Student Book

Direct Observation
AURLTE002 Diagnose and repair light vehicle engines
 AURLTE102 Diagnose and repair light vehicle engines

Comment [RH1]: Header and footer must b

Assessment 2 – Direct Observation changed to new unit code.

Student Name Hafiz Ali Sharjeel Sattar Student ID Number 0000013717

Unit Start Date 1-11-2023 Unit End Date 2-11-2023

Assessment Due Date 9-11-2023 Date Submitted 8-11-2023

This cover sheet is to be completed by the student and assessor and used as a record to determine student
competency in this assessment task

The assessment process and tasks were fully explained. Yes / No

I am aware of which evidence will be colected and how. Yes / No

I am aware of my right to appeal an assessment decision. Yes / No

I am aware that I can locate the AIBT’s Complaints and Appeals Policy and Procedure on their Yes / No
website at https://aibtglobal.edu.au/

I have discussed any additional educational support or reasonable adjustments I require in order to
undertake this assessment with the Student Support Services Officer and Trainer / Assessor, (if Yes / No
applicable). e.g. Student Handbook and Access and Equity Policy https://aibtglobal.edu.au/

I have access to all required resources? Yes / No

Cheating & Plagiarism Declaration

Student Declaration: In accordance with the AIBT’s Academic Misconduct Policy, I hereby acknowledge by
signing this declaration that I have not cheated or plagiarised any work regarding the assessment tasks undertaken
in this unit of competency except where the work has been correctly acknowledged.
NOTE: Student must sign this prior to submitting their assessments to the assessor

__8____ / _11_____ /
Signature Date:
2023______

Satisfactory or Not Yet Satisfactory

Assessment Results
(Please circle the assessment result for this task)

Feedback to Student - Please provide general feedback on the Student’s performance

Student Declaration: - I verify that the work completed

Assessor Declaration: - I verify that I have adequately
is my own and that I was adequately informed of the
explained and negotiated the assessment tasks with the
assessment process prior to commencing this
student prior to commencing assessment.
assessment task.

Student Signature
Assessor Signature

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 AURLTE102 Diagnose and repair light vehicle engines

Date 8-11-2023 Date

Context and Conditions of Assessment

This assessment will ensure that the elements, performance criteria, performance evidence and knowledge
evidence required and conditions are adhered to demonstrate competency in this unit assessment task.
 Read the assessment carefully before commencing.
 This is an open book assessment and will be conducted at your designated campus / workshop /
specialised lab.
 Your Assessor will use the assessment criteria in this document and will provide feedback / comment.
 You must answer all the questions in the assessment tasks in your own words and own handwriting.
 Your Trainer / Assessor will inform you of the due date for this assessment task.
 Your Assessor will grade as either S – Satisfactory or NS – Not Satisfactory for the assessment. In all
cases your Assessor will provide you with feedback.
 Only when all assessment tasks have been graded as S – Satisfactory you will be deemed C – Competent in the
final result of the unit of competency; if you do not satisfactorily complete all the assessment tasks you will be
deemed NYC – Not Yet Competent.

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

The RTO will ensure access to:

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 AURLTE102 Diagnose and repair light vehicle engines

 automotive repair workplace or simulated workplace

 workplace instructions
 manufacturer engine specifications
 three different light vehicle engines with faults specified in the performance evidence
 diagnostic equipment for light vehicle engines
 tools, equipment and materials appropriate for repairing light vehicle engines.

Evidence to be submitted by the student: -

 Participation in demonstration of skills as required in the assessment task.

 Completion of Practical Activity Tasks for Job Cards 1 to 3

Assessment Decision Making Rules

Your assessor will assess the evidence submitted for the following elements, performance criteria, performance
evidence and knowledge evidence to confirm that the student evidence submitted demonstrates validity,
sufficiency, authenticity and confirms current skills and knowledge relevant to the unit of competency.
Your assessor will be looking for the following in this assessment task: -
 Prepare to diagnose and repair light vehicle engines
 Diagnose engines
 Repair engines
 Complete work processes
 diagnose and repair the following faults in three different light vehicle engines:
o a fault in an engine cylinder head with an overhead camshaft, in which the work must involve
removing the cylinder head from the engine
o a fault in two of the following components, in which the work must involve removing the
components from the engine:
 engine valve timing belt
 engine valve timing chain
 engine valve lifters
 cylinder head valve stem seals
 camshaft
 camshaft bearings
 crankshaft
 balance shaft or its bearings
 pistons and connecting rods
 cylinder block sleeves
 main bearings and big-end bearings
 internal oil pump
o dismantle and reassemble one of the above engines

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 AURLTE102 Diagnose and repair light vehicle engines

Assessment 2 – Direct Observation

Practical Demonstration of Tasks

Task 1: Diagnose and repair light vehicle engines

Upon completion of this task, you should be able to demonstrate how to diagnose and repair light vehicle engines.

Student instructions:
You MUST diagnose and repair a fault in three (3) different light vehicle engines, in which the work must involve:

 a fault in an engine cylinder head with an overhead camshaft, in which the work MUST involve removing the
cylinder head from the engine
 a fault in two (2) of the following components, in which the work MUST involve removing the components from
the engine:
o engine valve timing belt
o engine valve timing chain
o engine valve lifters
o cylinder head valve stem seals
o camshaft
o camshaft bearings
o crankshaft
o balance shaft or its bearings
o pistons and connecting rods
o cylinder block sleeves
o main bearings and big-end bearings
o internal oil pump
 dismantle and reassemble one of the above engines.

Tools and Materials

 Three (3) different light vehicles  Angle gauge
 Workshop manuals (WSM) for vehicles (MUST  Feeler gauge
be used)  Straight edge
 Micrometres  Special service tools
 Compression gauge  Telescoping gauge or dial bore gauge
 Cylinder leak-down gauge  Engine stand
 Oil pressure gauge  Plastigauge
 Cooling system pressure tester  Inspection light
 Ultraviolet (UV) light  Gaskets and seals
 Hydrometer or Refractomer  Timing belt kit
 Workshop hand tools  Engine coolant
 Torque wrench  Engine oil

Protective Clothing:
 PPE
 Safety goggles or glasses with side shields
 Steel-toed shoes

Trainer / Assessor Notes:

1 The Student MUST diagnose and repair a fault in three (3) different light vehicle engines, in which the work
must involve:

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 AURLTE102 Diagnose and repair light vehicle engines

 a fault in an engine cylinder head with an overhead camshaft, in which the work MUST involve removing
the cylinder head from the engine
 a fault in two (2) of the following components, in which the work MUST involve removing the components
from the engine:
o engine valve timing belt
o engine valve timing chain
o engine valve lifters
o cylinder head valve stem seals
o camshaft
o camshaft bearings
o crankshaft
o balance shaft or its bearings
o pistons and connecting rods
o cylinder block sleeves
o main bearings and big-end bearings
o internal oil pump
 dismantle and reassemble one of the above engines.

2. Trainer / Assessors MUST verify performance evidence through questioning on skills and
knowledge to ensure correct interpretation and application.

3. Assessor MUST observe the student performing each step in the practical observation checklist

WARNING!

The Assessment will be STOPPED IMMEDIATELY if you are attempting to carry out any step in an unsafe or
dangerous way.

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 AURLTE102 Diagnose and repair light vehicle engines

Job Card 1: Diagnose and repair light vehicle engines

Job Details:

Upon completion of this task, you should be able to demonstrate how to diagnose and repair light vehicle engines.

Tool and Materials:

 One (1) OHC light vehicle  Angle gauge
 Workshop manuals (WSM) for vehicles (MUST  Feeler gauge
be used)  Straight edge
 Compression gauge  Plastigauge
 Cylinder leak-down gauge  Inspection light
 Cooling system pressure tester  Gaskets and seals
 Workshop hand tools  Engine coolant
 Torque wrench  Engine oil

Protective Clothing:
 PPE
 Safety goggles or glasses with side shields
 Steel-toed shoes

Customer Concern:
The customer is concerned that the engine is overheating and they are constantly topping up the coolant level.

Procedure:

WARNING!

The Assessment will be STOPPED IMMEDIATELY if you are attempting to carry out any step in an unsafe or
dangerous way.

1. Obtain tools and equipment from your trainer.

2. Ask your trainer to direct you to a work area.
3. Answer the questions between the Job Card
4. Identify the nature of the fault or problem. 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.
5. Report the faults or problems. 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
Assessor, record the conversation with the customer on the back of the Job Card.
6. Repair the engine as specified in the vehicles workshop manual.
7. Complete post repair testing to confirm repair
8. 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.

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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 environment used, please tick 

Make: TOYOTA Model: CAMRY Colour: WHIT License No: NA

VIN No: GH695955 Odometer Reading:
Engine No: NA Engine Type: PETROL Trans Type: AUTO

Customer Concern

The engine is concerned that the engine is overheating and they are constantly topping up the coolant level

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 ess ential. 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 p art of yourself or
your contractors or servants or from any cause whatsoever. Any claims for faulty workmanship is to be raised wit hin 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 clai m for loss consequential or otherwise
being admissible.
X J Smith / / 20
Signature of Owner Date (Fill in the date)

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1. Understand and Verify the Customer's Concern: The first part of this step is to obtain as much information as
possible from the customer. Are there aftermarket accessories on the vehicle? When does the condition
occur? Where does the condition occur? How long does the condition last? How often does the condition
occur?

Note your findings on the back of the Job Card.

2. Vehicle Operating as Designed: This condition exists when the vehicle is found to operate normally. The
condition described by the customer may be normal. Compare with another like vehicle that is operating
normally under the same conditions described by the customer.

Note your findings on the back of the Job Card.

3. Preliminary Checks: Conduct a thorough visual inspection. Review the service history. Detect unusual sounds
or odours.

Note your findings on the back of the Job Card.

4. Check for related Bulletins, Recalls and Preliminary Information.

Note your findings on the back of the Job Card.

5. Locate the procedure in the WSM that details how to diagnose overheating faults in light vehicle engines and
write the location below.

chapter 1 - THE DIAGNOSTIC PROCESS

6. Locate the procedure in the WSM that details which Pinpoint test to follow and write it below.

chapter 0/22/14

WARNING!

When releasing the system pressure, cover the expansion tank cap with a thick cloth to prevent the
possibility of coolant scalding, Failure to follow this instruction may result in personal injury.

7. As per the WSM, Inspect and test the cooling system using the cooling system pressure test; including the
radiator cap. Also, inspect the following:

 Inspect the radiator and the A/C condenser cooling fins for swarf or any other obstruction.
 Inspect the drive belt system and the drive belt tensioner for proper operation in order to ensure that
the coolant pump is rotating properly.
 Inspect for loose, damaged and/or missing air deflector(s).
 Check for a pinched or kinked cooling system hose.
 Inspect the thermostat for proper operation

Does the cooling system pass the inspection test? Yes or No

Note your findings on the back of the Job Card.

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8. Verify that the cooling fans are operating properly.

Does the cooling system pass the test? Yes or No

Note your findings on the back of the Job Card.

9. Use a hydrometer or refractomer to measure the coolant/antifreeze concentration. What is the recommended
coolant/antifreeze and concentration for this vehicle?

Vehicle Coolant/antifreeze Concentration Manufacturers Specification

antifreeze 50% water antifreeze 50%—50% water

10. With the radiator cap removed, start the engine and inspect for a constant flow of air bubbles in the engine
coolant.

Is there a constant flow of air bubbles in the engine Yes or No

coolant?

11. Isolate the problem by performing cylinder leak down test to determine the possible cause.

1 Disconnect the battery ground negative cable

2 Remove the spark plugs.

3 Rotate the crankshaft to place the piston in the cylinder being tested at Top Dead Centre (TDC) of the
compression stroke.

4 Install the cylinder leak down tester.

5 Apply compressed air pressure to the cylinder leak down tester and adjust according to the
manufacturer’s instructions.

6 Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent is considered excessive
and may require component service. In excessive leakage situations, inspect for the following
conditions:

 Air leakage sounds at the throttle body or air inlet hose that may indicate a worn or burnt inlet
valve or a broken valve spring
 Air leakage sounds at the exhaust system tailpipe that may indicate a worn or burnt exhaust
valve or a broken valve spring
 Air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube that may indicate
worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or
a damaged cylinder head
 Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder
head gasket

7 Perform the leakage test on the remaining cylinders and record the values

Note your findings on the back of the Job Card

12. What is the cause of the overheating concern?

Note your findings on the back of the Job Card.

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13. Locate the procedure in the WSM that details how to repair the cause of the overheating concern and write
location below.

engine chapter Haynes

Combustion gas in cooling system. Disconnect -ve battery. Drain coolant
and remove radiator.
Discard upper and lower rad hoses and thermostat. remove exhaust
manifold from cyl head. disconnect hoses and electrical connections.
remove valve cover to dis assemble rocker gear. keep rockers and
pushrods in same sequence.
Remove the cylinder head bolts and remove the cylinder head with the
inlet manifold still attached. The radiator will require cleaning and
maintenance due to electrolysis from combustion and coolant reactions.
Take full care
All cooling system hoses for any damage. NB Bolts need to be replaced
every so often. Regroup

14. Repair the cause of the overheating concern as per the WSM.

15. Locate the torque specifications in the WSM for the components that were removed to repair the cause of the
overheating concern, and write them below.

Component Torque Specification

Head bolts 20nm,180deg,allow then 90 deg

Rocker bolts 20nm

8mm bolts 20nm

6mm bolts 8nm

10mm bolts 70nm

16. Using a straight edge and feeler gauge, measure the cylinder head distortion

Cylinder Head Distortion Manufacturers Specification

0.25 0.05nm maximum

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17. What is the recommended coolant/antifreeze and concentration for this vehicle?

50/50 glycol to H20

18. Locate the procedure in the WSM that details how to fill and bleed the cooling system and write or attach it
below.

Auto data lubricants and capacities

Open bleed screw at thermostat, radiator and rear of cylinder head.
Using coolant fill funnel
introduce coolant mix to system. Fill until all air is out of system and
lock off bleed screw. Pressure test system before start. If ok fit radiator
cap and run engine until thermostat opens. Stop the engine and allow
to cool and recheck the cooling level.

19. With the cylinder head assembly fitted, fill and bleed the cooling system as per the WSM.

20. Complete post repair testing to verify the repair by carrying out a cooling system pressure test, that the engine
fan operates correctly and the engine oil is at the correct level.

Note your findings on the back of the Job Card.

21. 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.

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 AURLTE102 Diagnose and repair light vehicle engines

Fault: Record of Conversation with Customer:

over heated engine Date: 5-10-2023

Time: 2pm

Service Advisor: Mr Stewart

Conversation: engine over heated and
topping

Cause:

Radiator core blocked, combustion gas in cooling system.

Cyl head distortion 0.25mm Min spec is 0.05

Rectification: Parts Used

Remove cyl head and radiator for repair. Replace lower and 1x head bolt kit. VRS set.
upper rad hose and thermostat. Thermostat

Reassemble engine, hot run test and re tension fitting bolts Upper rad hose, lower rad hose
4x 50mm hose clamp air filter

Recommendations: Sublet Repairs Order No

Fluids QTY Tyre Report Tech # Job # Time Clock Record

Gear Oil L/H/F R/H/F ON 2hr

pesla
Auto Oil mm mm OFF

Engine Oil L/H/R R/H/R ON

Diff Oil mm mm OFF

Coolant Brake Report ON

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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

Instructions:
Ensure that the following actions / tasks / checks in your work area have been performed:
a. Tools & equipment used are in working order and have been put away ready for use next time. Where
necessary, tag any tools / equipment which had faulted during use and inform the Assessor about it.
b. Waste materials is to be disposed of via the appropriate recycling methods or place in general waste.
c. Ensure that any reusable materials are stored away appropriately and ready for reuse at another time.
d. Make sure the work area is cleaned and tidy. All equipment is put away and report on any issues / faults
with equipment when problems are noticed.

Job Card 1: AURLTE002 Diagnose and repair light vehicle engines

Student’s Name (Must fill in) Student’s Signature (Must fill in) Date of Assessment (Must fill in)

Hafis ali sharjeel Sattar 5-10-2023

Location of Assessment (Must fill in)

Workshop copper plans

End of Practical Task

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Job Card 2: Diagnose and repair light vehicle engines

Job Details:

Upon completion of this task, you should be able to demonstrate how to diagnose and repair light vehicle engines.

Tool and Materials:

 One (1) OHC light vehicle fitted with timing belt  Inspection light
 Workshop manuals (WSM) for vehicles (MUST  Gaskets and seals
be used)  Timing belt kit
 Micrometres  Engine oil
 Ultraviolet (UV) light
 Workshop hand tools
 Torque wrench

Protective Clothing:
 PPE
 Safety goggles or glasses with side shields
 Steel-toed shoes

Customer Concern:

The customer is concerned that engine oil is leaking from the front of the engine.

Procedure:

WARNING!

The Assessment will be STOPPED IMMEDIATELY if you are attempting to carry out any step in an unsafe or
dangerous way.

1. Obtain tools and equipment from your trainer.

2. Ask your trainer to direct you to a work area.
3. Answer the questions between the Job Card
4. Identify the nature of the fault or problem. 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.
5. Report the faults or problems. 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
Assessor, record the conversation with the customer on the back of the Job Card.
6. Repair the engine as specified in the vehicles workshop manual.
7. Complete post repair testing to confirm repair
8. 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.

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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 environment used, please tick 

Make: FORD Model: VXR Colour: SILVER License No: NA

VIN No: ERFG48454 Odometer Reading: 5676945
Engine No: NA Engine Type: PETROL Trans Type: AUTO

Customer Concern

Engine oil is leaking from the front of the engine

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 car e 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 fre e 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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1. Understand and Verify the Customer's Concern: The first part of this step is to obtain as much information as
possible from the customer. Are there aftermarket accessories on the vehicle? When does the condition
occur? Where does the condition occur? How long does the condition last? How often does the condition
occur?

Note your findings on the back of the Job Card.

2. Vehicle Operating as Designed: This condition exists when the vehicle is found to operate normally. The
condition described by the customer may be normal. Compare with another like vehicle that is operating
normally under the same conditions described by the customer.

Note your findings on the back of the Job Card.

3. Preliminary Checks: Conduct a thorough visual inspection. Review the service history. Detect unusual sounds
or odours.

Note your findings on the back of the Job Card.

4. Check for related Bulletins, Recalls and Preliminary Information.

Note your findings on the back of the Job Card.

5. Locate the procedure in the WSM that details how to diagnose engine oil leak faults in light vehicle engines
and write the location below.

Keep a close eye on the oil dipstick to check for engine oil leaks. If the
level drops over time, there is an oil leak. While driving, check if there is
blue smoke coming from the tail pipe.

6. Locate the procedure in the WSM that details which Pinpoint test to follow and write it below.

Pinpoint tests can provide helpful guides to diagnosis. But they should
be used with a clear understanding of the system and circuits under test.

7. Safety position the vehicle on the hoist and raise the vehicle to the desired working height.

CAUTION!

Consider the vehicle's centre of gravity when positioning the vehicle on the hoist.
Position the hoist contact pads under the lift points on the vehicle.

WARNING!

Before working under a vehicle, make sure the hoist locking device is engaged.

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WARNING!

Be extremely careful when working near a running engine. Always wear safety goggles or glasses with side
shields when working around moving machinery and be sure that your clothing is not loose.

WARNING!

To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail pipe,
muffler, etc.

9. With the vehicle at the desired working height, inspect the engine for engine oil leaks.

Note your findings on the back of the Job Card.

10. If the engine oil leak cannot be identified clearly by a visual inspection, carry out an ultraviolet (UV) test.

11. Locate the procedure in the WSM that details how to carry out an ultraviolet (UV) engine oil test and write or
attach it below.

UV test manual

12. What is the cause of the engine oil leak?

Note your findings on the back of the Job Card.

13. Locate the procedure in the WSM that details how to repair the engine oil leak and write location below.

From main seal leaking. engine chapter Haynes

14. Repair the cause of the oil leak concern as per the WSM.

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15. Locate the torque specifications in the WSM for the components that were removed to repair the oil leak
concern and write them below.

Component Torque Specification

Crank bolts 160nm

Timing cover bolts 12nm

Timing pin cover 12nm

Acc belt adjuster 25nm

16. Complete post repair testing to verify the repair, the engine oil is at the correct level and there are no oil leaks
from the engine.

Note your findings on the back of the Job Card.

17. 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.

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Fault: Record of Conversation with Customer:

Oil leakage Date: 2-10-2023

Time: 10am

Service Advisor: Mr Stewart

Conversation: oil leakage from the front of

engine

Cause:
Oil leakage crank pulley damage

Main lower seal leakage and some bolts brken

Rectification: Parts Used

Main seal and oil
Oil filter and 16mm bolts x3

Recommendations: Sublet Repairs Order No

Fluids QTY Tyre Report Tech # Job # Time Clock Record

Gear Oil L/H/F R/H/F ON 1.30 hr

pesla
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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Instructions:
Ensure that the following actions / tasks / checks in your work area have been performed:
a. Tools & equipment used are in working order and have been put away ready for use next time. Where
necessary, tag any tools / equipment which had faulted during use and inform the Assessor about it.
b. Waste materials is to be disposed of via the appropriate recycling methods or place in general waste.
c. Ensure that any reusable materials are stored away appropriately and ready for reuse at another time.
d. Make sure the work area is cleaned and tidy. All equipment is put away and report on any issues / faults
with equipment when problems are noticed.

Job Card 2: AURLTE002 Diagnose and repair light vehicle engines

Student’s Name (Must fill in) Student’s Signature (Must fill in) Date of Assessment (Must fill in)

Hafiz Ali Sharjeel Sattar 2-10-2023

Location of Assessment (Must fill in)

Copper plans

End of Practical Task

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Job Card 3: Diagnose and repair light vehicle engines

Job Details:

Upon completion of this task, you should be able to demonstrate how to diagnose and repair light vehicle engines.

Tool and Materials:

 One (1) light vehicle  Straight edge
 Workshop manuals (WSM) for vehicles (MUST be used)  Feeler gauge
 Micrometres  Telescoping gauge or dial bore gauge
 Oil pressure gauge  Plastigauge
 Workshop hand tools  Inspection light
 Torque wrench  Gaskets and seals
 Angle gauge  Engine Coolant
 Engine stand  Engine Oil
 V blocks

Protective Clothing:
 PPE
 Safety goggles or glasses with side shields
 Steel-toed shoes

Customer Concern:
The customer is concerned that there is a dull steady knock noise from the engine. Louder on acceleration.

Procedure:

WARNING!

The Assessment will be STOPPED IMMEDIATELY if you are attempting to carry out any step in an unsafe or
dangerous way.

1. Obtain tools and equipment from your trainer.

2. Ask your trainer to direct you to a work area.
3. Answer the questions between the Job Card
4. Identify the nature of the fault or problem. 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.
5. Report the faults or problems. 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
Assessor, record the conversation with the customer on the back of the Job Card.
6. Repair the engine as specified in the vehicles workshop manual.
7. Complete post repair testing to confirm repair
8. 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.

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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 environment used, please tick 

Make: SUZUKI Model: ALTO Colour: RED License No: NA

VIN No: SZ454897 Odometer Reading: 456345
Engine No: NA Engine Type: PETROL Trans Type: AUTO

Customer Concern

Customer is concerned that there is a dull steady knock noise from the engine. Louder on acceleration

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 car e 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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1. Understand and Verify the Customer's Concern: The first part of this step is to obtain as much information as
possible from the customer. Are there aftermarket accessories on the vehicle? When does the condition
occur? Where does the condition occur? How long does the condition last? How often does the condition
occur?

Note your findings on the back of the Job Card.

2. Vehicle Operating as Designed: This condition exists when the vehicle is found to operate normally. The
condition described by the customer may be normal. Compare with another like vehicle that is operating
normally under the same conditions described by the customer.

Note your findings on the back of the Job Card.

3. Preliminary Checks: Conduct a thorough visual inspection. Review the service history. Detect unusual sounds
or odours.

Note your findings on the back of the Job Card.

4. Check for related Bulletins, Recalls and Preliminary Information.

Note your findings on the back of the Job Card.

5. Locate the procedure in the WSM that details how to diagnose dull steady knock noise from the engine and
write the location below.

problem under the hood. If there is a smooth rumble, the engine is

replaced by a repetitive tapping or pinging sound.
Which gets faster and faster with the speed of the vehicle.

6. Locate the procedure in the WSM that details which Pinpoint test to follow and write it below.

Chapter 0/22/14

7. Locate the procedure in the WSM that details how to carry out an oil pressure test pressure test write or
attach it below.

An oil pressure tester uses a gauge to read the pressure and a high
pressure hose to connect to the appropriate place on the engine. After
reaching temperature the engine should be brought up to the
recommended speed and the gauge should be read. The reading should
be compared with the specification.

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8. Safety position the vehicle on the hoist and raise the vehicle to the desired working height.

CAUTION!

Consider the vehicle's centre of gravity when positioning the vehicle on the hoist.
Position the hoist contact pads under the lift points on the vehicle.

WARNING!

Before working under a vehicle, make sure the hoist locking device is engaged.

WARNING!

Be extremely careful when working near a running engine. Always wear safety goggles or glasses with side
shields when working around moving machinery and be sure that your clothing is not loose.

WARNING!

To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail pipe,
muffler, etc.

9. Locate the engine oil pressure specification in the WSM.

Oil Pressure Specification

OPERATING MANUAL · 2. Low oil level below suction line. · 4. Oil temperature excessive(above 190 F). ·
888 Pressure Gauge 0-60 psi 2

10. With the vehicle at the desired working height, preform an engine oil pressure check.

Is the engine oil pressure at the correct specification? Yes or No

Note your findings on the back of the Job Card.

11. Inspect the following engine external components for loosens or damage:

 Crankshaft pulley
 Torque converter
 Flywheel

Note your findings on the back of the Job Card.

12. Is the cause of the dull steady knock noise from the engine from low oil pressure or engine external
components?

Yes or No

Note your findings on the back of the Job Card.

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13. What is the cause of the dull steady knock noise from the engine.

Note your findings on the back of the Job Card.

14. Locate the procedure in the WSM that details how to remove the engine and write location below.

Chapter 0/22/14

15. Remove the engine as per the WSM and attach the engine to an engine stand.

16. Locate the procedure in the WSM that details how to disassemble the engine and write location below.

Chapter 0/22/14

17. Disassemble the engine as per the WSM. Once disassembled, clean and measure the engine components as
specified in the Engine Inspection Sheet below.

18. Thoroughly carry out the cylinder block visual inspection and note your findings on the Engine Inspection
Sheet below.

19. Locate the procedure in the WSM that details the inspection methods and specifications for the following:

 Cylinder block distortion

 Cylinder bore taper
 Cylinder bore out-of-roundness

Note your findings on the Engine Inspection Sheet below.

Engine Inspection Sheet

Engine Block Inspection

Visual Inspection

Note Serviceability

Cylinder Ridge on bore requires rebore S | U/S

Water jacket Need hot tank clean S | U/S

Welsh plug Replace S | U/S

Machined surface Distorted S | U/S

Threaded hole Engine mount drives side in block stripped S | U/S

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20. Measure the Cylinder block distortion and record measurements on the Engine Inspection Sheet below. Make
sure that measured surface is clean.

Distortion

Specification: 0.05mm maximum

Measured: 0.588

21. Using telescoping gauge or dial bore gauge, measure cylinder diameter. Using telescoping gauge, release the
lock screw at the end of the handle of the telescoping gauge. Compress the plungers and, using the lock
screw, secure them in the retracted position. Place the telescoping gauge into the bore, in an area below ring
travel and at 90° to the crankshaft.

22. Release the plungers by loosening the lock screw. Allow the plungers to expand until they contact the bore
walls. Rock the telescoping gauge back and forth and side to side to check for the correct resistance. Lock the
plungers into position using the lock screw, and carefully remove the telescoping gauge from the bore.

23. Use an outside micrometer to measure the distance between the two plunger faces. Record the reading
obtained for each cylinder on the Engine Inspection Sheet below. Make sure that measured surface is clean.

Cylinder Bore Diameter

No.1 3.71mm No.5 3.74mm

No.2 3.76mm No.6 3.745mm

No.3 3.70mm No.7 3.72mm

No.4 3.70mm No.8 3.723mm

Specification 3.70mm

24. Measure the taper of the cylinder. This can be achieved by measuring and comparing the diameters at the
highest point of piston ring travel and below the ring travel. Record the reading obtained for each cylinder on
the Engine Inspection Sheet below.

Bore: Taper

Top Diameter Bottom Diameter Amount of Taper

No.1 3.71mm 3.70mm 0.010mm

No.2 3.76mm 3.70mm 0.060mm

No.3 3.70mm 3.70mm 0.000mm

No.4 3.70mm 3.70mm 0.000mm

No.5 3.74mm 3.70mm 0.040mm

No.6 3.745mm 3.70mm 0.045mm

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No.7 3.72mm 3.70mm 0.020mm

No.8 3.723mm 3.70mm 0.023mm

Specification mm

25. Measure the cylinder for out-of-roundness. This can be achieved by first measuring the bore at a point parallel
to the piston pin, then at right angles to the piston. The difference between these measurements is the
amount of out-of-roundness.

26. Use an outside micrometer to measure the distance between the two plunger faces. Measure four out-of-
roundness at three locations (top, middle and bottom) in each bore. Record the reading obtained for each
cylinder on the Engine Inspection Sheet below.

Bore: Out-of-Roundness

Top Diameter Bottom Diameter Amount of Taper

No.1 94.286mm mm mm

No.2 94.286mm mm mm

No.3 94.286mm mm mm

No.4 94.002mm mm mm

No.5 94.000mm mm mm

No.6 94.300mm mm mm

No.7 93.802mm mm mm

No.8 94.250mm mm mm

Specification 93.698=+/_0.0254mm

Serviceability S | U/S

27. Report the overall condition and recommendation of the engine block on the back of the Job Card.

28. Thoroughly, carry out a visual inspection of the crankshaft. Record your finding on the Engine Inspection
Sheet below.

29. Locate the procedure in the WSM that details the inspection methods and specifications for the following:

 Run-out between adjacent journals

 Run-out between any journals
 Main journal diameter
 Crank journal diameter
 Journal taper and out-of-round
 Crankshaft end play

Note your findings on the Engine Inspection Sheet below

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Crankshaft Inspection

Visual Inspection

Note Serviceability

Main journal Scored S | U/S

Crankpin journal Damaged S | U/S

Oil gallery Clogged S | U/S

Machined surface scored S | U/S

30. Using the flat surface of the workbench, mount the crankshaft onto the V blocks. Using the dial indicator to
measure the crankshaft run-out at all main journals. Record your finding on the Engine Inspection Sheet
below.

31. Calculate maximum crankshaft run-out between any adjacent journals, and between any main journals.
Record your finding on the Engine Inspection Sheet below.

Run out

Maximum between Maximum between

Journal
adjacent journals any journals

No.1 (Front) 0.0025mm Measured Measured

No.2 0.0043mm

No.3 0.0026mm
0.00
No.4 0.0035mm 0.0022mm 0.0022mm

No.5 0.0028mm Specification Specification

No.6 0.0035mm

No.7 (Rear) 0.0026mm

0.02mm 0.0001mm

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32. Measure diameters on all journals (main journals and crankpin journals). Calculate journal taper and out-of-
round by measuring various positions and angles. Record your finding on the Engine Inspection Sheet below.

Journal Taper and Out-of-Round

Taper Out-of-Round

Main journals Main journals

No.1 (Front) 0.0762mm No.1 (Front) 0.0025mm

No.2 0.0532mm No.2 0.0043mm

No.3 0.055mm No.3 0.0026mm

No.4 0.0760mm No.4 0.0035mm

No.5 0.0752mm No.5 0.0028mm

No.6 0.0744mm No.6 0.0035mm

No.7 (Rear) 0.520mm No.7 (Rear) 0.0026mm

Specification 0.0025mm Specification 0.0002mm

Crankpin journals Crankpin journals

No.1 (Front) 0.0560mm No.1 (Front) 0.025mm

No.2 0.0236mm No.2 0.022mm

No.3 0.0225mm No.3 0.022mm

No.4 0.0366mm No.4 0.026mm

No.5 0.0466mm No.5 0.025mm

No.6 0.0236mm No.6 0.002mm

No.7 0.0236mm No.7 0.0003mm

No.8 (Rear) 0.0355mm No.8 (Rear) 0.022mm

Specification 0.002mm Specification 0.002mm

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33. Measure crankshaft end play. Install crankshaft, main bearings and caps and torque the main cap bolts to
specification. Position the dial indicator to the rear of the cylinder block. Using a screwdriver to move the
crankshaft backwards and forwards. Record your finding on the Engine Inspection Sheet below.

End play

Specification 0.025

Measured 0.225

34. Measure crankshaft main journals and crankpin journals with Plastigage. Record your finding on the Engine
Inspection Sheet below.

Bearing clearance

Main journals Crankpin journals

No.1 (Front) 0.100mm No.1 (Front) 0.060mm

No.2 0.075mm No.2 0.055mm

No.3 0.066mm No.3 0.066mm

No.4 0.022mm No.4 0.0423mm

No.5 0.023mm No.5 0.0455mm

No.6 0.0336mm No.6 0.056mm

No.7 (Rear) 0.0556mm No.7 0.0566mm

Specification 0.050mm No.8 (Rear) 0.0456mm

Specification 0.040mm

Serviceability S | U/S

35. Report the overall condition and recommendation of the crankshaft on the back of the Job Card.

36. Thoroughly, carry out a visual inspection on all the pistons. Record your finding on the Engine Inspection
Sheet below.

37. Locate the procedure in the WSM that details the inspection methods and specifications for the following:

 Piston diameter
 Piston-to-Cylinder clearance
 Piston ring clearance
 Piston ring end gap

Note your findings on the Engine Inspection Sheet below

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Piston Inspection

Visual inspection

Note Serviceability

Head Corroded cooling ports S | U/S

Lands Damaged S | U/S

Ring grooves Carbon build up S | U/S

Skirt Scuffed S | U/S

Piston pin Loose S | U/S

Connecting rod Need resizing S | U/S

38. Measure the piston diameter. Record your finding on the Engine Inspection Sheet below.

39. Measure the piston diameters across a specific point on the piston (skirt).

40. Calculate the piston-to-cylinder clearance and your finding on the Engine Inspection Sheet below. This can be
achieved by measuring and calculating piston diameter and cylinder bore inside diameter.

Piston to Cylinder clearance

Cylinder Piston diameter Cylinder bore diameter Clearance

No.1 93.978 93.978 93.978

No.2 93.978 93.978 93.978

No.3 93.978 93.978 93.978

No.4 93.978 93.978 93.978

No.5 93.978 93.978 93.978

No.6 93.978 93.978 93.978

No.7 93.978 93.978 93.978

No.8 93.978 93.978 93.978

Specification 94.286 94.286 94.286

41. Measure the piston ring side clearance and record on the Engine Inspection Sheet below. With the piston ring
fitted into the piston groove, measure the clearance between the ring and the piston land using thickness
gauge.

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Piston ring side clearance

Cylinder Top Second Oil

No.1 0.25 0.26 0.50

No.2 0.25 0.26 0.50

No.3 0.25 0.26 0.50

No.4 0.25 0.26 0.50

No.5 0.25 0.26 0.50

No.6 0.25 0.26 0.50

No.7 0.25 0.26 0.50

No.8 0.25 0.26 0.50

Specification 0.25to 0.30 0.26 to 0.30 0.50 to 0.55

42. Measure piston ring end gaps and record on the Engine Inspection Sheet below. Remove all piston rings from
the piston. Using a piston to send a piston ring down to where piston ring travel is. Using filler gauge to
measure the gap on all piston rings, on all cylinders.

Ring end gap

Cylinder Top Second Oil

No.1 0.500 0.450 0.450

No.2 0.450 0.500 0.462

No.3 0.350 0.650 0.452

No.4 0.800 0.452 0.553

No.5 0.450 0.453 0.552

No.6 0.520 0.750 0.336

No.7 0.330 0.552 0.556

No.8 0.360 0.622 0.556

Specification 0.370 0.370 0.400

Serviceability

No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8

S | U/S S | U/S S | U/S S | U/S S | U/S S | U/S S | U/S S | U/S

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43. Report the overall condition and recommendation of the pistons and rings on the back of the Job Card.

44. Inspect and analyse conditions of the Main and Crankpin bearings.

Note your findings on the back of the Job Card.

Bearing Inspection

Visual inspection

Main Journals

Note Colour Condition

No.1 Scored S | U/S S | U/S

No.2 SCORED S | U/S S | U/S

No.3 marked S | U/S S | U/S

No.4 marked S | U/S S | U/S

No.5 OK S | U/S S | U/S

No.6 OK S | U/S S | U/S

No.7 OK S | U/S S | U/S

No.8 OK S | U/S S | U/S

No.9 OK S | U/S S | U/S

Crankpin Journals

Note Colour Condition

No.1 blue S | U/S S | U/S

No.2 brown S | U/S S | U/S

No.3 grey S | U/S S | U/S

No.4 shiny S | U/S S | U/S

No.5 shiny S | U/S S | U/S

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No.6 Shiny S | U/S S | U/S

No.7 Shiny S | U/S S | U/S

No.8 shiny S | U/S S | U/S

45. Report the overall condition and recommendation of the Main and Crankpin bearings on the back of the Job
Card.

46. Locate the torque specifications in the WSM for the components that were removed to repair the dull steady
knock noise from the engine and write them below.

Component Torque Specification

crank main bearing cap new bolts 75nm

connecting rod nuts new nuts 34nm

flywheel bolts 54nm

crank pulley bolt 75nm

timing case bolt 20nm

rear main seal housing bolts 20nm

Torque convertor bolts 20nm

cylinder head bolts new bolts 88nm

rocker shaft bolts 88nm

cam shaft pulley bolt 54nm

intake bolts 54nm

exhaust manifold bolts 20nm

valve cover bolts 16nm

spark plugs 16nm

sump bolts 20nm

47. Reassemble the engine as per the WSM.

48. Complete post repair testing to verify the repair, the engine oil is at the correct level and there are no oil leaks
from the engine.

Note your findings on the back of the Job Card.

49. 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.

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Fault: Record of Conversation with Customer:

engine making knocking sound Date: 1-10-2023

Time: 2pm

Service Advisor: Mr Stewart

Conversation:

Cause:

Wrong grade fuel

Rectification: Parts Used

drain out fuel tank and drain fuel lines and fill with specified and
Proper oil
recommended fuel

Recommendations: Sublet Repairs Order No

use proper oil which suits the vehicle

Fluids QTY Tyre Report Tech # Job # Time Clock Record

Gear Oil L/H/F R/H/F ON 1hr

pesal
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

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OFF

Instructions:
Ensure that the following actions / tasks / checks in your work area have been performed:
a. Tools & equipment used are in working order and have been put away ready for use next time. Where
necessary, tag any tools / equipment which had faulted during use and inform the Assessor about it.
b. Waste materials is to be disposed of via the appropriate recycling methods or place in general waste.
c. Ensure that any reusable materials are stored away appropriately and ready for reuse at another time.
d. Make sure the work area is cleaned and tidy. All equipment is put away and report on any issues / faults
with equipment when problems are noticed.

Job Card 3: AURLTE002 Diagnose and repair light vehicle engines

Student’s Name (Must fill in) Student’s Signature (Must fill in) Date of Assessment (Must fill
in)

Hafiz Ali Sharjeel Sattar 1-10-2023

Location of Assessment (Must fill in)

Coopers plains

End of Practical Task

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Assessment 2 – Direct Observation – Assessor Checklist – Job Card 1

Assessment methods must be by direct observation of tasks on required skills and knowledge to ensure correct
interpretation and application

Satisfactory = S
Observable skills/tasks Not Satisfactory = NS

Safety

1. Did the student safely used appropriate safety equipment S| NS

2. Did the student complete work safely, efficiently and within acceptable timeframes S| NS

3. Did the student observe all safety, PPE, environmental and workplace policies
S| NS
throughout the work including correct manual handling techniques

4. Did the student safely use relevant tooling and equipment to the level required by
S| NS
industry

Setup / preparation

5. Did the student access a range of information sources, seeks assistance and used a
S| NS
range of strategies for learning and self-improvement

6. Did the student select appropriate safety equipment, materials, processes and
S| NS
procedures

7. Did the student attended at times required and was prepared for work S| NS

Generic skills

8. Did the student followed task and job instructions and specifications including correct S| NS
tool and equipment identification and testing in a safe and efficient manner

9. Did the student used technology such as diagnostic equipment without causing S| NS
damage to components or systems

10. Did the student use manufacturer’s workshop manual/publication/database to access, S| NS

interpret and apply information, safely makes adjustments where necessary

11. Did the student communicate respectfully and inclusively with teachers and others S| NS

12. Did the student adapt to changes in workshop environment S| NS

13. Did the student solve problems using analytical skills and sought assistance as S| NS
required

14. Did the student work consistently on tasks and managed time efficiently and S| NS
effectively

15. Did the student work well in a team environment and resolved conflict and differences S| NS

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 AURLTE102 Diagnose and repair light vehicle engines

16. Did the student display appropriate numeracy skills for the task at hand S| NS

Specific task skills

17. Did the student complete Job Card 1: Diagnose and repair light vehicle engines S| NS

18. Did the student complete Job Card 2: Diagnose and repair light vehicle engines (DO
S| NS
NOT USE)

19. Did the student complete Job Card 3: Diagnose and repair light vehicle engines (DO
S| NS
NOT USE)

Clean up/ reporting

20. Did the student complete documentation (e.g. job card) to workplace standard S| NS

21. Did the student check and stowed tools and equipment correctly; identified and
S| NS
reported any broken or faulty items for repair or replacement

22. Did the student keep work area clean ensuring all waste is scrapped and/or recycled S| NS

Assessment 2 - Direct Observation – Version: 2.0 Created: Apr 2021

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 AURLTE102 Diagnose and repair light vehicle engines

Verbal Questioning – In Relation to Practical Tasks Job Card 1

Assessment methods must include questioning on required skills and knowledge to ensure correct interpretation
and application

Q1. Identify five (5) important items of personal safety when diagnosing and repairing engines?

Students response:
No jewellery, PPE, eye protection, safety shoes, make sure the floor is dry

Q2. What safety precautions must be observed when working around engines?

Students response:
Because there is a chance of serious injury, and wearing metal can cause electric shock

Q3. Name the four (4) stroke of a four (4) stroke engine?

Students response:
Intake, compression, combustion, exhaust

Q4. A zero reading means there is no leakage in the cylinder. Readings of __________ indicate that the cylinder
will not hold any pressure?

Students response:
1200

Q5. How is deck warpage checked?

Students response:
Measure up and down the length of the head and record the thickest feeler
gauge blade that passed through the gap.

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 AURLTE102 Diagnose and repair light vehicle engines

Assessment 2 – Direct Observation – Assessor Checklist – Job Card 2

Assessment methods must be by direct observation of tasks on required skills and knowledge to ensure correct
interpretation and application

Satisfactory = S
Observable skills/tasks Not Satisfactory = NS

Safety

1. Did the student safely used appropriate safety equipment S| NS

2. Did the student complete work safely, efficiently and within acceptable timeframes S| NS

3. Did the student observe all safety, PPE, environmental and workplace policies
S| NS
throughout the work including correct manual handling techniques

4. Did the student safely use relevant tooling and equipment to the level required by
S| NS
industry

Setup / preparation

5. Did the student access a range of information sources, seeks assistance and used a
S| NS
range of strategies for learning and self-improvement

6. Did the student select appropriate safety equipment, materials, processes and
S| NS
procedures

7. Did the student attended at times required and was prepared for work S| NS

Generic skills

8. Did the student followed task and job instructions and specifications including correct S| NS
tool and equipment identification and testing in a safe and efficient manner

9. Did the student used technology such as diagnostic equipment without causing S| NS
damage to components or systems

10. Did the student use manufacturer’s workshop manual/publication/database to access, S| NS

interpret and apply information, safely makes adjustments where necessary

11. Did the student communicate respectfully and inclusively with teachers and others S| NS

12. Did the student adapt to changes in workshop environment S| NS

13. Did the student solve problems using analytical skills and sought assistance as S| NS
required

14. Did the student work consistently on tasks and managed time efficiently and S| NS
effectively

15. Did the student work well in a team environment and resolved conflict and differences S| NS

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 AURLTE102 Diagnose and repair light vehicle engines

16. Did the student display appropriate numeracy skills for the task at hand S| NS

Specific task skills

17. Did the student complete Job Card 1: Diagnose and repair light vehicle engines (DO
S| NS
NOT USE)

18. Did the student complete Job Card 2: Diagnose and repair light vehicle engines S| NS

19. Did the student complete Job Card 3: Diagnose and repair light vehicle engines (DO
S| NS
NOT USE)

Clean up/ reporting

20. Did the student complete documentation (e.g. job card) to workplace standard S| NS

21. Did the student check and stowed tools and equipment correctly; identified and
S| NS
reported any broken or faulty items for repair or replacement

22. Did the student keep work area clean ensuring all waste is scrapped and/or recycled S| NS

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 AURLTE102 Diagnose and repair light vehicle engines

Verbal Questioning – In Relation to Practical Tasks Job Card 2

Assessment methods must include questioning on required skills and knowledge to ensure correct interpretation
and application

Q1. What precautions are needed when draining the engine oil from an engine?

Students response:
Make sure the floor is dry, avoid contact with oil, make sure the drain pan is the correct size.

Q2. What is the function of the oil pan or engine sump?

Students response:
It covers the bottom of the engine block, and is where it holds the engine oil.
Circulating around the engine.

Q3. Engine oil pressure testing should be tested with the engine hot or cold?

Students response:
5 to 10 mins after shutting the engine down

Q4. When changing a timing belt or chain, a camshaft locking tool can be used. Why?

Students response:
To prevent the camshaft from rotating when removing the timing belt.

Q5. Identify the following fluid leaks?

1 Honey or Dark Greasy Fluid
2 Honey or Dark Thick Fluid with a Chestnut Smell
3 Green, Sticky Fluid
4 Slippery Red Fluid

Students response:

Assessment 2 - Direct Observation – Version: 2.0 Created: Apr 2021

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 AURLTE102 Diagnose and repair light vehicle engines

Assessment 2 - Direct Observation – Version: 2.0 Created: Apr 2021

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 AURLTE102 Diagnose and repair light vehicle engines

Assessment 2 – Direct Observation – Assessor Checklist – Job Card 3

Assessment methods must be by direct observation of tasks on required skills and knowledge to ensure correct
interpretation and application

Satisfactory = S
Observable skills/tasks Not Satisfactory = NS

Safety

1. Did the student safely used appropriate safety equipment S| NS

2. Did the student complete work safely, efficiently and within acceptable timeframes S| NS

3. Did the student observe all safety, PPE, environmental and workplace policies
S| NS
throughout the work including correct manual handling techniques

4. Did the student safely use relevant tooling and equipment to the level required by
S| NS
industry

Setup / preparation

5. Did the student access a range of information sources, seeks assistance and used a
S| NS
range of strategies for learning and self-improvement

6. Did the student select appropriate safety equipment, materials, processes and
S| NS
procedures

7. Did the student attended at times required and was prepared for work S| NS

Generic skills

8. Did the student followed task and job instructions and specifications including correct S| NS
tool and equipment identification and testing in a safe and efficient manner

9. Did the student used technology such as diagnostic equipment without causing S| NS
damage to components or systems

10. Did the student use manufacturer’s workshop manual/publication/database to access, S| NS

interpret and apply information, safely makes adjustments where necessary

11. Did the student communicate respectfully and inclusively with teachers and others S| NS

12. Did the student adapt to changes in workshop environment S| NS

13. Did the student solve problems using analytical skills and sought assistance as S| NS
required

14. Did the student work consistently on tasks and managed time efficiently and S| NS
effectively

15. Did the student work well in a team environment and resolved conflict and differences S| NS

Assessment 2 - Direct Observation – Version: 2.0 Created: Apr 2021

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 AURLTE102 Diagnose and repair light vehicle engines

16. Did the student display appropriate numeracy skills for the task at hand S| NS

Specific task skills

17. Did the student complete Job Card 1: Diagnose and repair light vehicle engines (DO
S| NS
NOT USE)

18. Did the student complete Job Card 2: Diagnose and repair light vehicle engines (DO
S| NS
NOT USE)

19. Did the student complete Job Card 3: Diagnose and repair light vehicle engines S| NS

Clean up/ reporting

20. Did the student complete documentation (e.g. job card) to workplace standard S| NS

21. Did the student check and stowed tools and equipment correctly; identified and
S| NS
reported any broken or faulty items for repair or replacement

22. Did the student keep work area clean ensuring all waste is scrapped and/or recycled S| NS

Assessment 2 - Direct Observation – Version: 2.0 Created: Apr 2021

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 AURLTE102 Diagnose and repair light vehicle engines

Verbal Questioning – In Relation to Practical Tasks Job Card 3

Assessment methods must include questioning on required skills and knowledge to ensure correct interpretation
and application

Q1. When using lifting equipment, what does SWL stand for?

Students response:
Safe work load

Q2. Describe the process of combustion?

Students response:
It is a chemical process in which a substance reacts rapidly with oxygen and releases heat.

Q3. What is the major thrust face of a piston?

Students response:
The left side of the cylinder liner

Q4. What is the function of the crankshaft thrust bearing?

Students response:
It limits the forward and backward movement of the crankshaft.
Within a certain range of crankshaft motion

Q5. When disassembling an engine, what should you be looking for?

Students response:
Old or worn parts because they can give clues to help you figure out what's wrong.
With the car

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