Assessment 5

AURTTA021 Diagnose complex system faults

Assessment 5 - Research Assignment AURTTA021

First submission Re-submission
Due date: ____/____/________ Due date: ____/____/________
Assessor and student instructions for research assignment:
As the student you are required to:
 Students must successfully research and answer all 7 questions below.
 Student is to complete the questions either handwritten (must be legible) or completed on a word
processor and submitted in hard copy form to your lecturer by the due date.
 Students are to talk to their lecturer if they have any questions related to completing the tasks.
 Students are to ensure the Student declaration is signed prior to submission stating all submitted work is
their own.
 The student is advised that their performance on assessment 4 and assessment 5 will be compared to
authenticate the students work in assessment 5. The student must demonstrate that the 10 similar
knowledge questions are answered successfully on both assessment 4 (5 questions in part A and 5
questions in part B) and assessment 5 to determine authenticity of assessment 5. If authenticity is unable
to be determined through successful completion of assessment 4, the student may also be deemed not
yet satisfactory for assessment 5.
 Adjustments to assessments may be made for you, providing the adjustments comply with set principles
of assessment and rules of evidence If you require support for literacy and numeracy issues; support for
hearing, sight or mobility issues; change to assessment times/venues; use of special or adaptive
technology; considerations relating to age, gender & cultural beliefs; format of assessment materials; or
presence of a scribe you need to inform your lecturer. Necessary adjustments can be discussed with the
trainer prior to the commencement of the course. Refer to college intranet for Policy and Legislation:
http://intranet.smtafe.wa.edu.au/org/cs/services/Pages/policy.aspx

Assessor Instructions: Students are to adequately answer all of the following questions. If any questions are
NOT answered correctly or completely, the student must be provided with feedback and will be required to
reattempt the question again and re-submit by a due date to be negotiated with them.

The assessor is required to authenticate the students work in assessment 5 by comparing their responses to
similar knowledge questions as those in assessment 4, 10 questions (5 questions in part A and 5 questions in part
B, refer to mapping document for specific details). The student must demonstrate satisfactory understanding of
the required knowledge assessed in assessment 4, before a satisfactory result can be given for assessment 5.

If a student requires reasonable adjustment please discuss with your Academic Leader, refer to the DAP and to
the Policy and Legislation on the Intranet: http://intranet.smtafe.wa.edu.au/org/cs/services/Pages/policy.aspx

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Complex system fault
 Assessment 5

AURTTA021 Diagnose complex system faults

Student ID:
Student Name
I declare that the evidence submitted is my own work:
Student
Declaration
…………………………………………..

Assessor
Feedback:

Student
Feedback:

Attempt Date Student performance

Student signature
(I confirm this is my own work)

Assessor Name Assessor signature

(Theory to be kept with
Summary)

1. Briefly describe the work health and safety (WHS) and occupational health and
safety (OHS) requirements relating to diagnosing complex system faults
including procedures for:

a) Selecting and using the correct PPE

RISK ASSESSMENTS:

o Proper movements such as bending, stretching, lifting or moving equipment and

materials, and working in awkward positions, such as under car bonnets.
o Proper clothing should be worn
o All jewelleries should be removed
o Appropriate PPE: Safety glasses, safety boots, gloves
o Noise is a big concern when working with engines, machinery and power tools. Use
ear muffs.
o Always perform automotive testing in a safe environment
o Put transmission in PARK (for automatic transmission) or NEUTRAL (for manual
transmission) and make sure the parking brake is engaged

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Complex system fault
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AURTTA021 Diagnose complex system faults

HAZARDS PRESENT HARMS PRESENT THINGS TO DO TO CONTROL

THE RISKS
Engine exhausts Fumes can cause eye irritations Use exhaust extractor
and breathing problems
Battery Charging Can cause burns from acids Do a safety check

Battery can explode from over Use PPE such a safety glasses
charging and gloves
Hoist Failure of Hoist, car can get off Do an inspection every 6
the hoist months

Check Safe Working Loads, SWL

Vehicle Airbags Airbags can explode if not fitted Do proper training for removing
correctly and cause injury and re fitting Airbags
Petrol and LPG Can cause fire, severe injuries Install Fire Alarms
and breathing difficulties
Fire extinghuishers – Inspected

Special Exits

Store Containers in a safe place

b) Using tools and equipment

Use Warrning/ Safety signs for co-workers' safety

Put Tags on Faulty Equipments.

Mechanical Equipments : Can cause serious injury from moving parts, sharp edges, hot parts
• Check equipments before use
• Put a Tag if necessary
• Get proper training
• Turn off equipment when not using

Electrical Equipments : Can cause burns/ Can get electric shocks. Faults can cause a fire
• Do a safety checks
• Ensure equipments are safe to use

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Complex system fault
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AURTTA021 Diagnose complex system faults

2. In the table below describe in detail the types, application, function and links of the
given complex systems.

Name Types Application Function Links

a) ABS ABS ABS ESP uses the

ABS and Four Channel ABS system: Vehicles with ABS stop at While braking, if a wheel- ABS system’s
ESP has a different valve for a shorter distance than locking situation is
(systems wheel-speed
that each wheel and also a other vehicles, more detected or anticipated, sensors, as
integrates separate speed sensor stable and safe,it ensures the ECU alerts the HCU by
well as
two or more for each of the four full control of the steering sending a current and
steering-angle
automotive wheels wheel by preventing the commands it to release the
systems) vehicle from locking the brake pressure, allowing and yaw-angle
The controller monitors wheels in sudden braking the wheel velocity to sensors, to
each wheel individually situations in all road increase and the wheel slip detect a loss of
to make sure it is conditions and at all to decrease stability. The
getting the required speeds car’s computer
braking force. ESP is then able to
It is controlled by an This system is developed to apply brake
Three Channel ABS electronic control unit
system: help the driver avoid the pressure to
which is called Brake danger of losing the control individual
has a speed sensor on
Control Module (BCM) of the vehicle stability due
all four wheels and a wheels, while
separate valve for each to under-steering or
ESP also
of the front wheels, but oversteering during
recognizes critical driving moderating
only one valve for both cornering
conditions, such as panic engine power,
of the rear wheels ESP ECU controls it by
reactions in dangerous to bring the
controlling the vehicle
situations, and stabilizes car back into
stability using the input
the vehicle by wheel-
values from the sensors line
individual braking and
and applying the brakes
engine control
independently to the
involvement
corresponding wheels

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AURTTA021 Diagnose complex system faults

b) Mechanical Usually pumps draws off As the camshaft rotates

EFI (a Fuel Pump fuel from the gas tank. It during engine operation, a
system that Usually mounted on the then pushes it to the shaft or rocker arm in the
incorporates
three or side of the engine block carburetor when the pump moves up and down
more or engine is cranking or or back and forward,
mechanical, cylinder head and running depending on the fuel
hydraulic, operated by a part on pump’s position. This
pneumatic, the engine's camshaft A check valve is used in causes the diaphragm to
electrical or the pump to prevent fuel move back and foward,
electronic from being pumped back
sub- drawing fuel from the fuel
into the tank. tank and sending it to the
systems)
carburetor or injectors

Hydraulic Controlled by a small Responsible for the

Fuel Pressure Regulator vacuum hose that goes to distribution of fuel to the
the intake engine
A device which controls
the pressure of fuel
supplied to the fuel
injectors on an engine
Pneumatic The ECU detects the A throttle position sensor
Throttle Body accelerator’s position and communicates the position
gives a message to the of the valve to the ECU.
Part of the air intake throttle body to open the The airflow meter
system that controls the valve recognizes the increased
amount of air flowing volume of air and gives a
into the engine message to the injection
system to inject more fuel

Electronic Allows fuel to spray out Fuel delivered is controlled

Injector of the nozzle and into the by cycling the injector
engine voltage on and off very
Responsible form rapidly
injection the fuel into
the engine, it is
controlled by ECU

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AURTTA021 Diagnose complex system faults

3. Describe in detail the diagnostic procedures and stages used for diagnosing faults in
complex systems.

- Gather information from the customer - Ask questions such as “when did you first notice the
problem? What conditions was the vehicle operating under at the time? In traffic? Cruising
on the freeway? How long since the engine was started? What repairs or service have been
done recently?”
- Confirm the Fault – Make sure what the customer said was true. Do a road test with the
customer to confirm the symptom
- Consider the information gathered – Use own knowledge
- Locate the fault and its cause
- Repair the fault - Decide on the most suitable repair to eliminate the fault, whether to repair
it or replace with new parts.
- Always confirm with the customer first before carrying out repairs, tell him about the cost,
time etc.
- Repair the fault - check all related systems, as well as the faulty one, to confirm that and also
no other faults has been introduced

4. Briefly describe 4 methods of gathering information on complex system faults,

including the use of questions when talking to customers.

- Own Knowledge
- Workshop Manual & Manufacturer’s Websites
- Other Technicians in the workshop
- Internet – Google Search & Forums

5. Briefly describe TWO different types of diagnostic flow charts and when you would
use them.

a) Type 1 – OEM Manufacturer’s Flowchart

When it is used – when diagnosing the causes of
various trouble codes

has a “feedback loop” which

prompts you to re-test or do further
tests if you don’t find the fault on
the first attempt

has actual Specs of vehicle

b) Type 2- Generic Fault Diagnostic Flowchart

When it is used – This could be used as a general
procedure to follow on other
diagnosis tasks.

Often you can make a few small

adjustments to suit the particular
job

Does not have actual Specs of Vehicle

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AURTTA021 Diagnose complex system faults

6. Given the following diagnostic tools in the table below briefly describe situations
where they are usually used, how they are used and any limitations they may have

Tool Where are they How are they used Limitations

used
(Operation)
(Application)

a) multimeters Testing for electrical Has connector such a Voltage limits

problems in a vehicle back probes, alligator Eg: Hybrid vehicles
clips (positive and require a more
negative) advanced type of
Used for Voltage test, multimeter
Resistance Test
Continuity Test
Cranking Battery
Load Test
Current Draw

b) scan tools access the vehicle’s - always refer to it cannot tell you if
including: ECU workshop manual the sensor is bad or
diagnosis trouble first the wiring is broken
codes (DTC) and display the DTCs on - has a 16 pin
the conditions the screen connector about 600 Software out of date
that caused the mm of the driver’s
code to be set, clear codes from the seat - near the Non-OEM
live data and
ECU’s memory steering column, or in Specifications
snap shots
the centre console
Live Data allows you - allow the mechanic
to view vehicle to run a diagnostic
sensor, switch and check when any
relay inputs in real service lights comes
time, while the engine on the dash in a
is running vehicle — check
engine, service light,
etc
- eliminates repairs -
Fault codes and other
scan tool data give
information about
area of malfunction
or the specific
component

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c) oscilloscopes a kind of electronic - always refer to Can be costly

test instrument workshop manual
designed to first Limited frequency/
graphically display - has Scope mode and voltages
different types of different adaptor
signal voltages over probes No storage memory
time using waveforms to store data
to interpret the values - has 3 different
Eg: Ignition (Primary & systems:
Secondary) vertical system –
• Injectors & Fuel control voltage range
Pumps
• Starter & Charging horizontal system –
Circuits to set the
• ABS sensors, Crank appropriate time
& Cam Sensors needed
• Lambda, Airflow,
Knock & MAP Sensors trigger system – to
stabalize a repeating
signal
d) mechanical test Torque wrench Wear PPE Size limitations
equipment
tighten fasteners Get specific torque
(nuts, bolts, studs and from workshop
screws) to a specific manual Sensitive when over
tightness used
Once the fastener
becomes tight, apply
steady, even pressure
until the torque
wrench clicks. You
will both hear, and
feel this click through
the torque wrench.

e) hydraulic test Hydraulic Spring Refer to workshop Very expensive

equipment compressor manual first

To remove and Wear PPE

replace springs from Requires periodic
your struts Has a foot pedal to maintenance
compress the strut

Slide strut into the

compressor correctly Need necessary
to secure it training before use to
avoid serious injuries
Position lower and
upper bracket then
compress the spring
until it can be
removed safely

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AURTTA021 Diagnose complex system faults

f) Pneumatic test Tyre pressure gauge Use workshop Dead battery (if
equipment such manual or the digital)
as tyre pressure Keeping the correct driver's door sticker
gauges, tyre pressures for best to get actual tyre
Compression driving condition pressure specs
Gauges. Petrol or
Diesel engines Connect pressure
gauge to read tyre
pressure

Compare values

7. a) Briefly describe how a fault symptom differs from a fault cause?

A symptom is a clue that something is wrong.

It is a noticeable change - we might see, hear, smell or feel something different

Finding the cause of the faults will allow the technician to choose the right repair to
correct the fault

Eg:
Symptom Fault Cause

Engine stopped suddenly, Broken cam belt, bent Belt overdue for replacement.
won’t re-start valves Leaking camshaft oil seal.

b) Briefly describe 2 methods that are used to differentiate between fault symptoms
and fault causes.

A symptom might indicate a fault in a customer’s vehicle, and a faulty (worn, broken)
component might be found

Something must have caused that change.

Finding the cause of the faults will allow the technician to choose the right repair to correct
the fault

Symptom Cause

In fifth gear, engine revs hard Clutch plate worn out

but car won’t accelerate

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