T163_ Automotive engine ignition system and powering AES- Automotive engine ignition system and powering T163 ‘Thursday, 04/8/2022 08:30 - 11:30 AM TVET NATIONAL EXAMINATION, RTQF LEVEL 5, 2021-2022 OPTION /TRADE: AUTOMOBILE ELECTRICITY AND ELECTRONICS SYSTEMS SUBJECT: Automotive engine ignition system and powering DURATION: 3 Hours INSTRUCTIONS TO CANDIDATES: PART II (QUESTION PAPER} ‘This Exam paper is composed of Two Sections (A, B). Follow the instructions given below, and answer the indicated questions fora total of 100 Marks. Section A: Attempt all Fifteen (15) questions. (60 Marks) Section B: Attempt any Four (4) questions out of Six (6)- (40 Marks) MARKING GUIDES 2022-NESA (National Examination and School Inspection Authority)T163_ Automotive engine ignition system and powering ‘Attempt all Fifteen (15) au 01. Define the following terms: (4 Marks) (4 marks) ANSWER: | | ‘a) Dwell angle: is a degree of distributor rotation that the point remains closed between each opening of the contact breaker point. /imark b) Engine Management system: is a type of electronic control unit that controls the running of an engine by monitoring the engine speed and ensure optimal engine performance. (1mark) c) ECU: it stands by Electronic control unit, it is a type of computer used in motor vehicle for detecting and calculate the information and send it to the actuator. (1mark) ) Actuator: in electromechanical device which receive electrical signal command from ECU and perform mechanical action in response to the sensor inputs. /1Mark 02. Mention six (6) basic functions of an ignition system. ~ (3Marks) (3 marks) ANSWER: ¥ It provides a method of turning a spark ignition engine ON and OFF. /0.5 mark ¥ It operates a various supply voltage (battery or alternator voltage). /0.5 mark Y It produces high-voltage arcs at the spark plug electrodes to start combustion. /0.5 mark ¥ It distributes high-voltage pulses to each spark plug in the correct sequence. /0.5 mark ¥ It times the spark so that it occurs as the piston near TDC on the compression stroke. /0.5 mark Y It varies spark timing as engine speed, load and other conditions charge. /Amark 03. Differentiate primary from secondary circuit. /3 marks {3 marks) (3Marks) ANSWER: Y The primary circuit of the ignition system includes all components and wires operating on low voltage/battery or alternator voltage. The ignition system primary voltage is normally below — battery —voltage (12.6 —volts). /1.5marks ¥ The secondary circuit of the ignition is high voltage section. ‘The ignition system secondary operating voltage can normally range from 4000-30000 volts, /1.5 marks 2022.NESA (National Examination and Schoo! Inspection Authority) ttT163_ Automotive engine ignition system and powering 04, What are five (5) advantages of petrol injection? /5 marks Answer: High engine torque ( mark) High engine power ( 1mark) Favorable engine performance curves ( 1mark) Low fuel consumption ( mark) Favourable exhaust-gas values ( Imark) 05. State eight (8) computers used by different automobile manufacturers. /4 marks Answer: Central processing unit(CPU) /0.5 mark electronic control unit (ECU) /0.5 mark electronic control module (ECM) /0.5 mark engine control module(ECM) /0.5 mark electronic control assembly (ECA) /0.5 mark powertrain control module (PCM) /0.5 mark Vehicle control module(VCM) /0.5 mark Microprocessor/0.5 mark Logic module /0.5 mark 06. What are the for systems? /4 marks ‘Answer: + Input/0.5Mark * Processing /0.5Mark * Storage /0.5Mark + Output /0.5Mark 07. Show any four (4) targets of modern engine techniques. /4M: Answer: i. Reduction of fuel consumption ratio/1Mark ii, Environmental protection/1Mark iii, Higher performance/1Mark iv. Higher comfort/1Mark v. Self-diagnostic function /1Mark 08. Explain at least five (5) common actuators used on a car- Answer: «Fuel injector solenoid: valve that control fuel flow/1mark + Fuel pump electri mechanism to force fuel out of the t 2022-NESA (National Examination and School Inspection Authority) sur (4) basic functions performed by all computer farks /Smarks ¢ motor: that drives a pumping nk and to the (5 marks) (4 marks) (4 marks) (4 marks) {5 marks) (iy1. 2. Temperature peaks, i A 3. Knocking combustion tok can occur/1mark 4. Engine performance drop/Imark 5. Deteriorations in exhaust gas values/1mark (2 element: ee S are enough) (0) Ignition point is too late: /2Marks 1. Reduction in the _ Pressure actin; i resulting piston force/Imark oan Increased fuel consumption. /Imark High exhaust gas values, /1mark Increased thermal load on the engine. /Imark Engine performance drop. /1mark rough auto-ignition of the A/F mixture aPop 12. What are any five (5) components of the evaporative emission (5 marks) system? /5 marks Answer: ‘The main components of an EVAP system are: - - Charcoal canister /Imark Purge valve/purge solenoid /1 mark «Vacuum lines /1mark + Puel tank filler cap /1mark + Fuel expansion tank /Imark » Fuel tank pressure sensor /1 mark © Vent valve/1mark 13, Examine any five (5) inspections that can be carried on spark plug. (5 marks) (4Marks) ANSWER: i. Check the state of insulator. /1mark ii, Check the damage of insulator. /Imarkk Check the electrode gap. /1mark iv. Check the state of spark. /Imark ¥. Check the state of plug wires. /1mark Vi Check the thread of spark plug. /1mark aracteristics of car battery. {5 marks) 14, a) Outline at least four (4) ch (2maarks) Answer: “ Nominal Voltage/0.5 mark Inspection Authority) fe} nd Schoo! 2022.NESA (ational Examination @ nd Schoo!T163_ Automotive engine ignition system and powering ‘+ Nominal Capacity/0.5 mark Cold start Current/0.5 mark ee ee + Battery rating/0.5 mark b) Name three (3) types of battery charging. (3marks) Answer: Normal charging/1 + Boost charging/1 * Trickle charging/1 15. Justify five (5) properties of electrical current (5 marks) Answer: ee Light properties: When current flows through gases, light is generated by the impact of the charged gas particles/1 mark Thermal properties: When electron move in a metallic conductor, the electron move between the individual atoms. the kinetic energy of the electron is transferred to the atom/1 mark Chemical properties: Liquid that conduct current are known as electrolyte their principal constituent break down when current through to them. This process is called electrolysis/1 mark Magnetic properties: A magnetic field is generated in every current-carrying conductor/1 mark Physiological properties: A current is able to flow through the human body when voltage source is touched. the electrical current electrifies the person receives an electrical shock/1 mark Section B: Attempt any Four (4) questions out of Six (6). (40 Marks) 16. a) Describe five (5) parts of an ignition system with their respective function (5Marks) ANSWER: ¥ Battery: Provides power for system. / mark ¥ Ignition: Switch allows the drive to turn ignition and engine ON and OFF. /Amark ¥ Ignition coil: Changes battery voltage into 30000 volts or more during normal operation. /1mark v Switching device: Mechanical or electr ‘onic switch that operates the ignition coil. /1mark . + Uses high voltage from the i an are, ignite the fuel charge, /1mark 2022-1 ional NESA (National Examination and Schoo} Inspection Authority) (5 marks) (10 marks) (vi)T163_ Automotive engine ignition system and powering (S elements are enough) ~~) What-are the parts which are found in electronic ignition —— = system and are not found in conventional ignition system? (5 Marks) ANSWE! Y Ignition module. /1.S5marks ¥ Crankshaft sensor/pickup coil. /1.Smarks Y Trigger wheel/pulse ring /reluctor. /2marks 17. Asa technician, suppose that someone brings to you a vehicle with a_ (10 marks) petrol engine which does not run. State at least five (5) possible causes and their corrections. / 10marks Answer: Possible causes _ Corrections No fuel /1 mark ‘Add fuel to the tank ii. Tank filter clogged./1 | Replace tank filter/1 mark mark iii, Fuel lines kinked or Straighten or clean clogged/1 mark fuel lines/1 mark iv, No spark /1 mark Ign system incorrect/1 mark v. Fuel pump inoperative [Replace pump /1 /1 mark mark vi Fuel filter or filters Replace filters /1 clogged /1 mark mark vi.No pressure causes by [replace /1 mark pressure reguretor /1 mark viii. Battery incorrect. | Charge or replace 2022.NESA {National Examination andl School Inspection Authority) (vtyT163_ Automotive engine ignition system and powering 18. 19, 71 mark 71 mark ix. Clogged injectors OR jet | Clean or replace ofcarburetor/1 mark | /1 mark x. Timing of ignition point | Adjust timing point incorrect /1 mark /1 mark Mention any ten (10) most common sensors used in modern motor (10 marks) vehicles. /10 marks Answer: i. Oxygen sensor/1 ii, Wheel speed sensor/1 iti Manifold absolute pressure sensor/1——— iv. Oil level sensor/1 : v. Barometric pressure sensor/1 vi, EGR sensor /1 vii. Throttle position sensor /1 viii, Impact sensor/1 ix, Engine speed sensor /1 x. Vehicle speed sensor/1 xi. Crankshaft position sensor/1 xii, Fuel tank pressure sensor/1 xiii. Camshaft position sensor /1 Battery temperature sensor/1 xiv. Mass airflow sensor /1 xv.Knock sensor /1 xvi, Transaxle/Transmission sensor/1 xvii, Brake switch /1 a) How does the pickup coil (sensor) produce signals for the (10 marks) 2022.NESA (National Examination and School Inspection Authority) (viii)T163_ Automotive engine ignition system and powering ignition control module? — (2Marks) —_—— ANSWER: —— As the trigger wheel tooth passes the pickup coil, it strengthens the magnetic field around the coil. This causes a change in the current flows through the coil. As a result, an electrical pulse (voltage change) is sent to the ignition control module as each trigger wheel tooth passes the pickup unit. /3marks b) Draw a conventional ignition system and name any five (5) parts of it. (3Marks) ANSWER: Each name is /7marks 20. a) Describe the timing advance and timing retard. (10 marks) (6Marks) ANSWE} “Timing advance occurs when the spark plugs fire sooner on the engine compression strokes. The timing is set several degrees before top dead center BTDC even more timing advance is needed at high engine speeds to give combustion enough time to develop pressure on the power stroke. /3 marks fey 2022-NESA (National Examination and Schoo! Inspection Authority)T163_ Automotive engine ignition system and powering 21. 2022.NESA (National Examination and Sehool Inspection Authority) -Timing retarder occurs when the spark plugs fire later on the compression strokes. It is the opposite of timing advance. Timing retard is needed at lower engine speed and under high load conditions. timing retard prevents the fuel from burning too much on the compression stroke. 3marks b) State four (4) possible causes of timing retard on an ignition system of an engine. (4 Marks) ANSWER: Y Timing retard prevents the fuel from burning too much on the compression stroke, causing a spark knock or ping (abnormal condition). /1mark Y The engine may be failing to ignite and burn its air-fuel mixture properly. /1mark ¥_ This increase exhaust emission. /1mark Y Lowers engine power and misfire. /Imark (4elements are enough) Design a sketch and describe an electrochemical process of a starter (10 marks) battery (Battery charged, Battery discharging, Battery discharged and Battery charging) (10 marks) Answer: (a) Battery charged /2.5 marks Trckore As the battery discharges, the chemical action taking place reduces the acid content in the electrolyte and increases the water content, At the same time, both the negative and the positive plates gradually change to lead sulphate (PbSO4), by)T163_ Automotive engine ignition system and powering (b) Battery discharging /2.5 marks A discharged battery has a very weak acid solution because most of the electrolyte has changed to water. Both series of plates are mostly lead sulfate. The battery now stops functioning because the plates are basically two similar metals in the presence of water, rather than two dissimilar metals in the presence of an electrolyte. (c) Battery discharged —//2.5 marks Posiive NeGatve During charging the chemical action is reversed. The lead sulfate on the plates gradually decomposes, changing the negative plates back to sponge lead and the positive plates to lead dioxide. The sulfate is re-deposited in the water, which increases the sulfuric acid content and returns the electrolyte to full strength. Now, the battery is again able to supply current. (4) Battery charging 12.5 marks 2022-NESA (National Examination and School Inspection Authority) ti)T163_ Automotive engine ignition system and powering rz a = ged ‘This electrochemical action and battery operation from fully char; to discharge and back to fully charge is called cycling. END OF MARKING GUIDES! 2022-NESA (National Exai Fxamination andl Schoot inspect ection Authorit y) (xii)T161_ Vehicle drive assistance system and Electronic accessories AES- Vehicle drive assistance system and Electronic accessories T161 Friday, 29/7/2022 08:30 - 11:30 AM TVET NATIONAL EXAMINATION, RTQF LEVEL 5, 2021-2022 OPTION/TRADE: AUTOMOBILE ELECTRICITY AND ELECTRONICS SYSTEMS SUBJECT: Vehicle drive assistance system and Electronic accessories DURATION: 3 Hours INSTRUCTIONS TO CANDIDATES: PART II (QUESTION PAPER) This Exam paper is composed of Two Sections (A, B). Follow the instructions given below, and answer the indicated questions for a total of 100 Marks. Section A: Attempt all Fifteen (15) questions. (60 Marks) Section B; Attempt any Four (4) questions out of Six (6) (40 Marks) MARKING GUIDES a 2022-NESA (National Examination and Sclool Inspection AutiT161_ Vehicle drive assistance system and Electronic accessories Section A: Attempt all Fifteen (15) questions. (60 Marks) 01. Define the following terms: (3Marks) (3 marks) a) Voltage: Is an electrical pressure causes electron to flow. /1Mark b) Current: Is transfer amount of free electron. /1Mark c) Resistance: Resistance disturbs of free electron flowing. /1Mark 02. What are five components of windshield wiper and (5 marks) washer system? (5Marks) ANSWER: Windshield wiper and washer system are composed by: i. Wiper blade/1Mark ii, Wiper linkage/1Mark Wiper motor/1Mark iv. Washer fluid/1Mark v. water pump/1Mark vi. Rain sensor/1Mark vii, Washer fluid tank/1Mark 03. Identify any six (6) electrical and electronics accessories (3 marks) system of motor vehicle. (3Marks) ANSWER: ‘The systems of electrical and electronic accessories are: a) Windshield wiper and washer system/0.5 Mark b) Gauges and meters System/0.5 Mark ©) Electrical power Windows/0.5 Mark 4) Car radio system/0.5 Mark 2022-NESA (National Examination and School Inspection Authority) ro)T161_ Vehicle drive assistance system and Electronic accessories €) Mirror system/0.5 Mark f) Central locking System/0.5 Mark g) Car alarm system/0.5 Mark h) Vehicle anti-theft System /0.5 Mark i) Cigarettes lighter/0.5 Mark 04. What are eight components included in the car alarm system assembly? (4Marks) ANSWER: The assemblage of car alarm system includes: Remote control /0.5 Mark Control Unit with power supply /0.5 Mark iii, Contact Switch /0.5 Mark iv. Infrared sensor or ultrasonic transponder /0.5 Mark v. Position sensor /0.5 Mark vi. Status display /0.5 Mark vii. Signal horn /0.5 Mark viii, Starting system /0.5 Mark 05. Write down eight (8) ways of power adjustable driver’s seat. (4 Marks) ANSWER: Eight way power adjustable driver's seat (height, tilt and lumbar) - Driver can individually electronically adjust the seating position 8 different way: i, Move seat forward. /0.5 Mark ii, Back. /0.5 Mark ili. Lower. /0.5 Mark iv. Raise the seatback up. /0.5 Mark 2022-NESA (National Exai ination and Schoo! Inspection Authority) (4 marks) (4 marks} (iyT161_ Vehicle drive assistance system and Electronic accessories v. Down. /0.5 Mark vi. Move the seat cushion up or down. /0.5 Mark vii, Forward/back. /0.5 Mark viii. Right or left. /0.5 Mark 06. a) What is the dependence of variables electric (4 marks) resistances? (2Marks) ANSWER: Variable electrical resistance depends on: Y Kind of material 0.5 Mark Y Sectional area of wire 0.8 Mark Y Length of wire 10.5 Mark ¥ Temperature 10.5 Mark b) What do you understand by vehicle electric central locking system? (2Marks) ANSWER: With this system the basic lock engagement and release function for instance at vehicle doors through activation of the servomotors, are carried out by electrically controlled actuators. /1Mark Actuation is often by why of two changeover contacts, whereby one is located in the door lock and the other in the actuator. /1Mark 07. Outline the purpose of vehicle antitheft system.(3Marks) (3 marks) ANSWER: Purpose of vehicle antitheft system are: Y Detecting vehicle theft and preventing false alarms /1Mark ¥ A secondary is alerting the owner. /1Mark Y Simply antitheft systems are all assemblies that serve to protect the vehicle and vehicle parts from theft and unauthorized use/1MarK 2022.NESA (National Examination and School Inspection Authority)T161_ Vehicle drive assistance system and Electronic accessories 08. Compare electronics system with mechanical system, (5 marks) (Marks) ANSWER: S/N] Electronic system | Mechanical system 1 | Quick response 1. Less response 2 | Good appearance 2. Occupy high space 3 | Simple design 3. Complex design 4 | High efficiency 4. Low efficiency 5 | High precisely 5. Have many difficulties in operation 09, Indicate any five (5) possible faults of drive assistance {5 marks) systems. (5Marks) ANSWER: i. Open circuits. /1Mark ii, High resistance circuit/wires. /1Mark iii. Short circuits/wires. /1Mark iv. Burnt wiring. /1Mark v. Damaged insulation. /1Mark vi. Damaged connector. /1Mark vii. Terminal damaged. /1Mark viii, Frayed wires. /1Mark ix. Water and moisture. /1Mark 2022.NESA (National Examination and Schoo! Inspection Authority) 2)T161_ Vehicle drive assistance system and Electronic accessories 10. Use true of False to answer for the following statement: (4 marks) ‘The fault is checked with scanning vehicle by using scan . tool. 4 marks (a) Readout the fault code. (b) Collect further information. (c) Clear fault code. ANSWER: (a) Readout the fault code. True / 1 mark (b) Collect further information. True / 1 mark {c) Clear fault code. True / 1 mark 11. a) What is the function of cruise control system? (5 marks) (1Mark) ANSWER: It automatically keeps the vehicle at a speed set by the driver. D) Define the following terms: (4Marks) Drive assistance system Cruise control system ANSWER: (a) Drive assistance system: Driver assistance systems, also known as advanced driver assistance systems (ADAS), are designed to support drivers of cars and trucks in driving and thus increase road safety. /2Marks (b) Cruise control system: Is a device in a motor vehicle which can be switched ON to maintain a selected constant speed without the use of the accelerator pedal. Is set the cruise on mph (Kmh. /2Marks 2022-NESA (National Examination and School Inspection Authority) (wyT161_ve i ~ Vehicle drive assistance system and Electronic accessories 12. Enumerate three (3) Sub-systems of drive assistance (3 marks) system, system, (3Marks) ANSWER: i. Cruise control. /1Mark ii, Parking assistance, /1Mark iii.Seat, sun roof and mirrors. /1Mark 13, Outline six (6) components of vehicle mirror system. (3 marks) (3Marks) ANSWER: Glass mirror. /0.5 Mark ii. Motor. /0.5 Mark iii. Switch. /0.5 Mark iv. Controller unit. /0.5 Mark vi-Relay--/0:5 Mark vi. Mechanical linkages. /0.5 Mark 14. Explain at least five (5) test of vehicle drive assistance _—_(& marks) system. (SMarks) ANSWE! Step 1: Start the vehicle. Let it warm up to operating temperature. /1Mark Step 2: Check the codes. Plug in the diagnostic scanner and download any existing error codes or clear the codes that showed up initially. /1Mark Step 3: Drive your vehicle to a highway. Find a place where 0 to 15 minutes wi you can drive smoothly for at least 1 the cruise control on. /1Mark Step 4: 2022-NESA (National Examination and Schoo! Inspection Authority) joyT161_ Vehicle drive assistance system and Electronic accessories Set your cruise control at 55 or 65 MPH. Press the off it on the dash turns Dutton, and if the cruise control li off and the system shuts down, this button is working correctly. /1Mark | Step 5: Reset your cruise control. Once it is set, press the accel button to sce if the cruise control increases the speed of the vehicle. If it does, the switch is good. /1Mark Step 6: Test the coast button. While traveling at speed and with very little traffic on the road, press the coast button and determine if the throttle is disengaged. If it is, release the coast button and verify that the cruise control returns to its setting. /1Mark Step 7: Reset the cruise control again and drive for 10 to 15 miles. Verify that the cruise control does not shut off automatically. /1Mark 15. Demonstrate the first ten (5) procedures /steps of (5 marks) dismounting the drive assistance with cruise control system. (5Marks) ANSWER: Step 1: Disconnect the battery. /0.5 Mark Step 2: Remove steering wheel column bolt covers. /0.5 Mark Step 3: Remove the steering wheel column bolts. /0.5 Mark Step 4: Remove the center air bag cluster. /0.8 Mark Step 5: Remove the electrical connector from air bag cluster. /0.5 Mark Step 6: Remove the cruise control switch, /0.5 Mark Step 7: Disconnect the cruise control electrical harness. 2022.NESA (National Examination and Schoo! inspection Authority)T161_ Vehicle drive assistance system and Electronic accessories /0.5 Mark ‘Step 8: Repeat the above siep(s) with the other side cruise control switch. /0.5 Mark Step 9: Replace the old cruise control switch with the new one. /0.5 Mark Step 10: Reconnect the wiring harness to air bag cluster. /0.5 Mark Step 11: Reconnect the air bag cluster. /0.5 Mark Step 12: Replace the bolts on the steering column. /0.5 Mark Step 13: Replace the two plastic caps. /0.5 Mark Step 14: Reconnect battery cables. /0.5 MarkT161_ vehicle drive assistance system and Electronic accessories hicle si y: ‘ks} Section B: Attempt any Four (4) questions out of Six (6). (40 Mar! a) Mention down any four (4) tools, materials and (10 marks) * equipment required during repairing of drive assistance system. (6 Marks) ANSWER: Tools:4 Materials:4 Equipment elements clements=2marks | 4 sements =2marks nQuiazice i. Spanners Scotch/insulator |i. PPE ii, Terminal tips ii, Car with cleaner Lubricant driver iii. Screw iii, Fuses assistance driver _| iv. Relays systems | iv.Hummer — |v. wires and iii, Hand v. Pliers connectors scanner vi. Bench vise | vi. Seals iv. Multimeter ii, Pulley vii. Grease v. Indicator remover viii. Driver lamp tester fii. Jump start | assistance spare | vi. Computer cable parts with ix. Wire brush | ix. Jump starting software cable (AUTO- X. Silicon DATA/ ALL- DATA vii. Soldering gun viii, Battery load tester ix. Battery charger L x. Car lift zi 2022-NESA (National Examination ancl School Inspection Authority) ) (x)T1 61_ Vehicle driv, © assistance system and Electronic accessories b) Ment ) Mention any four (4) visual inspections in drive as ANSWER: istance system, (4Marks) i, Inspections of corrosions, /1Mark ii, Inspection of burned wire: . Mark iii. Inspection of leak connections, /1Mark iv. Inspections of surface discontinuities on joints. /1Mark v. Checking the overall visual appearance. vi. Inspection of loosen wires, /1Mark Inspection of broken devises. /1Mark Inspection burned wires, /1Mark 17. Draw and label a wiring diagram of car radio.(10 Marks) (10 marks) ANSWER: coca Awe vest ces L226 cuctorane ge Care Sit rennet axCurre hop are renee teteyoven © Merery+r2rHetattetne rip rarer] J oper] ot Inspection Authority) te nat Examination and 5: 2022-NBSA (Natio!‘cessorie: T161_vehicte drive assistance system and Electronic ac Ss : 10 18. a) Name the figure below and label its parts: (10 marks) (6 Marks) ANSWER: (a) Installation of rear camera in Parking Assistance System /1,.5Marks (b) Name the labelled parts from Ito 9. (1) Controller (2) Positive (+) wire from reverse light (3) Wire connector (4) Reverse light (5) Negative (-) wire from reverse light (6) Negative (-) controller power wire (blac (7) Positive (+) controller power wire (red) (8) Right sensor (9) Left sensor. /4.5 marks National Examination an, ‘ 2022.NESA (National £. Yon and Schoo! Inspection Authority) aT161_ Vehicle drive as: - rive sistance system and Electronic accessories b) What ar a =ooa components required for designing the ‘sun roof system? (4Marks) ANSWE! i. Control switch. /1Mark ii, Drive motor. /1Mark iii, Relay. /1Mark iv. Mechanical linkages. /1Mark v. Sun roof. /1Mark 19, Discuss on inputs /output of the cruise control system. _ (10 marks) (10 Marks) ANSWE! i. System on/off: If on, denotes that the cruise- control system should maintain the car speed. /1.5Mark ii, Engine on/off: If on, denotes that the car engine is turned on; the cruise-control system is only active if the engine is on. /1.5Mark el; A pulse is sent for every revolution of the wheel. /1.5Mark ication of how far the accelerator iii, Pulses from whee iv. Accelerator: Ind has been pressed. /1.5Mark vy. Brake: On when the brake is pressed; the cruise- control system temporarily reverts to manual control if the b: ase Speed: Increase or decrease the ake is pressed. /1Mark vi. Increase/Decre maintained speed; only applicable if the eruise- control system is on. /1Mark ‘it, Resume: Resume the last maintained speed; only applicable if the eruise-control system is on. /1Mark -2022.nESA {National Examination ancl School Inspection Authonty) (xiti)T161_ Vehicle drive assistance system and viii, Clock: Timing pulse every millisecond. /1Mark ‘There is ONE output from the system ‘Throttle: Digital value for the engineer throttles setting. /1Mark 20. Draw and describe an clectro-pneumatic Central locking system. — (10Marks) ANSWER: ‘and unlocking" Electro:pneumatic actuator /4 marks Schematic diagram of electro-pneumatic central locking system 1. This comprises an electrical control circuit and a pneumatic single-loop control circuit/2Marks 2. Electric control unit: This controls the pneumatic single-loop control circuit. When the key is turned in the door lock, a micro-switch is actuated. The control unit receives this signal and activate the pneumatic control unit of all other locks (electro-pneumatic control circuit) /2Marks 3. Pneumatic single-loop control circuit: This actuates the actuators by way of vacuum or pressure in a line. When the vehicle is unlocked for example, there is pressure in the line. When the vehicle is locked, there is vacuum pressure in the system, /2Marks 2022.NESA (National Examination and School Inspection Authority) Electronic accessories (10 marks) bie)8) Complete the torowing tastes inspecting power window swite identify the ways of — (10 marks] +h continuity between termi = (5Marks) ewich Specified Position value LZ 3-4 Continuity ANSWER: : Switch Tester ‘Specified Position _| connection to / value terminals number up| 13 Continuity uP 3-4 i—orr | TZ Continuity OFF 3-4 |__| Continuity | 1-2 DOWN 45 {| __t cation and Schoo! Inspection Authority) Pa 2022.NESA (National xaT161_ Vehicle drive assistance system and Electronic accessories N.B: If the continuity is not specified replace the switch b) Discuss about any five (5) examples of cruise switches which are mounted on the steering wheel in adaptive cruises control. (5Marks) ANSWER: The Cruise Switches are mounted on the steering wheel and have several buttons, which allow the driver to command operation of the ACC system. The switches include: i. 'On': Place system in the ‘ACC standby’ state. /1Mark ii. 'Off": Cancel ACC operation and place system in the 'ACC off state. /1Mark iii.'Set +': Activate ACC and establish set speed or accelerate. /1Mark iv. Coast’: Decelerate. /1Mark v. ‘Resume’: Resume to set speed. /1Mark vi. ‘Time Gap+': Increase gap. /1Mark vii, "Time gap~’: Decrease gap. /1Mark END OF MARKING GUIDES! 2022-NESA (National Examination and Schoo! Inspection Authority) ty (xvi)T160_ Automotive electrical starting and charging system AES- Automotive electrical starting and charging system T160 Wednesday, 27/7/2022 08:30 - 11:30 AM TVET NATIONAL EXAMINATION, RTQF LEVEL 5, 2021-2022 OPTION/TRADE: AUTOMOBILE ELECTRICITY AND ELECTRONICS SYSTEMS SUBJECT: Automotive electrical starting and charging system DURATION: 3 Hours INSTRUCTIONS TO CANDIDATES: PART II (QUESTION PAPER) This Exam paper is composed of Two Sections (A, B). Follow the instructions given below, and answer the indicated questions for a total of 100 Marks. Section A: Attempt all Fifteen (15) questions. (60 Marks} Section B: Attempt any Four (4) questions out of Six (6). (40 Marks) MARKING GUIDES 2022.NESA (National Examination and Schocl inspection Authority) @T160_ Automotive electrical starting and charging system (60 Marks) 01. What is the function of the following parts of an (5 marks) automotive starting system? (5 Marks) a) Starter solenoid b) Overrunning clutch ¢) Carbon brushes ANSWER: {a) Starter solenoid: The starter solenoid is a high- current relay. It makes an electrical connection between the battery and the starting motor. The starter solenoid is an electromagnetic switch (switch using electricity and magnetism for operation). /1.5 Marks (b) Overrunning clutch: The starter overrunning, clutch locks the pinion gear in one direction and releases it in the other. This allows the pinion gear to turn the flywheel ring gear for starting. It also lets the pinion gear freewheel when the engine begins to run. /1.5Marks (c) Carbon brushes: It is designed for forming a sliding electrical connection with the commutator. They are made from carbon for self-lubrication property. /2Marks 02. Choose the correct answer: (1Mark) (1 mark) Which of the following is not part of starter motor? {a) Armature (b) Field winding {c) Commutator (a) Slip ring ANSWE! (a) Slip ring /1Mark 2022-NESA (National Examination andl Schoo! Inspection Authority “9T160_ Automotive electrical starting and charging system 03, List the tools, materials and equipment that can be (3 marks) used during starting system repairing, (3Marks) ANSWER: Tools/ imark | Materials / | Equipment/ | mark mark | i i, Spanners i, Water i. Multi-meter | ii, Terminal ii. Lamp tester | ii. Oscilloscope cleaner iii. Grease . Battery ; iii. Screw driver _ | iv. Paper sand charger iv. Hummer v. Mark pen _| iv. Battery load | v. Pliers vi. Lubricants tester | vi.Bench vise | vii. Brushes | v. Computer vii. Pulley viii. Lamps with | remover: ix. Insulator software { viii. Jump start | taps (Auto data) | cable vi. PPE 1 ix. Wire brush | 04, a) Define charging system. (2.5 marks) (5 marks) i b) What are the purposes of charging system? ! Answe: a) Define charging system? Charging system is an automotive electrical system, which has the purpose of charging the battery and also supplies the vehicle load with electrical energy when the vehicle is running. (2.5 marks) b) What are the purposes of charging system? | Answer: The purpose of the charging system is to maintain the charge in the vehicle's battery, and to provide the main source of electrical energy while the engine is running. (2.5 marks} 2022-NESA (National Examination and Schoo! Inspection Authority) ei)T160_ Automotive electrical starting and charging system 05. Demonstrate the procedures of dismounting alternator (5 marks) from the vehicle. — ~ (Smarks) Answer: Disconnect battery. (1) When removing the old battery, remember to first disconnect the cables from the negative terminal, which is usually black and has a minus (-) sign then disconnect the cables from the positive terminal, which is usually red and has a plus (+) sign. Disconnect wires. (1) Disconnect all wires from the alternator Remove drive belt. (1) Remove the Alternator belt (Refer alternator belt removal procedure). Unbolt alternator. (1) Disconnect the electrical connection. Remove. (1) Loosen and remove the front mounting bolts 1 and the rear mounting bolt 2 to remove the Alternator 3 06. Write down at least six (6) external components that (5 marks) can be found on charging system. (Smarks) Answer: The external components of charging system. > Battery. / 1 mark > Ignition switch. / 1 mark Relay, / 1 mark Charging indicator lamp. / 1 mark Voltage regulator (sometimes). / 0.5 mark External wiring. / 0.5 mark vvvy 2028 TESA ational Examination and Shoo Inspection Authority) (ix)T160_ Automotive electrical starting and charging system 07. One of the charging system external wiring components of battery has 12V and the internal resistance of 249. Calculate the capacity of that battery when the time of charge is 54 hours. {3 marks) Answer: Data: Voltage=12V / 0.5 mark Resistance= 240 / 0,5 mark ‘Time=S4hrs / 0.5 mark Find: The capacity Solution: K = 1.t(0.5) =¥.¢ = 22.54 = 27AN(1) RS a6 ‘The capacity of that battery is 27AH 08. Calculate the power of direct current of alternator produced in 2 minutes which has the voltages of 28V while its resistance is 130. (4marks) Answer: Data: Voltage=28V 0.5 mark Resistance=13Q / 0.5 mark Time = 2min / 0.5 mark Find: Power Hint: P = R./°(0.5) = Ry (0.5) Solution: 1 = 4 (0.5) = = 2.14mp / 0.5 mark. P= R(¢) = 13.(2.1)? = 13.4.41 = 57.3watt(0.5) ‘The power of alternator is 57.3watts 09. By applying Ohm's low, find the resistance to diagnose the following condition that occurs to the charging system: external wiring of Toyota land cruiser V8, where alternator supplies low voltage of 11.5 volts and intensity of 15 amps at high speed due to voltage drop in system, (Smarks) 2022.NESA (National Examination and Schoo! Inspection Authority) (3 marks) (4 marks) (5 marks) ) |T160_ Automotive electrical starting and charging system Answer: — Data: Voltage=11.5V / 0.5 mark Current=15A / 0.5 mark Find: Resistance by using ohm’s low (1) 0.760(1) Solution: R = ¢ (1) 10. Justify any five (5) tests which can be carried outon —(5 marks) starter motor components. (5Marks) ANSWER: 1) Battery (at least 70%). /1Mark 2) Hand and eye checks. /1Mark 3) Battery volts (minimum 10 V), /1Mark 4) Solenoid leads (same as battery). /IMark 5) Starter voltage (no more than 0.5 V less than battery). /1Mark 6) Insulated line volt drop (maximum 0.25 V). /1Mark 7) Solenoid contacts volt drop (almost 0 V). /1Mark 8) Earth line volt drop (maximum 0.25 V). /1Mark 11. What is the maximum output voltage of an alternator (2 marks) on 12V system? (2 marks) Answer: The output voltage of alternator on 12V system range between 13,5V-14.5-9V, 12. List down any two (2) types of tools, material and equipment required to test and repair charging system. Answer: (3marks) Tools » Power tools. / 0.5 mark 2022.NESA (National Examination and Schoo! Inspection Authority) (3 marks) (vi)T160_ Automotive electrical starting and charging syste m > Measuring tools. / 0,5 mark Materials > Grease. / 0.5 mark > Lubricants. / 0.5 mark Equipment > PPE. / 0.5 mark > Diagnostic machine, / 0.5 mark 13. a) What are the main components of alternator? «(4 marks) (1mark) b) What are the types of alternator? (8marks) Answer: a) The main components of alternator are Rotor-/0.5 mark —— Stator/0.5 mark b)Types of alternator (Smarks) > Alternator with winding less rotor. (1) > Guide piece alternator with liquid cooling. (1) > Alternator with flat-pack winding. (1) 14. What are any five (5) parts required for designing of (5 marks) charging system? (5 marks) Answer: An Alternator consists of: a) Stator (housing) with three-phase stator winding as the induction coils. (1) b) Diode plate with 6 power diodes and 3 excitation diodes to rectify the voltage. (1) c) 12-poles, rotating claw pole rotor with excitation winding for generating the magnetic field and collector rings and carbon brushes for 2022.NESA (National Examination and Schoo! Inspection Authonty) (vitjT160_ Automotive electrical starting and charging system current supply. (1) d) Fan for cooling. (1) e) Voltage regulator for constant operating voltage. QQ) f) Connections B+/B- for voltage discharge. (1) g) A pulley for driving the alternator at a speed of 2- 3 times the engine speed. (1) 15. Alternator is said to be the main part of charging (3 marks) system and it handles all electrical loads by providing supply voltage to them, but before it does this it needs the excitation current, Prove that changing of indicator (telltale) lamp has important function in this situation. (3marks) Answer: ‘The telltale lamp is part of charging system that allows current to flow through it to the voltage regulator to make an excitation circuit in alternator. And when it fails this circuit will be generated. /3marks 2022. Xe '22-NESA (National Examination and School Inspection Authority) (itiT160_ Automotive electrical starting and charging system Section B: Attempt any Four (4) questions out of Six (6). (40 Marks) 16. Draw a net sketch of the simple starting system control (10 marks) circuit, (10Marks) ANSWER: Ignition ‘switch / Starter safaty sith motor 12022-NESA (National Examination and School Inspection Authority) fe)T160_ Automotive electrical starting and charging system 17. a) Explain the voltage drop test in starting system. (10 marks) (4Marks) ANSWER: i. A voltage drop test will assess voltage losses at the battery, the alternator and the starter. /1Mark. ii. The voltage drop test is performed while cracking the engine. /1Mark iii. The voltage drop test across a cable, components, or connections resistance reduces voltages. /1Mark iv. Voltage drop tests can isolate unwanted high resistance in the charging system. /1Mark b) Mention six (6) major steps to be followed in ebuilding starter motor. (6Marks) SWE) i. Fix brush holder. /1Mark ii, Mount armature with commutator into brush holder. /1Mark iii. Mount engagement lever into spring with overrunning clutch. /1Mark iv. Install starter housing. /1Mark v. Fix solenoid switch and electrical connector. /1Mark vi. Tighten long bolt into starter housing, /1Mark 2022-NESA (National Examination and Schoo! inspection Authority) tsT1 60_ Automotive electrical starting and charging system 18. Design and compare the symbols of stator winding (10 marks) internal connections circuit. (10marks) OO Answer: * Most AC generators use three stator windings yn ine (4 marks) Star or (Wye) connection. | Delta connection. / 0.5 /1 mark mark These windings allow These windings allow for a higher voltage at lower —_| higher current flow at RPM.. /1 mark lower RPM... /1 mark Has 4 connections (3 Has only 3 stator leads leads and neutral ends.. /1 mark junction)... /1 mark 19, Explain any four (4) inspections which can be performed (10 marks) on diagnosing of an alternator. (10 marks) Answer: Inspect the following parts for wear and damage: A, BRUSH/REGULATOR ASSEMBLY - inspect for cracked casing, damaged brush leads, poor brush leads solder connections, weak or broken brush 2022-NESA (National Exarnination and Schoo! Inspection Authority) tx)T160_ automotive electrical starting and charging system springs or worn brushes. Replace brush set if brushes are less than 1/4 in. (6 mm) long. / 2 marks B, ROTOR - inspect for stripped threads, scuffed pole piece fingers or damaged bearing surfaces (Because of bearing turning on shaft). / 2marks ©. Rotor-Slip Rings ~ clean slip rings with 400 grain (or finer) polishing cloth while spinning rotor in a lathe. Blow off dust with compressed air. Inspect slip rings for grooves, pits, flat Spots or out-of-round [.002 in. (0.051 mm) maximum| and replace rotor, if present. / 2 marks D, ROTOR SHAFT AND FRONT END BEARINGS — inspect for damaged seals, lack of lubrication, discoloration (from overheating) and excessive side or end play. Bearing should turn freely without binding or evidence of rough spots. / 2 marks E, STATOR - inspect for damaged insulation or wires; also inspect insulating enamel for heat discoloration, as this is usually a sign of a shorted or grounded winding or a shorted diode. / 2 marks F. FRONT AND REAR END FRAMES ~ inspect for cracks, distortion, stripped threads or wear in bearing bore (from bearing outer race spinning in bore). End frame(s) MUST BE replaced, if bearing has spun. Also, inspect bearing retainer recess in front end frame for damage. / 2 marks 2022-NESA (National Examination and Sehoo! Inspection Authority) xt)T160_ Automotive electrical starting and charging system ~ G FAN TS,- - inspect for cracked or bent fins, broken welds (bi- rotational fan only) or worn mounting hole (from fan spinning on shaft). / 2 marks H. PULLEY - inspect pulley mounting bore end for wear. Inspect drive surface of pulley sheaves for trueness, excessive wear, grooves, pits, nicks and corrosion. Repair damaged surfaces, if possible, with a fine file and a wire brush or replace pulley, if beyond repair. Drive surfaces must be perfectly true and smooth or drive belt wear will be greatly accelerated. / 2 marks 20. Design a simple electrical schematic of alternator (10 marks) operation and label its parts. (10marks) B Brushes Hm gabgcien oe Rotor Slip Rings wa Stator Coils Three Phase AC Out ELECTRICAL SCHEMATIC OF ‘ATYPICAL ALTERNATOR 21. Label the parts of the figure below: (10Marks) (10 marks) 2022-NESA (National Examination and Schoo! inspection Authority) (xitiptem T160_ Automotive electrical starting and charging syste! un 2022.NE: 2 2 8 4 END OF MARKING GUIDES! 'SA (National Examination andl Schoo! In 3 . ANSWER: contac se pe ew mex, wince 5 ——— Conta Onmnning Brushes armature ~ (Only 10 elements are enough) sspection Authority) (xiv)T162_ Vehicle electronics stability and signaling system AES- Vehicle electronics stability and signaling system T162 Monday, 01/8/2022 08:30 - 11:30 AM TVET NATIONAL EXAMINATION, RTQF LEVEL 5, 2021-2022 OPTION/TRADE: AUTOMOBILE ELECTRICITY AND ELECTRONICS SYSTEMS SUBJECT: Vehicle electronics stability and signaling system DURATION: 3 Hours INSTRUCTIONS TO CANDIDATES: PART II (QUESTION PAPER) ‘This Exam paper is composed of Two Sections (A, B). Follow the instructions given below, and answer the indicated questions for a total of 100 Marks. Section A: Attempt all Fifteen (15) questions. (60 Marks) Section B: Attempt any Four (4) questions out of Six (6). (40 Marks) MARKING GUIDES 2022-NESA (National Examination and School Inspection Authority) “T162_ Vehicle electronics stability and signaling system 01. Define the following systems: a) vehicle electronic stability control system b) Antilock brake system Answer: a, vehicle electronic stability control system: Electronic stability control (ESC) is a computerized technology (active safety system) that improves a vehicle's stability by detecting and reducing the risk of a driver losing control of the vehicle when it skids, swerves suddenly or when road conditions change. /2marks b. Antilock brake system: It is an electronic system/ automobile safety system which monitor and control the skidding of the vehicle during breaking and prevent the wheels from locking while braking. ABS allows the driver to maintain steering control while braking and shorten braking distances on slippery surfaces like wet or icy surfaces. But it increases the stopping distances in simple surfaces. /2marks 02, What is the working principle of Antilock brake system? /4 marks Answer: When the pedal is pressed, the liquid is forced along the pipe lines to the wheel cylinders. ‘The skidding and lack of control was caused by the locking of wheels. When whcel stops/locks due to brake oil pressurized, Speed Sensor sends signal to BCU. ECU Sends signal to Pump and Solenoid valve to stop brake fluid flow and release pressure on wheel by return the brake fluid through the return line. ‘The release and reapply of the brake pedal will avoid the locking of the wheels which in turn avoid the skidding. 03, What are three (3) purpose of electronic controlled suspension system? /3 marks Answer: a) Adjust shock stiffness depending on conditions b) Change settings to firm for cornering ¢) Selects soft for cruising 2022-NNESA (National Examination and School Inspection Authority) co) Section A: Attempt all Fifteen (15) questions. - (60 Marks) (4 marks) (3 marks)T162_ vehicle electronics stability and signaling system 04. List at least five (5) parts of ABS that are inspected during (5 marks) conduction of visual inspection. /5 marks Answer: i, Check the master cylinder fluid level. /1 mark ii, Inspect all brake hoses, lines, and fittings for signs of damage, deterioration, and leakage. /1 mark iii, Inspect the hydraulic modulator unit for any leaks or wiring damage. /1 mark iv. Inspect the brake components at all four wheels. Make sure that no brake drag exists and that all brakes react normally when they are applied. /1 marke v. Inspect for worn or damaged wheel bearings that may allow a wheel to wobble. /1 mark vi. Check the alignment and operation of the outer CV joints. /. mark vii. Make sure the tires meet the legal tread depth /1 mark requirements and that they are the correct size. /1 mark viii, Inspect all electrical connections for signs of corrosion; damage; fraying-and— aa disconnection, /1 mark ix, Inspect the wheel-speed sensors and their wiring. Check the air gaps between the sensor and ring, and make sure these gaps are within the specified range. Also check the mounting of the sensors and the condition of the toothed ring and wiring to the sensor. /1 mark 05. Use True or False for answering the following statement: (8 marks) /3 marks When brakes begin to lock, an ABS kicks in...... Brake pedal will drop to floor. b) Brake pedal may have a pulsating feel. c) Brake pedal will become much timer. Answer: a) Brake pedal will drop to floor ‘True /Amark b) Brake pedal may have a pulsating feel False /.mark ©) Brake pedal will become much timer False /Amark 06. What are the procedures to follow during removing (4 marks) headlight? eed (National Examination and School Inspection Authority)T162_ vehicle electronics stability and signaling system ANSWER: (4Marks) ee power your car down mart) _—_____— — ¥ open engine compartment (1mar] ; Y Disconnect the headlight bulb power wires (Imark) ¥ Unscrew the old headlight (1mark) ¥ Screw in the new headlight bulb (1mark) 07. Classify three (3) types of reflectors used in headlight {3 marks) system, ANSWER: (3Marks) Y Headlight systems with paraboloid reflectors (1Mark) Y Headlight systems with ellipsoid-shaped reflectors (1Mark) Y Headlight systems with freeform reflectors{1Mark) 08. a) State four (4) inert gases used in gas discharge (5 marks) bulbs. (2Marks) ANSWER: Argon /05 Mark Neon /05 Mark krypton/05 Mark and xenon /O5 Mark b) Differentiate single wire from dual wires light bulbs /3marks ANSWER:Single wire bulb | Dual wire bulb One filament in one bulb Two filaments in one (1.5mark) bulb(1.Smark) 09. Identify any eight (8) information of report of achieved (4 marks) work, /4marks Answer: i, customer information /0.5 mark vehicle identification /0.5 mark iii, service history of the vehicle /0.5 mark. iv. customer's complaint /0.5 mark v. preliminary diagnosis of the problem /0.5 mark vi. estimated amount of the time required for service/0.5 mark vii, estimated costs of the /0.5 mark viii, time the services should be completed /0.5 mark fig MESA (National Examination and Schoo! Inspection Authority) in) Parts involved in the serviceT1 62_ Vehicle electronics stability and signaling system The name or other identification of the techni x assigned to perform the services/0.5 mark mean * .ctual services performed with their cost /0.5 mark parts replaced during the services /0.5 mark Recommendations for future services /O.5 mark total cost of the services /0.5 mark 10. Mention any five (5) visual ° system pected ie ae for Antilock brake (5 marks) Answer: i, Improper battery voltage. /1 mark ii, Check the master cylinder fluid level. /1 mark iii. Inspect all brake hoses, lines, and fittings for signs _ of damage, deterioration, and leakage. /1 marke iv. Inspect the hydraulic modulator unit for any leaks or wiring damage. /1 mark v. Inspect the brake components at all four wheels Make sure that no brake drag exists and that all brakes react normally when they are applied. /1 mark __ vi. Inspect for worn-or damaged wheel bearings that may allow a wheel to wobble. /1 mark vii, Make sure the tires meet the legal tread depth requirements and that they are the correct size. /1 mark viii, Inspect all electrical connections for signs of corrosion, damage, fraying, and disconnection. /1 mark ix. Inspect the wheel-speed sensors and their wiring. Check the air gaps between the sensor and ring, and make sure these gaps are within the specified range. /1 mark ‘Also check the mounting of the sensors and the condition of the toothed | /1 mark xi. ring and wiring to the sensor. /1 mark Check the condition of the brake pads and rotor. /1 mark x. xii, 11. List down three (3) methods used to control tractive force, (3 marks) /3 marks Answer: + Throttle valve (throttle valve adjustment) controls/1 mark + Ignition system (ignition timini retard) control/1 mark «Braking effect/1 mark g advance or 12. Identify any four (4) basic components that are shared by (4 marks) 2022-NESA (National Examination and School Inspection () Authority)T162_ Vehicle electronics stability and signaling system traction control system and anti-lock brake systems? /4-marks. Answer: Wheel speed sensor/ Imark Hydraulic modulator assembly /1mark k Pump and high pressure accumulator/ Imari Power control module/Body control module/ABS controller depend on vehicle year and model/1mark * Brake system assembly/1 mark 13. Explain an operating principle of hazard warning signal. (3 marks) ANSWER: ¥ Turn signal flashing operation: The flasher receives battery power via a fuse, the ignition switch and normally closed hazard warning switch contact. (1.5Marks) Y Hazard warning operation: flasher receives power directly from the battery, via a fuse and hazard warning switch contacts. (1.5Marks) 14. Describe the following terms: L a) Four-channel anti-lock brake system configuration b) Three-channel anti-lock brake system configuration Answer: /5 marks FOUR-CHANNEL ABS SYSTEMS /2.5 marks Each wheel is equipped with its own speed sensor and each wheel speed sensor provides input for a separate hydraulic control circuit or channel for that wheel. For vehicle stability systems to function, there has to be four-wheel speed sensors and four channels so the hydraulic control unit can pulse individual wheel brakes to help achieve vehicle stability. THREE-CHANNEL ABS SYSTEMS /2.5 marks In this type of configuration, ABS systems have a separate wheel speed sensor for each front wheel but use a common speed sensor for both rear (vi) wheels, ‘The rear wheel speed sensor is mounted in either the differential or the transmission. The sensor reads the combined or average speed of both rear wheels. This type of setup saves the cost for an additional sensor and reduces t allowing he complexity of the system by both rear wheels to be controlled simultancously, ‘Three-channel systems ar 2022-NESA (National Exa e the most common type ‘mination and School Inspection Authority) (3 marks) (5 marks)T162_Vehicte electronics stability and signaling system of ABS setup used on rear-wheel-drive applications. ao (5 marks) Answer: Antilock brake system /1 mark b) Indicate the name of above components. Answer: 1. Master cylinder /0.5 mark 2.Brake booster /0.5 mark 3.ABS ECU/0.5 mark 4.Rear Wheels /0.5 mark 5.Load valve /0.5 mark 6. Rear ¥ 0.5 mark 7.Wheel speed sensor /0.5 mark 8.Hydraulic modulator /0.5 mark r (4) questions out of Six (6). (40 Marks| ard warning circuit by Using the (10 marks) tery, ignition switch, hazard her, turn switch and turn, given components: (1 switch, turn signal F lamps: (10 Marks) ANSWER: 2022-NESA (Natonal Examination and Schoo! Inspection Authority) (vit)T162_ Vehicle electronics stability and signaling system Ainguith —azardswich Tunsiged Tums Tunlarps 17, Discuss on five (5) components of electronic power (10 marks) steering control systems and give their roles? /10 marks Answer: i, Torque sensor: The torque sensor detects and measures: the direction of rotation of the steering whcel and the torque applied by the driver. /2 marks ii, ECU: performs calculations on assisting force based on signals from the torque sensor, /2 marks iii, Electric motor: produces turning force according to output from the ECU. /2 marks iv. Reduction gear: increases the turning force from the motor and transfers it to the steering mechanism. /2 marks v. Vehicle speed sensor: The vehicle speed must be used to adjust the sensitivity of the torque controller. /2 marks vi. Rotational angle sensor: The angle of rotation of the steering wheel must also be used to adjust the sensitivity and the performance around the null position of the steering wheel. /2 marks 18. Using a table to compare conventional hydraulic {10 marks) brake system to Antilock brake system? /10 marks Answe: HYDRAULIC BRAKE | ABS SYSTEM (1.Use “tandem master | 1.Us hydraulic | 2022.NESA (National Examination and Schoot Inspection Authorit aa id Schoo! Inspection Authority)T162_vehicte etectro; le et nics stability and signaling system cylinder /1 mark modulator /1 mark 2.No sensors need 1 ark 2.Use sensors /1 mark 3.No ECU /1 mark 3.Use the ABS Control unit /1 mark 4. No actuators need 10.5 mark ae actuators/0.5 5.No self-diagnosis |5.Selfdiagnosis _/0.5 system /0.5 mark mark 6.Low maintenance /0.5 6.High mai o Low igh maintenance /0.5 mark 7.Low cost /0.5 mark 7.High cost /0.5 mark 19. a) Mention the procedures of testing an installed solenoid valve operation of the electronic suspension control system. /6.5 marks Answer: Solenoid Valve Test After installing a solenoid valve, perform the following test procedure: Start the engine. /1.5 marks Wait until the system is fully charged. /1 mark Press the “Normal” button on the remote control to fill the air bags. This will place the Electronic Controlled Air Suspension at normal level. /1 mark ‘Turn the ignition to the OFF position. /1 mark Listen for leaks at the solenoid valve air line connections. /1mark Use the remote control to raise and lower the Vehicle height, checking for correct operation/1 mark ‘b) Determine al malfunction steering that has bec t least seven (7) causes of the ‘electrical and electronic power ome too stiff. /3.S5marks Answer: i Torque sensor. /0.5 mark ii, Vehicle Speed sensor /0.5 marke ii, Temperature sensor on the EPS units/0.5 mark jv. Speed sensors mounted on the gearbox. /0.5 ark vy. EPS control unit /0.5 marke iL Interconnections with the injection & ignition pnd/or ABS control units /0.5 mark vii, steering assistance motor /0.5 marke 2022.NESA (National Examination and Schoo! Inspection Authority) fi) (10 marks}7T162_ Vehicle electronics stability and signaling system 20. ABS warning light remains ON during vehicle travel: (10 marks) Propose any four (4) possible causes and their corrections for that waring. /10 marks Corrections L.Wheel sensor or | 1.Replace sensor /1.5 associated wiring open | marks cireuit/high resistance. /1.5 marks 2.Wheel sensor air gap|2.Adjust the air gap incorrect./1.5 marks 11.5 marks 3.Power supply/earth to|3.Check and connect ECU low or not present. | supply/earth to control /1 mark module /1 mark 4. ABS system fault./1|4.Check the ABS fault mark and correct /1 mark 21. _a) Determine at least eight (8) possible causes of ___(10 marks) Traction control inoperative. /8 marks Answer: i. loss of a signal from a wheel speed sensor /1 mark Switch open circuit ABS system fault /1 mark Pump fail to run (faulty pump relay, bad wiring connection, fault pump relay fuse etc.) /1 mark iv. High pressure accumulator leakage /1 mark v, Faulty solenoid valves in the TCS/ABS modulator assembly (The problem may be mechanical or electrical) /Imark vi. Module fault /Imark vii. Communication errors between the TCS/ABS module and PCM or BCM /1mark vii, Throttle actuator inoperative or open circuit connections /1mark b) Discuss why it is necessary to report an achieved work. /2 marks Answer: Report is important because they keep important information about what happens in a workplace. Reporting is also essential to monitor work performance over any period of time. It enables you to make better business decisions, project future results and drive improvements. 2022-NESA (National Exay tx amination and School inspection Authority)T162_Vehicte electronics Stability and signaling system As a support worker, you will ite reports cea you will have to write rep. “People -you take care of and about what — happens at work. /2 marks — END OF MARKING GUIDES! 2022.NESA (National Examination and School Inspection Authority) ip° o tee PA T159_ Automotive engine and auxiliaries systems a vA 20 Ca AES & ATC- Automotive engine and auxiliaries systems T159 ‘Tuesday, 26/7/2022 08:30 - 11:30 AM ‘TVET NATIONAL EXAMINATION, RTQF LEVEL 5, 2021-2022 OPTIONS/TRADES: AUTOMOBILE ELECTRICITY AND ELECTRONICS SYSTEMS AUTOMOTIVE TRANSMISSION AND CONTROL SYSTEMS SUBJECT: Automotive engine and auxiliaries systems DURATION: 3 Hours INSTRUCTIONS TO CANDIDATES: PART II (QUESTION PAPER) ‘This Exam paper is composed of Two Sections (A, B). Follow the instructions given below, and answer the indicated questions for a total of 100 Marks. Section A: Attempt all Fifteen (15) questions. (60 Marks) Section B: Attempt any Four (4) questions out of Six (6). (40 Marks) MARKING GUIDES 2022-NESA (National Examination and School Inspection Authority) “)T159_ Automotive engine and auxiliaries systems Section A: Attempt all Fifteen (15) questions. (60 Marks) 01. — State at least three (3) tools and equipment used during exhaust (3 mari system repairing. /3Marks Answer: Tools Equipment ‘Spanners/0.5mark Overall /0.5mark Pliers/0.Smark Gloves/0.5mark Repair manual Safety boots//0.Smark service/0.Smark 02. Explain five (5) strategies used for reducing pollutant in exhaust (5 marks system, /Smarks Answer : + Suitable engine design: Optimization of combustion chamber and compression ratio. /Imark * Type and quality of mixture formation: Exterior/interior mixture formation, homogeneous mixture; stratified charge./ Imark * Exhaust-gas recirculation: Internal by valve overlap; external by exhaust-gas recirculation system, /Imark + Engine-management system: Map-controlled ignition and fuel injection, overrun fuel cut-off, boost-pressure control; checking function of exhaust-gas-relevant components, e.g. lambda sensors, catalyst. /Imark * Turbocharger with charge-air cooling: Increase in power output per litre with simultaneous reduction of peak combustion-chamber temperature. This reduces the formation of NOx. /Imark 03. a) List down any four (4) stresses on the exhaust system are (4 marks) exposed /2marks b) Outline any two (2) functions of cooling system in internal combustion engine 2marks Answer Y To heat the engine quickly to optimal operating temperature and 1 Y To dissipate excess heat during engine operation. 1 Answer: High temperature /0.5 mark External corrosion /0.5 mark Internal corrosion /0.5 mark Strong mechanical stresses to the exhaust system caused by a stone impacts body /0.5 mark 5. The individual components are manufactured from a variety PONE 2022-NESA (National Examination and School Inspection Authority) (ii)T159_ Automotive engine and auxiliaries systems 04. _05.—List down-five (5}-steps of dismantling exhaust system:/Smarks 06. 07. 2022-NESA (Nation of materials in order to withstand these stresses. /0.5 mark What are the functions eee aaa of the following exhaust system components? (4 marks) a) Catalytic converter/2marks b) EGR valve/2marks Answer: a) Catalytic converter: /2marks The catalytic converter is a device placed in the exhaust pipe, which converts hydrocarbons, carbon monoxide, and NOx into less harmful gases by using a combination of platinum, palladium and rhodium as catalysts. b) EGR VALVE: /2marks ‘The main purpose of the exhaust gas recirculation valve (EGR) valve is to allow a small amount of exhaust gas to enter into the intake system, this dilutes the air/fuel mixture so as to decrease the combustion chamber temperature (5 marks) ‘Answer: Remove the accessories (EGR, turbocharger, Lambda sensor, Heat shields) /Imarle ii, Unscrew the exhaust manifold bolts /Imark Remove the exhaust manifold gasket /Imark Remove the exhaust manifold mountings from chassis /Imark Remove the exhaust manifold system/1mark Define the following terms: (3Marks) (3 marks) a) Air-fuel ratio b) Rich mixture ¢) weak mixture ANSWER: a, The Air-Fuel Ratio is the proportion of air and fuel, by weight, supplied to the engines cylinders. /1Mark ‘b. Rich mixture: It is a mixture that contains a little more (too much) fuel mixed with the available air. /1Mark ¢. Weak mixture: It is a mixture that contains a large amount of air for the available fuel. /1Mark Match the following parts of fuel system on the right with their {5 marks) functions: (5Marks) Functions Parts of fuel supply | al Examination and School Inspection Authority) atT159_ Automotive engine and auxiliaries systems 08. 09. 2022.NESA (Wa system a) Stores fuel T. Fuel filter b) Cleans the fuel 2. Fuel injection ©} Supplies fuel to nozzle injection pump 3. Fuel injection 4) Times, measures, and pumps sure at low delivers fuel pressure. 4, Fuel tank under pressure to 5. Fuel transfer pump injection nozzles 6. Unit injector e) Atomizes and combustion distributes fuel evenly chamber into. 1) Performs functions of both the injection pump and nozzle as one unit. ANSWER: > ad vvvvyv 9) p05: nea Answer the following statement by selecting the correct word from (4 marks) brackets: (4Marks) a) A (primary, secondary) filter is located on the suction side of the transfer pump, /1 mark b) The (primary, secondary) filter is usually the final filter. /1 mark ¢) Disposable filters are (easy, difficult) to change. /1 mark 4) A water separator separates water by (gravity, pumps). /1 mark ANSWER: a~-Primary, b-- Secondary, c-Easy, d-- Gravity Outline any four (4) functions of lubricating system in internal (2 marks) combustion engine. 2 marks Answer ¥ To cool 0.5 Y Lubricate 0.5 tional Examination and Schoo! Inspection Authority) )T159_ Automotive engine and auxiliaries systems 10. 11. 12. 2022-NESA (National Examination and Schoo! Inspection Authority) Y Clean 0.5 Y Seal 0.5 Y Protect against corrosion 0.5 v Damp engine noise 0.5 a) Choose the harmless gas among the following gases: /1 mark —_ (5 marks) i Carbon monoxide (CO). ii, Hydrocarbons (HCs). iii, Particulate matter (PM). iv. Oxygen (02) Answer: iv) Oxygen (02) /1 marks b) Indicate four (4) engine's oil pollution. 4 marks Answer 1, Temperature_/1 mark ___ 2. Dust /1 mark 3. Metal particles /1 mark 4. Carbon deposit /1 mark Justify why Air flow is more useful more than air pressure. 3 marks (3 marks) Answer ‘Airflow refers to the amount of moving air around a given space or ‘area. It is created by the natural means of wind and circulation, or it gan be created artificially by the mechanical means of a fan or blower unit. BUT the air around you has weight, and it presses against everything it touches, That pressure is called atmospheric pressure, or air pressure. It is the force exerted on a surface by the air above it as gravity pulls it to Earth. Discuss about possible causes of replacing water pump 5 marks {5 marks) Answer ‘Awater pump must be replaced when one of its parts has damaged. ‘The water pump doesn't need to be changed in regular mileage intervals. It must be inspected during regular services and replaced if it's bad or shows early signs of failing. In some cases a water pump is replaced as a precaution; for example, ©T159_ Automotive engine and auxiliaries systems 13. 14, 15. when changing the timing belt, or when it's suspected to cause __ overheating or in cars that are known for water pump failures. — In an average car a water pump lasts for 100,000-150,000 miles, although it can fail prematurely. How would you adjusting manually the tension of belt? 5 marks (5 marks) Answer 1. Locate the pulley /0.5 mark 2. Use a ruler to find the mid-point on the belt's longest run between pulleys /0.5 mark 3. See how much it deflect at the center of the run 1 4, To tighten the bet, lever he generator outward with a piece of wood or tubing 1 5. Loosen the pivot bolts on the generator, then on the adjuster strap 1 a 6. Hold the alternator steady and check the tension. When it is correct retighten the bolts. 1 Suggest the procedures of replacing timing belt. 4 marks (4 marks} Answer STEP 1: align timing marks / 0.5 mark STEP 2: Place the new belt over the pulleys. / 0.5 mark STEP 3: Loosen the tensioner adjustment bolt slowly. / 0.5 mark STEP 4: Rotate crankshaft (in the direction of normal rotation) at least two complete turns to remove any slack in the belt and to allow the tecth of the belt to seat themselves perfectly in the pulley grooves. / 0.5 mark STEP 5: Loosen the tensioner and re-tension the belt according to the vehicle manufacturer’s recommendations. / 0.5 mark STEP 6: Reinstall all of the parts that were removed. / 0.5 mark STEP 7: Reconnect the battery earth cable. / 0.8 mark STEP 8: start the engine, check the ignition timing and make any necessary adjustments, / 0.5 mark Match the below types of filters on the right with the correct stages of (8 marks) fuel filtration on typical diesel fuel system: Stages of filtration | Types of filter a. First stage 1, Secondary filter b. Second stage 2. Primary filter ©. Third stage 3. Filter screen TEST DF-35 ANSWER: 71 mark 1 mark 2022-NESA (National Examination and School Inspection Authority) wo_—— 16. 17 2022-NESA (National Examinat Section Attempt any Four (4) questions out of Six (6). (40 Marks With help of P of neat sketch, explain how exhaust gas recirculation reduce pollutants emissions. /10 marks Answer: Electrically,” ‘control ‘oxhoust-qos: recirculation valve Exhaust ECU. Position . Teed / oF 4 Tomporatuia Sy [tester Rotational + + spond Load External exhaust-gas recirculation involves a portion of the exhaust gas being removed shortly after the exhaust manifold and being remixed with the fuel-air mixture in the intake manifold, Exhaust-gas recirculation reduces the charge of fuel-air mixture supplied to the cylinders. The combustion temperature is reduced since the recirculated exhaustgas components are no longer able to take part in combustion. In this way, significantly fewer nitrogen oxides are formed during combustion (up to 40%). As the exhaust-gas recirculation rate rises, both the content of unburnt HC compounds and the fuel consumption increase. ‘After treatment of exhaust gases in catalyst: The exhaust gases are subjected to after treatment in order to convert the pollutants created during combustion after they have left the combustion chamber ely or partially into harmless substances. complet tem components from the Organize the following lubricating syst a) ig components: Oil pump, Oil start of oil delivery to the Iubricatin} filter, Oil strainer, Relief valve, by pass valve and oil pan. 6 tion and School inspection Authority) (10 marks) (10 marks) (vii)T159_ Automotive engine and auxiliaries systems marks Answer 1. Oil pan 1 Oil strainer 1 Oil pump 1 Relief valve 1 Oil filter 1 aA en By pass valve 1 b) Justify the factors of selecting engine oil. 4 marks Answer 1. Function: What Does the Lubricant Do? 1 2, Ingredients: What's in the Lubricant? 1 3. Ease of Use: Not alll oils are applied the same way. The method of application will depend on your particular equipment 1 4. Cost: As with most things in life, you get what you pay for 1 18. Design a forced feed lubricating system diagram which consists of the following equipment: Oil pump, Oil filter, Oil strainer, Relief valve, overflow valve, Oil pan, oil gallery and lubricating points. 10 marks Answer: 2022-NESA (National Examination and School Inspection Authority) (10 marks) (wittyT159_ Automotive engine and auxiliaries systems 4 | k 19, Create the steps of engine oil draining and oil filter replacement. /10 (10 marks} marks Answer Step 1: always make sure the vehicle is positioned safely on a lift or supported by jack stands before working under it /1 mark Step 2: place the oil drain pan under the drain plug before beginning to drain the oil. /1 mark Step 3: loosen the drain plug with the appropriate wrench. After the drain plug is loosened, quickly remove it so the oil can frecly drain from the oil pan /1 mark Step 4: make sure the drain pan is positioned so it can catch all of the oil /1 mark StepS: while the oil is draining, use an oil filter wrench to loosen and remove the oil filter /1 mark Step 6: make sure the oil filter seal came off with the filter. Then place the filter into the drain pan so it can drain. After it has completely drained, discard the filter according to local regulations /0.§ mark Step 7: wipe off the oil filter sealing area on the engine block, Then apply a coat of clean engine oil onto the new /0.5 mark 2022-NESA (National Examination and School Inspection Authority) feT159_ Automotive engine and auxttartes systems 20. Step 8: tightened acs Install the new filter it, Oil filters should be nd hand-tighte ‘ording to the direction given on the filter /0.5 mark Step 9: prior to install the drain plug, wipe off its threads and se nrag /0.5 mark surfa with ac Step 10: tighten the drain plug according to the manufacture’s recommendations. /0,5 mark Step 11: with the oil filte and remove the oil filler cap. /0.5- mark and drain plug installed, lower the vehicle Step 12: carefully pour th oil into the engine. The use of a funnel usually keeps oil from pilling on the engine, /0.5. mark Step 13: after the recommended amount of oil has been put in the engine chi kc the oil level. /0.5 mark Step 14: start the engine and allow it to reach normal operating temperature. While the engine is running /0.5. mark Step 1 correct it as nec iter the engine has been turned off recheck the oil level and ary. /0.5 mark Demonstrate how to check leakages on cooling system using Cooling system pressure tester. /10 marks Answer a) Pressure testing the cooling system is a simple process to determine where a Icak is located, ‘This test is only performed after the cooling system has cooled sufficiently to allow you to safely remove the pressure cap. Once you are sure that the cooling system is full of coolant, a cooling system pressure tester is attached in place of the radiator cap. /2 marks ») The tester is than pumped to build up pressure in the system. 2022-NESA (National Examination and Schoo! Inspection Authority) (10 marks) tx)T159_ Automotive engine and auxiliaries systems ‘There is a gauge on the tester indicating how much pressure is being pumped; You should-pump it-to-the pressure indicated-on ; = the pressure cap or to manufacturer's specs. /2 ©) Once pressure is applied, you can begin to-look for leaks, Also watch the gauge on the tester to see if it loses pressure. If the pressure drops more than a couple of pounds in two minutes, there is likely a leak somewhere that may be hidden. /2 marks d) It is not always easy to see where a leak is originating from. It is best to have the vehicle up on a lift so you can look over everything with a shop light or flashlight. /2 marks @) Ifthe heater core in leaking, it may not be visible since the core is enclosed and not visible without major disassembly, but one sure sign is the unmistakable odor of antifreeze inside the car. You may also notice the windshield steaming up with an oily residue. /2 marks 21. The following are the steps/procedures of testing exhaust gas: Arrange (10 marks) the first ten (10) orders of them. /10 MARKS i, Enter data of the vehicle in the machine ii, make the leakage test for checking the leakage of the machine iii, Put gas in put probe into exhaust system iv. read the displayed data on the machine v. Connect the testing machine to the vehicle to be tested vi. Connect the testing machine to the power supply and switch it on. vii. Wait for the machine to warm up. vii, _print the data displayed ix, Remove gas in put probe x. Disconnect the machine to the vehicle xi, Switch off the machine and lean the machine xii. approach the vehicle at the test station where the electrical power supply is available /1mark xiii. check the state of exhaust gases analyzer xiv, Ensure that the vehicle is not free of motion (block the 2022-NESA (National Examination and School Inspection Authority) bei)T159_ Automotive engine and auxiliaries systems wheel) Answer: i, -approach the vehicle at the test station where the electrical power supply is available /Imark ii. check the state of exhaust gases analyzer /1mark ili, Ensure that the vehicle is not free of motion (block the wheel) /imark iv, Connect the testing machine to the vehicle to be tested /1mark v. Connect the testing machine to the power supply and switch it on. mark vi, Wait for the machine to warm up. /1mark vii, Enter data of the vehicle in the machine / mark viii make the leakage test for checking the leakage of the machine [1mark ix. Put gas in put probe into exhaust system/ mark X. read the displayed data on the machine / mark xi. print the data displayed /1mark xii. Remove gas in put probe mark xiii, Disconnect the machine to the vehicle / mark xiv. ‘Switch off the machine and lean the machine /Imark END OF MARKING GUIDES! 2022. NESA National Examination and Schoo! inspec ne ction Authority) (xii)