AURLTB104 Diagnose complex faults in light vehicle braking

systems

Assessment 1 – Questioning – Written Assessment

Student Name Student ID Number

Unit Start Date Unit End Date

Assessment Due Date Date Submitted

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

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

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

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

I am aware that I can locate The College Complaints and Appeals Policy and Procedure on their Yes / No
website.

I have discussed any additional educational support or reasonable adjustments I require in order to
Yes / No
undertake this assessment with the Student Support Services Officer and Trainer / Assessor.

I have access to all required resources? Yes / No

Cheating & Plagiarism Declaration

Student Declaration: In accordance with the 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

Signature Date: ______ / ______ / 20______

Satisfactory or Not Satisfactory

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

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

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

Student Name: Assessor’s Name:

Student Signature Date Assessor Signature Date

Student Guide for Written Knowledge Assessment

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 AURLTB104 Diagnose complex faults in light vehicle braking
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Overview of This is a written assessment task you will be assess on your knowledge of diagnosing complex
Assessment faults in light vehicle braking systems.
The topics that will be covered in the assessment are:
1. Identify and confirm the work requirement
2. Prepare to diagnose complex faults
3. Apply diagnostic procedures
4. Complete work processes
This assessment will ensure that the elements, performance criteria, performance evidence and
knowledge evidence required, and conditions are adhered to demonstrate competency in this
unit assessment task.
 Read the assessment carefully before commencing.
 Your Assessor will use the assessment criteria in this document and will provide
feedback / comment.
 You MUST answer all the questions in the assessment tasks in your own words and
own handwriting.
 This is an “Open Book” assessment, and students can use the resources listed in the
“Resources Required” section below.

Task/s to be To complete this written assessment, you will need to answer the 74 questions comprising of
assessed Multiple Choice, True and False, Fill-in the Gap and Short Answer questions.

Decision To receive a ‘satisfactory’ outcome for this assessment students MUST successfully answer all
making rules questions. If a student achieves less than 100%, they can reattempt the assessment after further
study has taken place. Students who cannot achieve a minimum of 100% you will not have
satisfactorily completed this assessment
Your assessor will be looking for the following in this assessment task: -
 Methods to locate and interpret information required to diagnose complex faults in light
vehicle braking systems, including:
o Light vehicle braking system manufacturer specifications
 Workplace procedures required to diagnose complex faults in light vehicle braking
systems, including:
o Establishing the serviceability of tools and equipment
o Documentation procedures
o Housekeeping procedures, including:
 Examination of tools and equipment
 Storage of equipment
 Identification, tagging and isolation of faulty equipment
 Safe disposal of materials
 Recycling procedures
 Workplace health and safety (WHS) requirements relating to diagnosing complex faults
in light vehicle braking systems, including procedures for managing and controlling
brake dust and brake fluid
 Environmental requirements, including procedures for trapping, storing and disposing of
fluids and material released from braking systems
 Types of complex faults relating to light vehicle braking systems, including:
o Intermittent
o Multi-system
o Introduced as a result of system repair
o Indirect, caused by the influence of external systems
 Types, functions and operation of light vehicle braking systems, including mechanical,
hydraulic and electronic subsystems
 Testing procedures for light vehicle braking systems, including procedures for:
o Vehicle dynamic and static testing

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o Abnormal noise analysis

o Component failure analysis
 Types, and key features of diagnostic testing equipment required to diagnose complex
faults in light vehicle braking systems
 Procedures for accessing and interpreting scan tool system data, including:
o Diagnostic trouble codes (DTCs), including:
 Conditions that set the DTCs
 Conditions for running DTCs
o Live data
o Waveforms
o Vehicle continuous and non-continuous monitored systems

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

conditions reflects performance in a real workplace setting.
Assessment MUST include direct observation of tasks.
Where assessment of competency includes third-party evidence, individuals MUST provide
evidence that links them to the light vehicle braking systems that they have worked on, e.g.,
Repair orders.
Assessors MUST verify performance evidence through questioning on skills and knowledge to
ensure correct interpretation and application.
The following resources MUST be made available:
 Automotive repair workplace or simulated workplace
 Workplace instructions
 Manufacturer light vehicle braking system specifications
 Three [3] different light vehicles with complex faults in their braking systems, including a
vehicle with an anti-lock braking system
 Light vehicle braking system diagnostic equipment, including scan tool
 Tools, equipment and materials appropriate for diagnosing complex faults in light vehicle
braking systems
Assessors of this unit MUST satisfy the requirements for assessors in applicable vocational
education and training legislation, frameworks and/or standards.

Resources Learning Resources available to students include:

required
 Automotive Technology (A System Approach) 7th Edition – Chapters 2, 5, 6, 7, 50, 51,
52 & 53
 Websites –
 Trainer Handouts

Results/Re-  The Assessor will grade the assessment and record the result on the front page of this
assessment document (S) – Satisfactory if all observable behaviours are correct and (NS) not
satisfactory if any areas are left incorrect
 Feedback will be provided on either result
 Where a student receives a ‘NS – Not Satisfactory’ result, the assessor will discuss the
area of the non-compliant observable behaviour and an opportunity given for re-
assessment.
 If the outcome is again not satisfactory the student result will be deemed (NC) not
competent. Additional feedback will be given, and a time agreed upon for further
assessment after additional training and skills practice has taken place.

Reasonable If the participant is unable to undertake the written assessment as designed, an interview (verbal
Adjustment questioning) may be used as an alternate approach.

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 AURLTB104 Diagnose complex faults in light vehicle braking
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Assessment 1 – Questioning

Written Assessment

Multiple Choice question. Select the correct answer.

1. What items of personal safety are needed when diagnosing vehicles or machinery braking systems?

A. Safety glasses and shields.

B. Footwear.
C. Clothing.
D. Skin protection.
E. All these answers are correct.

2. There are two special types of equipment used to safely contain asbestos while inspecting and servicing
brakes? A negative-pressure enclosure and high-efficiency particulate air (HEPA) vacuum system and briefly
explain how they work?

True or False question

3. The supply, sale, storage, use, re-use, installation, and transport of asbestos-containing products are
prohibited. Replacement brake pads, brake shoes and clutch plates fitted to vehicles in Australia must be
asbestos free.

True or False

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Multiple Choice question. Select the correct answer.

4. Removing the air from the closed hydraulic brake system is very important. This is done by bleeding the
system. Bleeding can be safely done manually, with a ________, or with a pressure bleed?

A. Vacuum pump.
B. Mop bucket.
C. Storm water drain.
D. Funnel.

5. When handling, trapping, storing and disposing of asbestos-containing products, new or waste brake fluid,
which document should you use to find this information?

True or False question

6. Brake fluid and chlorinated solvents can be drained into the workshop’s waste oil container.

True or False

7. Referring to the VACC Automotive Environmental Guide, explain the four [4] step procedure for trapping,
storing and disposing of hydraulic fluids released from braking systems.

8. What is an intermittent fault?

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9. Intermittent faults with sensors, and most ABS system circuits, will usually set a DTC. However, the DTC will
be stored instead of active when the technician retrieves them. What does this mean?

10. Identify various causes of intermittent braking system electrical faults?

11. A customer complaining of brakes fading away when braking. What is brake fade?

True or False question

12. A loss of hydraulic fluid or power pressure disables the ABS brake system?

True or False

True or False question

13. A faulty base brake system component may cause the ABS to shut down.

True or False

Fill in the Missing Word

14. Place the missing words to complete the following statement about braking system warning lights using the
following words.

Missing Words: Hydraulic, Parking, Reservoir

Besides indicating ABS faults for some systems, the red brake warning lamp on the instrument panel can
indicate failure of the _______________ brake system, application of the _______________ brake, or low
fluid level in the brake _______________.

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15. What could be the fault if a module does not respond to the diagnostic scan tool?

Multiple Choice question. Selected the correct answer.

16. Which of the following can lead to brake hose failure?

A. Incorrect brake fluid.

B. Stressing the hose during installation.
C. Extreme cold operation.
D. All answers are correct.

Multiple Choice question. Selected the correct answer.

17. A technician is diagnosing a vehicle with a braking systems fault. When he removes the filler cap to check the
fluid level in the master cylinder reservoir, he notices that the rubber seal on the cap is swollen and has begun
to disintegrate. What could be the problem?

A. Water in the brake fluid.

B. Petroleum-based lubricants in the fluid.
C. Fluid overheating.
D. Incorrect type of brake fluid.

Multiple Choice question. Selected the correct answer.

18. A technician is diagnosing a vehicle that had both front brake hoses replaced 5000km’s ago. An inspection
reveals that the right front hose has ruptured. What could have been the cause of the fault?

A. Specification called for DOT 3 fluid, and DOT 4 fluid cause the failure.
B. Faulty brake hose caused the failure.
C. The brake hose was twisted and stressed too much when installed.
D. None of these answers are correct.

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Multiple Choice question. Selected the correct answer.

19. After replacing the vacuum booster, the brakes lock-up on a road test. What could be the problem?

A. The vacuum booster pushrod needs adjusting.

B. There is air trapped inside the brake lines.
C. Specification called for DOT 3 fluid, and DOT 4 fluid was used.
D. All answers are correct.

Multiple Choice question. Selected the correct answer.

20. When the vehicle is road tested after replacement of an axle shaft, the ABS warning light illuminates. What
could be the problem?

A. Need to perform an ABS speed sensor relearn procedure.

B. No tone ring fitted to the new axle shaft.
C. Need to count the teeth on the tone ring of the old axle and compare it to the new axle.
D. All answers are correct.

21. What non-brake component concerns can cause the vehicle to pull when the brakes are applied?

22. Identify the two (2) dual brake system layouts?

23. Describe the function of the hydraulic system combination valve?

24. What is a tandem master cylinder?

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25. Identify three (3) electrical switches found in modern brake systems?

Multiple Choice question. Selected the correct answer.

26. The purpose of the master cylinder is to?

A. Generate the hydraulic pressure needed to apply the brake mechanisms.

B. Automatically pump the brakes during panic stops.
C. Supply mechanical force to the brake mechanisms.
D. All answers are correct.

True or False question

27. A metering valve delays front braking until the rears are applied.

True or False

True or False question

28. A proportioning valve controls rear brake pressure, especially during gentle stops?

True or False

True or False question

29. The size of the pads, shoes, drum and rotors is based on the weight of the vehicle?

True or False

Multiple Choice question. Selected the correct answer.

30. The upward movement of the rear suspension opens the.

A. Residual pressure check valve.

B. Metering valve.
C. Height-sensing proportioning valve.
D. Pressure differential valve.
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Multiple Choice question. Selected the correct answer.

31. The function of the wheel cylinders is to?

A. Convert hydraulic pressure to mechanical force at the drum brakes.

B. Maintain correct shoe position and clearance.

C. Prohibit the shoes from following the movement of the rotating drum.

D. Provide the rubbing surface area for the linings.

Multiple Choice question. Selected the correct answer.

32. Caliper pistons that have threaded adjuster pushrods and internally threaded adjuster nuts are found on?

A. Front wheel calipers.

B. Rear wheel calipers with auxiliary drum parking brakes.
C. Rear wheel actuating calipers.
D. All answers are correct.

Multiple Choice question. Selected the correct answer.

33. The function of the pressure switch in the hydraulic control unit is to?

A. Activate the ABS warning light.

B. Trigger the solenoids when pressure has exceeded pre-set limits.
C. Turn the booster pump off and on.
D. All answers are correct.

34. Explain the role of the wheel sensors in an ABS system?

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Multiple Choice question. Selected the correct answer.

35. A technician is checking a vehicle with the customer’s complaint of poor braking performance and a low brake
pedal. The master cylinder is full, and there are no signs of fluid leaks in the brake system. When he holds
firm pressure on the brake pedal, the pedal slowly drops. What could be the problem?

A. Internally leaking master cylinder.

B. Internally leaking.

C. Leaking wheel cylinder.

D. Frozen pressure differential valve.

Multiple Choice question. Selected the correct answer.

36. The customer of a vehicle complains the vehicle is hard to stop. The technician doing the diagnosis starts by
pumping the brake pedal several times with engine off, and then starts the engine while holding firm pressure
on the brake pedal. The pedal falls away slightly, and less pressure is needed to maintain the pedal in
position. This test proves that.

A. The master cylinder is working.

B. The vacuum booster is working.
C. The front brake require adjustment.
D. There is air in the hydraulic.

Multiple Choice question. Selected the correct answer.

37. A customer complains that the vehicle pulls to the left during moderate to hard braking. An inspection shows
that the front pads and rear shoes are worn. After resurfacing the rotors and drums and replacing the pads
and shoes, a road teste reveals that the vehicle still pulls to the left when braking. What could be the problem?

A. The wheel alignment should be checked.

B. The tyres could be the problem and should be swapped left to right to check whether the direction of pull
changes.
C. Both A and B.
D. Neither A nor B.

Multiple Choice question. Selected the correct answer.

38. A brake inspection reveals that the outboard pad is significantly thinner than the inboard pad. What could be
the problem?

A. The problem could be a defective dust boot that caused the caliper to seize.
B. The problem could be caused by poor lubrication or deformation of the machined sliding areas on the
caliper and/or anchor plate.
C. The problem could be a sticky or sized caliper piston.
D. All answers are correct.

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Multiple Choice question. Selected the correct answer.

39. A vibration or pulsation in the brake pedal when the brakes are applied is usually caused by?

A. Warped rotors.
B. Oil or grease on the linings.
C. Frozen or sticking calipers.
D. Brake hose collapsed on the inside.

Multiple Choice question. Selected the correct answer.

40. A hard pedal normally indicates a problem with the.

A. Master cylinder.
B. Power brake booster.
C. Rotors.
D. Brake pads.

Multiple Choice question. Selected the correct answer.

41. The customer complains of a high-pitched squeal whenever the wheels are turning, except when brakes are
applied. What could be the problem?

A. The pads are worn and need replacement.

B. The rotors are scored and must be replaced.
C. The brake pads require lubricating.
D. None of these answers are correct.

Multiple Choice question. Selected the correct answer.

42. A grinding noise when the brakes are applied could be caused by?

A. Weak return spring.

B. Weak hold-down springs.
C. Worn shoes.
D. All answers are correct.

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Multiple Choice question. Selected the correct answer.

43. A clicking noise heard when the brakes are applied could be caused by?

A. Frozen star wheel.

B. Play in the attachment of the pad or shoe.
C. Brake fluid or grease on the linings.
D. Scored drums.

Fill in the Missing Words

44. Place the missing words to complete the following statement about braking system diagnostic equipment
using the following words.

Missing Words: ABS, Braking, CAN, Capabilities, Dangerous, Equipment, Functional, Important, Lead,
Misuse, Scan, Sensor, Solenoid, Tester, Trouble

Different vehicle manufacturers provide _______________ test and _______________ tools with varying
capabilities. Some _______________ are used simply to access the digital _______________ codes. Others
may also provide _______________ test modes for checking wheel _______________ circuits, pump
operation, _______________ testing, and so forth. Current ABSs are tied to the _______________ bus and
do not require special testers. It is _______________ to research the _______________ and proper use of
the test equipment the vehicle manufacturer provides. _______________ of test equipment can be
_______________. For example, connecting test _______________ during a test drive that is not designed
for this use may _______________ to loss of _______________ ability.

Multiple Choice question. Selected the correct answer.

45. What does a brake fluid tester test?

A. The age of the brake fluid.

B. The mileage of the brake fluid.
C. The moisture content in the brake fluid.
D. All answers are correct.

46. Explain how a brake fluid tester operates?

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Multiple Choice question. Selected the correct answer.

47. A brake performance tester is testing what?

A. Tests service and emergency brake efficiency.

B. Tests braking effort between front and rear brakes.
C. Tests suspension movement.
D. All answers are correct.

48. Describe the four (4) steps to operate the brake performance tester?

Fill in the Missing Word

49. Place the missing words to complete the following statement about scan tool using the following words.

Missing Words: activate, computer, correct, diagnose, diagnosing, procedures, braking, system

A scan tool and/or a special electronic tester is used to _______________ most electronic _______________
system. These can only retrieve DTCs; they may also be able to _______________ various actuators in the
system. The exact _______________ and available data from the vehicle’s _______________ will vary with
manufacturer and the _______________ found on the vehicle. Always refer to the _______________ service
information when _______________ electronic systems.

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50. From the image below, explain what the technician is checking for?

51. From the image below, explain what the technician is checking for?

52. Referring the Additional Information Book, what are the conditions for running DTC C1242/42 IG2 Power
Source Circuit?

53. Referring the Additional Information Book and 2014 Mazda 6, explain how to access the “Live Data” list using
the scan tool?

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Multiple Choice question. Selected the correct answer.

54. Referring the Additional Information Book and 2014 Mazda 6, C0001:01 Dynamic Stability Control (DSC)
when viewing the PID data for the ABS wheel speed sensor inputs, what you compared to on the vehicle, and
if outside the specification, what could be the fault?

A. The ABS wheel speed sensor input is compared to the vehicle speed and speed sensor would be faulty.
B. The ABS wheel speed sensor input is compared to the vehicle RPM and speed sensor would be faulty.
C. The ABS wheel speed sensor input is compared to the vehicle ABS light and speed sensor would be
faulty.
D. All these answers are correct.

55. Referring the Additional Information Book, what would be the conditions that DTC C0200/31 Front Speed
Sensor RH circuit or C0205/32 Front Speed Sensor LH circuit can be logged as a fault in the ABS system?

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Multiple Choice question. Selected the correct answer.

56. The sensor and output status data stored when a DTC is set is called?

A. Live data.
B. Freeze frame data.
C. Mode 6 data.
D. Failure record.

57. A customer is concern with ABS, and TCS/DSC and Brake master warning light ON their 2014 Mazda 6. You
verify the concern and connect the scan tool to find DTCs C0020:01, C0020:11, C0020:13, C0020:16,
C0020:1C and C0020:71 Pump Motor/Motor Relay. Referring the Additional Information Book and following
the troubleshooting chart for C0020:01, C0020:11, C0020:13, C0020:16, C0020:1C and C0020:71 Pump
Motor/Motor Relay, look up the related PIDs you will need to active and monitor during your diagnosis.

True or False question

58. The ABS control module monitors the electromechanical components of the braking systems?

True or False

True or False question

59. During vehicle operation, the control module monitors all electrical ABS functions and some hydraulic
functions during normal and antilock braking?

True or False

60. Looking at the wheel speed sensor waveform below, answer the different fault waveforms?

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True or False question

61. A loss of hydraulic fluid or power booster pressure disables the antilock brake system?

True or False

Fill in the Gaps

62. Complete the following statement about documenting you’re diagnostic finding on the job card using the
following words.

Words: Clear, Defective, Diagnostic, Documentation, Equipment, Found, Job, Multimeter, Operations,
Problem, Sensor, Technician, Trouble, Write

The service _______________ must document the _______________ card. This means that the service
technician must _______________ (or type) what all was done to the vehicle including documenting
_______________ components or conditions that were _______________ in the course of the
_______________. The _______________ is often called “telling the story” and should include the following:
 The test _______________ used to diagnose the _______________. For example: Used a scan tool
to retrieve C0210/33 R/H/R speed sensor diagnostic _______________ code.
 Used a digital _______________ to determine a wheel speed _______________ wire was defective.
 List what parts or service _______________ were performed. For example: Replaced the wheel
speed wire on R/H/R wheel. Used a scan tool to _______________ the diagnostic trouble codes and
verify that the system operated correctly.

63. Why is it very important that the Job Card is completed correctly?

Multiple Choice question. Selected the correct answer.

64. When retuning a vehicle to the customer the vehicle should?

A. Be cleaned.
B. Have documentation completed.
C. Post repair test completed.
D. All answers are correct.

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True and False

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

True or False

True and False

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

True or False

True and False

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

True or False

True and False

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

True or False

Multiple Choice question. Select the correct answer.

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

A. Be unsafe or potentially unsafe.

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

True and False

70. Disposing of excess hydraulic oil, can be dispose into their correct sealed recycling drum.

True or False

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True and False

71. Second-hand braking components that are in good condition can be reused on the other similar vehicle?

True or False

Multiple Choice question. Selected the correct answer.

72. Which source of information will give you the most detail about diagnosing faults in braking systems on the
vehicle you are working on?

A. Workshop manual.
B. Owner’s manual.
C. Google.
D. Textbooks.

73. You are diagnosing braking system fault 2008 Mitsubishi Pajero and checking brake booster push rod to
master cylinder clearance. Referring to the 2008 Mitsubishi Pajero Brake System Workshop Manual, locate
and interpret the brake booster push rod to master cylinder clearance specification. The vehicle has a master
cylinder with effective diameter of 180 to 205mm:
Brake Booster Push Rod to Master Cylinder Clearance:

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