/dead gas mixture to the __________ cylinders. This gas mixture is used for __________, cooling and cylinder __________. Even when naturally __________ and especially when turbocharged, diesel engines are __________ for lean-burn operation. This means that under most __________ phases, there is significantly __________ air present in the engine __________ than that required to burn the __________.
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
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 __________ system is to minimise __________ noise while keeping harmful exhaust __________ at a minimum. The turbocharger is common to both __________ and exhaust systems. Its __________ is to use the exhaust system to recapture some __________ heat from the engine cylinders by __________ the air delivered to the engine __________ from the intake system. __________ intake and exhaust systems have to __________ together to achieve the best __________ economy while minimising emissions.
24. What is scavenging?
Student’s Copy AURLTE005
Diagnose complex faults in light vehicle diesel engines Version 3|2019
25. What is meant by valve timing?
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)
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
Piston slap
or diesel
knock
Piston pin
knock
Main bearing noise
Rod bearing noise
Thrust bearing noise
Tappet noise
Timing chain noise
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?
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 __________ engines, the compression __________ should be performed when the __________ is close to operating __________ by first removing all the __________, fitting the compression test __________ to the injector bore in one of the __________, and then cranking through five __________. The __________ should be fully charged during this test because __________ velocity should exceed 250 rpm; therefore, __________ the injectors should be __________. Test each cylinder __________ and match the test results to __________. The results should be __________ the engine __________ cylinder compression __________ 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.
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 __________, the engine should be close to its __________ temperature at the beginning of the __________. The test is performed with the __________ in the cylinder to be tested at __________, and regulated air __________ is delivered to the __________. The test may indicate valve seal __________, head gasket leaks, leaks to the __________ jacket, zleaking piston __________, and defective pistons. The cylinder __________ test regulator delivers air at a __________ volume and pressure, then measures the __________ 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 __________ tester is a gauge with a __________ hose attached to it. The scale of the __________ typically reads from 0 to 100 __________ (0 to 690 __________). Using the correct fittings and __________, the hose is connected to an __________ passage in the __________ block. The __________ normally includes the following steps:
1 Remove the oil pressure __________ and tighten the threaded end of the gauge’s __________ into that bore.
2 __________ the engine until it reaches normal __________ temperature.
3 Observe the gauge __________ while the engine is __________ at about 1,000 rpm and at 2,500 rpm (or the specified engine speed).
4 Compare the readings to the __________ specifications.
Excessive bearing __________ are not the only possible causes for __________ oil pressure readings; others are oil pump-related __________, a plugged oil pickup __________, weak or broken oil pressure __________ valve, low oil level, __________ oil, or low oil viscosity. Higher than normal readings can be caused by too __________ oil, cold oil, high oil __________, restricted oil passages, and a __________ pressure regulator.
39. What is an interference engine?
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