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T1010(E)(N17)T NOVEMBER EXAMINATION

NATIONAL CERTIFICATE

MOTOR TRADE THEORY N1

(11040651)

17 November 2016 (X-Paper) 09:00–12:00

Calculators may be used.

This question paper consists of 6 pages and 4 diagram sheets.

(11040651) -2- T1010(E)(N17)T

Copyright reserved Please turn over

DEPARTMENT OF HIGHER EDUCATION AND TRAINING REPUBLIC OF SOUTH AFRICA

NATIONAL CERTIFICATE MOTOR TRADE THEORY N1

TIME: 3 HOURS MARKS: 100

INSTRUCTIONS AND INFORMATION 1. 2. 3. 4. 5. 6.

Answer ALL the questions. Read ALL the questions carefully. Number the answers according to the numbering system used in this question paper ALL the sketches and diagrams must be large, clear and neat. Keep questions and subsections of questions together. Write neatly and legibly.

(11040651) -3- T1010(E)(N17)T


QUESTION 1 1.1 Various options are given as possible answers to the following questions.

Choose the answer and write only the letter (A–D) next to the question number (1.1.1–1.1.10) in the ANSWER BOOK.

1.1.1 The correct sequence of strokes of a four-stroke engine is ... A

B C D

compression, induction, power and exhaust. induction, compression, exhaust and power. induction, compression, power and transfer. induction, power, compression and transfer.

1.1.2 One of the advantages of good housekeeping is ... A

B C D

poor ventilation. hazardous atmospheric conditions. inadequate support or guidance. a work area that is kept neat and orderly.

1.1.3 The most common hammer used in an automotive workshop: A

B C D

Ball-peen hammer Soft-face hammer Lump hammer Mallet hammer

1.1.4 The timing chain is the connection between the ... A

B C D

camshaft and crankshaft. big-end bearing and camshaft. big-end bearing and crankshaft. timing cover and gasket cover.

1.1.5 Dilution of motor oil can be very detrimental to an engine and its

components and may be caused by ONE of the following:

A

B C D

Varnish formation Reduction of oil viscosity Low oil pressure Leaking injector

1.1.6 Tyres should be inflated to the recommended pressure when

they ...

A

B C D

are carrying a load. are hot. are cold. are at the operating temperature.

(11040651) -4- T1010(E)(N17)T


1.1.7 An engine that overheats can cause ... A

B C D

engine seizure. a cracked cylinder head. bearing failure. All the above-mentioned.

1.1.8 Insufficient clutch pedal free-play can cause … A

B C D

clutch slipping. excessive clutch-plate wear. excessive release-bearing wear. All the above-mentioned.

1.1.9 The conventional sequence for tightening down the cylinder head

is from ...

A

B C D

front to back. back to front. the middle towards the outer ends. the ends to the middle.

1.1.10 The main function of the thermostat in a cooling system is to

regulate the ...

A

B C D

coolant pressure. engine speed. engine operating temperature. coolant level.

(10 × 1) (10) 1.2 FIGURE 1, DIAGRAM SHEET 1 (attached) shows a two-stroke petrol engine.

Name the parts labelled A–G. Write only the answer next to the letter (A–G) in the ANSWER BOOK. (7 × 1)

(7)

1.3 Give the names of the tools required for each of the following tasks: 1.3.1 To finish off corners and cutting V-grooves 1.3.2 To tighten the cylinder-head bolt 1.3.3 To check small gaps between components

(3 × 1) (3) [20]

(11040651) -5- T1010(E)(N17)T


QUESTION 2 2.1 FIGURE 2, DIAGRAM SHEET 1 (attached) shows a sketch of the flywheel of

an internal combustion engine. Name the parts labelled A–F. Write only the answer next to the letter (A–F) in the ANSWER BOOK. (6 × 1)

(6)

2.2 State the main function of each of the following engine components: 2.2.1 Connecting rod 2.2.2 Radiator fan 2.2.3 Thermostat 2.2.4 Oil pump 2.2.5 Spark plug

(5 × 1) (5) 2.3 Name FOUR types of oil pumps used in an internal combustion engine. (4) 2.4 FIGURE 3, DIAGRAM SHEET 1 (attached) shows a sketch of the oil pump of

an internal combustion engine. Name the parts labelled A–E. Write only the answer next to the letter (A–E) in the ANSWER BOOK. (5 × 1)

(5)

[20] QUESTION 3 3.1 Make a large, neat, sectional sketch of a four-stroke diesel engine (C.I) during

the power stroke. Draw only one cylinder and label all the parts. The piston direction must be indicated by means of arrows. Also give a brief explanation of its operation.

(7)

3.2 Define oil clearance. (3) 3.3 Give THREE reasons for low engine-oil pressure although there is enough oil

in the sump.

(3) 3.4 FIGURE 4, DIAGRAM SHEET 2 (attached) shows the single-plate clutch

assembly. Name the parts labelled A–G. Write only the answer next to the letter (A–G) in the ANSWER BOOK. (7 × 1)

(7)

[20]

(11040651) -6- T1010(E)(N17)T


QUESTION 4

4.1 Indicate whether the following statements are TRUE or FALSE. Choose the answer and write only 'true' or 'false' next to the question number (4.1.1–4.1.5) in the ANSWER BOOK.

4.1.1 Hardness is the opposite of brittleness.

4.1.2 Overhead camshaft means the camshaft is situated below the cylinder head.

4.1.3 Constant velocity joints are found on front-wheel drive cars.

4.1.4 The main function of the radiator is to increase the engine temperature.

4.1.5 One of the functions of engine oil is to act as a cushion to protect the moving parts.

(5 × 1) (5) 4.2 Name THREE common causes of accidents in the workshop. (3) 4.3 State THREE functions of the thermostat. (3) 4.4 FIGURE 5, DIAGRAM SHEET 2 (attached) shows a sketch of the cooling-

system parts of the internal combustion engine. Name the parts labelled A–E. Write only the answer next to the letter (A–E) in the ANSWER BOOK. (5 × 1)

(5)

4.5 Give FOUR causes of engine overheating. (4) [20]

QUESTION 5

5.1 Give THREE good sawing techniques. (3) 5.2 Give TWO safety measures when working on a grinding machine. (2) 5.3 Give THREE reasons for accidents in the workshop due to poor

housekeeping.

(3) 5.4 Give FIVE reasons why it is important that correct tyre pressure be

maintained.

(5) 5.5 FIGURE 6, DIAGRAM SHEET 3 (attached) shows various tools used in the

workshop. Name the tools numbered 5.5.1–5.5.7. Write only the answer next to the question number (5.5.1–5.5.7) in the ANSWER BOOK. (7 × 1)

(7)

[20]

TOTAL: 100

(11040651) -7- T1010(E)(N17)T


DIAGRAM SHEET 1

FIGURE 1

FIGURE 2

FIGURE 3

-1-

(11040651) -2- T1010(E)(N17)T


DIAGRAM SHEET 2

FIGURE 4

FIGURE 5

(11040651) -3- T1010(E)(N17)T


DIAGRAM SHEET 3 5.1

5.5.1

5.5.2

5.5.3

5.5.4

(11040651) -4- T1010(E)(N17)T

Copyright reserved

5.5.5

5.5.6

5.5.7

FIGURE 6



NOVEMBER EXAMINATION


17 NOVEMBER 2016

This marking guideline consists of 5 pages.

MARKING GUIDELINE

MARKING GUIDELINE -2- T1010(E)(N17)T MOTOR TRADE THEORY N1


QUESTION 1 1.1 1.1.1 C 1.1.2 D 1.1.3 A 1.1.4 A 1.1.5 D 1.1.6 D 1.1.7 C 1.1.8 D 1.1.9 D 1.1.10 C

(10 × 1) (10) 1.2 A–exhaust stroke B–power stroke C–spark plug D–exhaust port/outlet port E–crankshaft F–mixture of air and fuel G–inlet port (7) 1.3 1.3.1 Diamond point chisel 1.3.2 Torque wrench 1.3.3 Feeler gauge

(3 × 1) (3) [20] QUESTION 2 2.1 A–Ring gear B–Flywheel C–Clutch face D–Attaching hole E–Spigot hole F–Balancing holes (6 × 1) (6) 2.2 2.2.1 To connect the piston to the crankshaft. 2.2.2 To drive air though the radiator core. 2.2.3 To maintain a minimum operating temperature. 2.2.4 It circulates engine oil under pressure to the rotating bearings, the

sliding pistons and the camshaft.



2.2.5 It ignites the compressed fuel/air by an electric spark.

(5 × 1) (5) 2.3 Gear type

Eccentric rotor

Internal gear type

Sliding type

Plunger type (Any 4 × 1)

(4)

2.4 A–Outer rotor

B–Drive shaft C–Inner rotor D–Casing E–Outlet (5 × 1)

(5)

[20] QUESTION 3 3.1

(3 marks for sketch and 4 for labels and explanation)

(7)

3.2 Oil clearance is the small space/gap between moving engine parts for

lubricating oil film.

(3)



3.3 Defective gauge

Worn bearings

Stuck regulator valve

Clogged pump inlet (Any 3 × 1)

(3)

3.4 A–Flywheel

B–Clutch plate C–Crankshaft D–Pressure plate E–Release lever F–Thrust bearing G–Spring (Any 7 × 1)

(7)

[20] QUESTION 4 4.1 4.1.1 False 4.1.2 False 4.1.3 True 4.1.4 False 4.1.5 True

(5 × 1) (5) 4.2 Unsafe actions

Unsafe conditions

Fooling about/playing around (3 × 1)

(3)

4.3 To help the engine reach its normal running temperature.

To maintain its running temperature whatever the weather conditions.

To meet the requirements of the car's interior heating conditions.

(3)

4.4 A–Radiator

B–Drain plug C–Overflow bottle D–Top hose E–Cap (5 × 1)

(5)

4.5 Rust or scale

Stuck thermostat

Low coolant level

Slipping of fan belt

No fan shroud

Retarded ignition timing

Bad water pump

Collapsed water hose (Any 4 × 1)

(4)

[20]


Copyright reserved

QUESTION 5 5.1 Cut slowly using full length of the blade.

Do not apply too much downward pressure on the blade.

Insert the blade with the teeth pointing to the front.

The blade must be properly tensioned.

After use, slack the blade.

Use the correct blade for the job. (Any 3 × 1)

(3)

5.2 Safety goggles must be used at all times.

A work rest must always be in place; gap between is ±2 mm.

Grading wheels must be balanced.

Work piece should not be knocked.

Permanent transparent shield should be mounted above work area.

Sides of the grinding wheels should not be used for grinding.

Work piece should not be pressed too hard against the grinder. (Any 2 × 1)

(2)

5.3 Negligence of a person involved

Ignorance of the danger involved

Fooling about, playing, jokes

Tiredness or daydreaming

Failure to take adequate precaution

Lack of skills through inadequate training

Untidy or obstructed working area (Any 3 × 1)

(3)

5.4 Assures vehicle safety.

Ensures comfortable ride.

Prevents excessive heat build up.

Ensures full tread area of the tyre touching the road.

It ensures good balance of the vehicle. (5 × 1)

(5)

5.5 5.5.1 External circlip 5.5.2 Soldering iron 5.5.3 Taps and dies 5.5.4 Feeler gauge 5.5.5 Hone 5.5.6 Diamond-point chisel 5.5.7 Socket spanner

(7 × 1) (7) [20]

TOTAL: 100


T1160(E)(M30)T APRIL EXAMINATION



(11040651)

30 March 2016 (X-Paper) 09:00–12:00

This question paper consists of 10 pages.

(11040651) -2- T1160(E)(M30)T





INSTRUCTIONS AND INFORMATION 1. 2. 3. 4. 5. 6. 7.

Answer ALL the questions. Read ALL the questions carefully. Number the answers according to the numbering system used in this question paper. Start each question on a NEW page. ALL sketches must be provided with the necessary labels. Correct spelling and terminology is important. Do not use words like 'top' for cylinder head. Write neatly and legibly.

(11040651) -3- T1160(E)(M30)T


QUESTION 1 1.1 Various options are provided as possible answers to the following questions.


1.1.1 A worn cylinder head gasket is likely to cause … A

B C D

incorrect valve timing. engine misfiring. oil dilution. incorrect timing.

1.1.2 During engine operation, the intake and exhaust valves are closed

by the …

A

B C D

valve spring. camshaft. piston pressure. valve rockers.

1.1.3 The conventional sequence for tightening cylinder heads is from … A

B C D

front to back. back to front. middle towards outer ends. ends to the middle.

1.1.4 ONE of the following is NOT the function of the flywheel: A

B C D

Serves as a mounting facility of the gearbox. Serves as a mounting facility for the ring gear. Serves as a mounting facility for the clutch assembly. Carries the engine through the non-firing strokes.

1.1.5 Excessive clutch pedal free play can cause ... A

B C D

excessive release-bearing wear. excessive clutch pedal wear. difficult gear selection. All of the above.

1.1.6 The main function of a thermostat in the cooling system is to

regulate the …

A

B C D

engine pressure. engine speed. engine operating temperature. coolant pressure.

(11040651) -4- T1160(E)(M30)T


1.1.7 When the thermostat is closed the water circulates mainly through

the …

A

B C D

radiator. water pump. engine. cylinder head.

1.1.8 Tyres should be inflated to their recommended pressure when they

are …

A

B C D

loaded. at operational temperature. hot. cold.

1.1.9 A pressure relief valve is used in the engine lubricating system

to …

A

B C D

lubricate the oil pump. seal the oil pump. push upwards. limit the maximum speed.

1.1.10 Two 12-volt batteries connected in parallel produce ... A

B C D

12 volts. 18 volts. 24 volts. 6 volts.

(10)

1.2

Safety sign regulations are established in accordance with international standards. Name the precautions that each of the signs in FIGURE 1 below illustrates. Write only the answer next to the question number (1.1.1–1.1.3) in the ANSWER BOOK.

1.2.1

1.2.2

(11040651) -5- T1160(E)(M30)T


1.2.3

FIGURE 1 (3)

1.3 State FIVE unsafe acts that cause accidents in the workshop. (5) 1.4 Name TWO types of fans used in the internal combustion engine. (2) [20] QUESTION 2 2.1 Give THREE reasons for a low engine oil pressure although there is enough

oil in the sump.

(3) 2.2 Name THREE functions of the piston. (3) 2.3 FIGURE 2 below shows a sketch of the parts of the internal combustion

engine.

Name the parts marked A–F. Write only the answer next to the letter (A–F) in the ANSWER BOOK.

FIGURE 2 (6)

(11040651) -6- T1160(E)(M30)T


2.4 Make a neat large sectional sketch of the four-stroke diesel engine during the

power stroke.

Name ALL the parts of the engine and indicate the direction of the piston travel by means of arrows.

(8)

[20] QUESTION 3 3.1 State TWO functions of each of the following engine parts: 3.1.1 Crankshaft 3.1.2 Camshaft 3.1.3 Flywheel

(3 × 2) (6) 3.2 FIGURE 3 below shows a sketch of a single-plate clutch assembly. Name the

parts marked A–G. Write only the answer next to the letter (A–G) in the ANSWER BOOK.

FIGURE 3 (7)

3.3 Give TWO reasons for clutch slip. (2)

(11040651) -7- T1160(E)(M30)T


3.4 Give TWO reasons why clutch free play is important. (2) 3.5 Name THREE functions of tyres on the vehicle. (3) [20] QUESTION 4 4.1 Indicate whether the following statements are TRUE or FALSE. Choose the

answer and write only 'true' or 'false' next to the question number (4.1.1–4.1.5) in the ANSWER BOOK.

4.1.1 Oil clearance is the small space between the moving engine parts

for the lubricating oil film.

4.1.2 A by-pass valve or a hose permits coolant circulation through the

engine when the thermostat is open.

4.1.3 One of the causes of the engine overheating is the absence of a

fan shroud.

4.1.4 The slave cylinder is mounted on the clutch bell housing. 4.1.5 Sulphation is the formation of lead sulphate on the surface of the

negative plate.

(5 × 1) (5) 4.2 Explain the features/characteristics of the following lubricating oil SAE

number: 20 W.

(2) 4.3 Name THREE oil additives. (3)

(11040651) -8- T1160(E)(M30)T


4.4 FIGURE 4 below shows a sectional sketch of a radiator.

FIGURE 4

4.4.1 Name ALL the labelled parts (A–G) in the ANSWER BOOK. (7) 4.4.2 State ONE function of the parts labelled A, B and C in FIGURE 4. (3) [20] QUESTION 5 5.1 State FOUR safety measures when replacing a battery in a vehicle. (4) 5.2 Name TWO defects on a motor vehicle that can be caused by a faulty lead

acid battery.

(2) 5.3 Name FOUR causes of sulphation. (4) 5.4 Name ONE function of the hydrometer. (1)

(11040651) -9- T1160(E)(M30)T


5.5 FIGURE 5 below shows various tools used in the workshop. Name the tools

and write the answer next to the question number (5.5.1–5.5.9) in the ANSWER BOOK.

5.5.1

5.5.2

5.5.3

5.5.4

Copyright reserved

5.5.5

5.5.6

5.5.7

5.5.8

5.5.9

FIGURE 5

(9 × 1) (9) [20]

TOTAL: 100



APRIL EXAMINATION


30 MARCH 2016


MARKING GUIDELINE

MARKING GUIDELINE -2- T1160(E)(M30)T MOTOR TRADE THEORY N1


QUESTION 1

1.1 1.1.1

1.1.2

1.1.3

1.1.4

1.1.5

1.1.6

1.1.7

1.1.8

1.1.9

1.1.10

C

B

D

C

C

C

A

A

D

D

(10 × 1) (10)

1.2 1.2.1 Hearing protection shall be worn

1.2.2 Wearing of safety helmets prohibited

1.2.3 Keep area clean (3 × 1) (3)

1.3 Negligence

Ignorance

Fooling about

Tiredness

Lack of skills

Untidy working area

Use of wrong tools or equipment (Any 5 × 1)

(5)

1.4 Direct drive fan

Indirect drive fan

Electric fan (Any 2 × 1)

(2)

[20]

QUESTION 2

2.1 Worn-out oil rings

Weak oil pump

Wrongly placed oil rings

(3)

2.2 It produces a vacuum in order to draw the fuel charge into the cylinder.

It compresses the mixture in the cylinder.

It traps the expanding gas at the top of the piston.

It transmits energy during the power stroke to the crankshaft.

It moves up and down the cylinder, and exhausts the burnt fuel charge.

It conducts heat from the piston to the cooled cylinder walls. (Any 3 × 1)

(3)



2.3 A. Outer rotor

B. Drive shaft C. Outlet D. Inlet E. Inner rotor F. Casing

(6)

2.4 Just before the piston reaches top dead centre, the injector sprays diesel oil

under pressure into the cylinder which has both ports closed. The diesel ignites with the hot air and the resulting explosion forces the piston downwards.

(8)

[20] QUESTION 3 3.1 3.1.1 Crankshaft

It provides a constant turning force to the wheels.

It changes reciprocating movement of piston to rotary.

It distributes oil from the main journals to big end journals of the connecting rod.

3.1.2 Camshaft

It opens and closes the valves.

It drives mechanical petrol oil pumps and distributor.



3.1.3 Flywheel

It smoothes out engine speed and keeps the crankshaft spinning between power strokes.

It serves as a mounting surface for the clutch assembly.

It helps the starter motor to crank the engine. (3 × 2)

(6) 3.2 A. Clutch plate

B. Flywheel C. Release bearing D. Clutch cable E. Clutch pedal F. Bell housing G. Release lever

(7)

3.3 Insufficient free play

Linkage binding/sticking

Weak/broken clutch plate spring

Grease/oil on friction surface

Incorrectly adjusted release lever (Any 2 × 1)

(2)

3.4 Prevents slipping.

Ensures that the release bearing is not in continual contact with the release lever.

(2)

3.5 It provides an air cushion between road and car wheels.

It provides friction between tyre and the road for traction.

It supports the weight of vehicle and distributes it over the road.

It offers minimum rolling resistance to motion.

It gives safe operating to maximum speed.

It provides comfortable, quiet running of the vehicle.

It absorbs road shock. (Any 3 × 1)

(3)

[20] QUESTION 4 4.1 4.1.1

4.1.2 4.1.3 4.1.4 4.1.5

True False True True False

(5 × 1) (5) 4.2 20 – oil viscosity

W – winter conditions

(2)



4.3 Viscosity index

Oil body

Fluidity

Detergent dispersant

Corrosion inhibition

Pour point depressant

Oxidation inhibitor

Foaming inhibitor

Resistance to carbon formation

Extreme pressure resistance (Any 3 × 1)

(3)

4.4 4.4.1 A. Radiator

B. Drain plug C. Overflow bottle D. Hose clamp E. Bottom hose F. Top hose G. Cap

(7)

4.1.2 Radiator – To reduce the temperature of the engine coolant

Drain plug – To remove used water when servicing the vehicle

Overflow bottle – To release overflow water from the radiator

(3)

[20] QUESTION 5 5.1 Wear protective clothing.

Use two spanners to loosen the terminals.

Remove the earth terminal first.

Do not place the battery on paintwork of the vehicle.

Clean the battery and the battery shelf with baking soda.

Ensure that the battery shelf is dry before replacing the battery.

The new battery should be clamped down properly.

Connect cables to battery posts or terminals.

Use two open-ended spanners to tighten clamp nuts.

Check the level of the electrolyte, top up if necessary. (Any 4 × 1)

(4)

5.2 Engine difficult to start.

Engine fails to start.

(2)


Copyright reserved

5.3 Prolonged discharging

Local chemical action in the cells, due to entry of dirt and impurities

Insufficient or infrequent charging

The electrolyte level being too low

The specific gravity of the electrolyte being too low (Any 4 × 1)

(4)

5.4 To measure the density of the electrolyte in the battery (1) 5.5 5.5.1

5.5.2 5.5.3 5.5.4 5.5.5 5.5.6 5.5.7 5.5.8 5.5.9

Trolley jack The hacksaw Ring squeezer The Vernier calliper Centre punch Vice-grips/pipe pliers Circlip pliers Engine crane Socket spanner

(9 × 1) (9) [20]

TOTAL: 100

Copyright reserved

T1150(E)(A3)T

AUGUST EXAMINATION



(11040651)

3 August 2015 (Y-Paper) 13:00–16:00


(11040651) -2- T1150(E)(A3)T






Answer ALL the questions. Read ALL the questions carefully. Number the answers according to the numbering system used in this question paper. ALL sketches must be provided with the necessary labels. Correct spelling and terminology is important. For example, do NOT use 'top' for a cylinder head. Start each question on a NEW page. Write neatly and legibly.

(11040651) -3- T1150(E)(A3)T




1.1.1 A worn cylinder-head gasket is likely to cause ... A

B C D

incorrect valve timing. engine misfiring. oil dilution. incorrect timing.

1.1.2 During engine operation, the intake and exhaust valves are closed

by the …

A

B C D

valve spring. camshaft. piston pressure. valve rockers.

1.1.3 The conventional sequence for tightening cylinder heads is from ... A

B C D

front to back. back to front. middle towards outer ends. ends to the middle.

1.1.4 ONE of the following is NOT the function of a flywheel: A

B C D

To serve as a facility of mounting the gearbox To serve as a mounting facility for the ring gear To serve as a facility for mounting the clutch assembly To carry the engine through the non-firing strokes

1.1.5 Excessive clutch pedal free play can cause ... A

B C D

excessive release bearing wear. excessive clutch pedal wear. difficult gear selection. All the above mentioned.

1.1.6 The main function of thermostat in the cooling system is to regulate

the ...

A

B C D

engine pressure. engine speed. engine operating temperature. coolant pressure.

(11040651) -4- T1150(E)(A3)T


1.1.7 When the thermostat is closed the water circulates mainly through

the …

A

B C D

radiator. water pump. engine. cylinder head.

1.1.8 Tyres should be inflated to their recommended pressure when they

are ...

A

B C D

loaded. at operational temperature. hot. cold.

1.1.9 A pressure relief valve is used in the engine lubricating system

to ...

A

B C D

lubricate the oil pump. seal the oil pump. push upwards. limit the maximum speed.

1.1.10 Two 12-volt batteries connected in parallel produce ... A

B C D

12 volts. 18 volts.

A. 24 volts. 6 volts.

(10 × 1)

(10)

1.2 Safety signs regulations are established in accordance with international

standards. Name the precautions that each of the signs illustrated on DIAGRAM SHEET 1 in FIGURE 1 (attached). Write only the number next to the question numbers (1.2.1–1.2.3) in the ANSWER BOOK.

(3)

1.3 State FIVE unsafe acts that cause accidents in the workshop. (5) 1.4 Name TWO types of fans used in the internal combustion engine. (2)

[20]

(11040651) -5- T1150(E)(A3)T


QUESTION 2 2.1 Give THREE reasons for a low engine oil pressure although there is enough

oil in the sump.

(3) 2.2 Name THREE functions of the piston. (3) 2.3 Illustrated by DIAGRAM SHEET 1 (attached) is FIGURE 2 showing the parts

of an internal combustion engine. Name the labelled parts (A–F) in the ANSWER BOOK.

(6)

2.4 Make a neat large sectional sketch of a four-stroke diesel engine during the

power stroke. Name ALL the parts of the engine and indicate the direction of the piston travel by means of arrows.

(8)

[20] QUESTION 3 3.1 State TWO functions for each of the following engine parts: 3.3.1 Crankshaft

3.3.2 Camshaft

3.3.3 Flywheel (3 × 2)

(6)

3.2 Illustrated on DIAGRAM SHEET 3 (attached) is FIGURE 3 which shows a

sketch of a single plate clutch assembly. Name ALL the parts (A–G) in the ANSWER BOOK.

(7)

3.3 Give TWO reasons for clutch slip. (2) 3.4 State TWO reasons why clutch free play is important. (2) 3.5 Name THREE functions of tyres on a vehicle. (3)

[20]

(11040651) -6- T1150(E)(A3)T

Copyright reserved

QUESTION 4


4.1.1 Oil clearance is the small space between the moving engine parts for lubricating oil film.

4.1.2 By-pass valve or a hose permits coolant circulation through the engine when the thermostat is open.

4.1.3 One of the causes of the engine overheating is no fan shroud.

4.1.4 The slave cylinder is mounted on the clutch bell housing.

4.1.5 Sulphation is the formation of lead sulphate on the surface of the negative plate.

(5 × 1)

(5)

4.2 Explain features or characteristics of the following lubricating oil: SAE number 20W

(2)

4.3 Name THREE oil additives. (3)

4.4 The illustration on DIAGRAM SHEET 4 (attached) shows in FIGURE 4 a sectional view of a radiator.

4.4.1 Name ALL the labelled parts (A–G) in the ANSWER BOOK. (7)

4.4.2 State ONE function of the parts labelled A, B and C in FIGURE 4. (3) [20]

QUESTION 5 5.1 State FOUR safety measures normally taken when a vehicle's battery is

replaced.

(4)

5.2 Name TWO defects on a motor vehicle that can be caused by a faulty lead acid battery in a motor.

(2)

5.3 Name FOUR causes of sulphation. (4)

5.4 Name ONE function of the hydrometer. (1)

5.5 FIGURE 5 below shows various tools used in the workshop. Name the tools and write the answer next to the question numbers (5.5.1–5.5.9) in the ANSWER BOOK.

(9) [20]

TOTAL: 100

(11040651) -7- T1160(E)(A3)T


DIAGRAM SHEET QUESTION 1.3

FIGURE 1 QUESTION 2.1

FIGURE 2

-1-

(11040651) -2- T1160(E)(A3)T


QUESTION 3.2

FIGURE 3

A

B

C

E D

(11040651) -3- T1160(E)(A3)T


QUESTION 4.4

FIGURE 4

A

B

C

D

E

F

G

H

I

(11040651) -4- T1160(E)(A3)T


QUESTION 5.5

5.5 5.5.1

FIGURE 5.5.1

5.5.2

FIGURE 5.5.2

5.5.3

(11040651) -4- T1160(E)(A3)T


QUESTION 5.7



AUGUST EXAMINATION


3 AUGUST 2015


MARKING GUIDELINE

MARKING GUIDELINE -2- T1160(E)(A3)T MOTOR TRADE THEORY N1


QUESTION 1 1.1 1.1.1 C 1.1.2 B 1.1.3 D 1.1.4 C 1.1.5 C 1.1.6 C 1.1.7 A 1.1.8 A 1.1.9 D 1.1.10 D (A correct answer)

(10 × 1)

(10) 1.2 1.2.1 Hearing protection shall be worn. 1.2.2 Wearing of safety helmets prohibited 1.2.3 Keep area clean

(3 × 1)

(3) 1.3 Negligence

Ignorance

Fooling about

Tiredness

Lack of skills

Untidy working area

Use of wrong tool or equipment (Any 5 x 1)

(5)

1.4 * Direct drive fan

* Indirect drive fan * Electric fan (Any 2 x 1)

(2) [20]

QUESTION 2 2.1 Worn out oil rings

Weak oil pump

Wrongly placed oil rings

(3)

2.2 It produces a vacuum in order to draw fuel charge into the cylinder

It compresses the mixture in the cylinder

It holds the expanding gas at the top of the piston

It transmits energy during power stroke to crankshaft

It moves up and down the cylinder, and exhausts the burnt fuel charge

It conducts heat from the piston to the cooled cylinder walls (Any 3 x 1)

(3)



2.3 A – Outer rotor

B – Drive shaft

C – Outlet (Inner rotor correct answer)

D – Inlet (Cusing correct answer)

E – Inner rotor (Outlet correct answer)

F – Casing (Inlet correct answer)

(6)

2.4

FIGURE 1

Rubric to mark:

6 marks for labelling

Labelled items: Inlet manifold Exhaust manifold Inlet valve Exhaust valve Piston Conrod Diesel injector (2 marks for drawing + Any 6 x 1)

(8) [20]



QUESTION 3 3.1 3.1.1 Crankshaft

It provides a constant turning force to the wheels

It changes reciprocating movement of piston to rotary

It distribute oil from the main journals to big end journals of connecting rod

3.1.2 Camshaft

It opens and closes the valve

It drives mechanical petrol oil pumps and distributor

3.1.3 Flywheel

It smoothes out engine speed and keeps the crankshaft spinning between power strokes

It serves as a mounting surface for the clutch assembly

It helps the starter motor to crank the engine (3 × 2)

(6)

3.2 A – Clutch plate

B – Flywheel

C – Release bearing

D – Clutch cable

E – Clutch pedal

F – Bell housing

G – Release lever (7 x 1)

(7)

3.3 Insufficient free play

Linkage binding/sticking

Weak/broken clutch plate spring

Grease/oil on friction surface

Incorrectly adjusted release lever

Worn friction linings

Oil or greases present on the linings (Any 2 x 1)

(2)

3.4 Prevent slipping

Ensures that release bearing is not in continual contact with release lever

(2)

3.5 It provides an air cushion between road and car wheels

It provides friction between tyre and the road for traction

To support the weight of vehicle and distribute over the road

To offer minimum rolling resistance to motion

To give safe operating to maximum speed

To provides comfortable, run quietly of the vehicle

Absorbs road shock (Any 3 x1)

(3)

[20]



QUESTION 4 4.1 4.1.1 True 4.1.2 False 4.1.3 True 4.1.4 True 4.1.5 False (5 x 1) (5) 4.2 Oil viscosity

W - Winter condition

(2)

4.3 Viscosity index (viscosity index improvers)

Oil body

Fluidity

Detergent dispersant

Corrosion and inhibition (corrosion and rust inhibition)

Pour point depressant (flow point)

Oxidation inhibitor

Foaming (foaming resistance)

Resistance to carbon formation

Extreme pressure resistance (Any 3 x 1)

(3)

4.4.1 A – Radiator

B – Drain plug

C – Overflow bottle

D – Hose clamp

E – Bottom hose

F– Top hose

G – Cap (7 x 1)

(7)

4.4.2 Radiator – To reduce the temperature of the engine coolant

Drain plug – To remove used water when service the vehicle

Overflow bottle – To release overflown water from the radiator

(3)


Copyright reserved

QUESTION 5 5.1 Wear protective clothing

Use two spanners to loosen the terminals

Remove the earth terminal first

Do not put the battery on paintwork of the vehicle

Clean the battery and battery shelf with baking soda

Make sure that battery shelf is dry before putting another battery

The new battery should be clamped down properly

Connect cables to battery posts or terminals

Use two open-ended spanners to tighten clamp nuts

Check the level of the electrolyte, top up if necessary (Any 4 x 1)

(4)

5.2 Engine is difficult to start

Engine fails to start

(2)


Local chemical action in the cells, due to entry of dirt and impurities

Insufficient or infrequent charging

The electrolyte level being too low

The specific gravity of the electrolyte being too low (Any 4 x1)

(4)

5.4 To measure the density of the electrolyte in the battery (1) 5.5 5.5.1 Trolley jack 5.5.2 The hacksaw 5.5.3 Ring squeezer 5.5.4 The Vernier calliper 5.5.5 Centre punch 5.5.6 Vice-grips/pipe pliers 5.5.7 Circlip pliers 5.5.8 Engine crane 5.5.9 Socket spanner (9 × 1) (9)

[20]

TOTAL: 100


T1160(E)(A16)T

APRIL EXAMINATION



(11040651)

16 April 2015 (Y-Paper) 13:00–16:00


(11040651) -2- T1160(E)(A16)T





INSTRUCTIONS AND INFORMATION 1. 2. 3. 4. 5. 6.

Answer ALL the questions. Read ALL the questions carefully. Number the answers according to the numbering system used in this question paper. ALL sketches must be provided with the necessary labels. Start each question on a NEW page. Write neatly and legibly.

(11040651) -3- T1160(E)(A16)T


QUESTION 1 1.1 Various options are given as possible answers to the following questions.


1.1.1 The main function of the thermostat in the cooling system is to

regulate the …

A

B C D

coolant pressure. engine speed. engine operating temperature. coolant level.

1.1.2 The conventional sequence for tightening down cylinder heads is

from …

A

B C D

front to back. back to front. the middle towards the outer ends. the ends to the middle.

1.1.3 Insufficient clutch pedal free-play can cause … A

B C D

clutch slipping. excessive release bearing wear. excessive clutch plate wear. all the above-mentioned.

1.1.4 An engine that overheats can cause … A

B C D

engine seizure. a cracked cylinder head. bearing failure. all the above-mentioned.

1.1.5 Tyres should be inflated to the recommended pressure when they

are …

A

B C D

carrying a load. hot. cold. at the operating temperature.

1.1.6 The correct sequence of strokes of a two-cylinder four-stroke

engine is …

A

B C D

compression, induction, power, exhaust. induction, compression, exhaust, power. induction, compression, power, transfer. induction, power, compression, transfer.

(11040651) -4- T1160(E)(A16)T


1.1.7 ONE of the advantages of good housekeeping is … A

B C D

poor ventilation. hazardous atmospheric condition. inadequate support or guards. keeping work area neat and orderly.

1.1.8 The most common hammer used in an automotive workshop is a… A

B C D

ball peen hammer. soft face hammer. lump hammer. mallet hammer.

1.1.9 The timing chain is the connection between … A

B C D

camshaft and crankshaft. big end bearing and camshaft big end bearing and crankshaft. timing cover and gasket cover.

1.1.10 Dilution of motor oil can be very detrimental to an engine and its

components. One of the following is the cause of oil dilution:

A

B C D

vanish formation. reduction of oil viscosity low oil pressure. leaking injection.

(10 × 10 (10) 1.2 DIAGRAM SHEET 1, FIGURE 1 shows a two stroke petrol engine. Name the

parts labelled (A–G) in the ANSWER BOOK.

(7) 1.3 Give the names of the tools required for each of the following tasks. 1.3.1 To finish off corners and for cutting “V” grooves 1.3.2 To tighten cylinder head bolt 1.3.3 To check small gaps between components

(3 × 1) (3) [20]

(11040651) -5- T1160(E)(A16)T


QUESTION 2 2.1 State the main function of each of the following engine components: 2.1.1 Connecting rod 2.1.2 Radiator fan 2.1.3 Thermostat 2.1.4 Oil pump 2.1.5 Spark plug

(5 × 1) (5) 2.2 DIAGRAM SHEET 1, FIGURE 2 shows a sketch of a crankshaft of an internal

combustion engine. Name the labelled parts (A–F) in the ANSWER BOOK.

(6) 2.3 Explain step by step, how you would go about to check an engine’s oil level. (4) 2.4 DIAGRAM SHEET 1, FIGURE 3 shows the sketch of an alternator and

cooling fan drive system. Name the labelled parts (A–E) in the ANSWER BOOK.

(5) [20] QUESTION 3 3.1 Give three reasons for low engine oil pressure although there is enough oil

in the sump.

(3) 3.2 Give THREE functions of the piston. (3) 3.3 DIAGRAM SHEET 2, FIGURE 4 shows the single plate clutch assembly.

Name the parts labelled (A–G) in the answer book.

(7) 3.4 Make a large neat sectional sketch of a four stroke diesel engine (C.I.) during

the inlet stroke. Draw only ONE cylinder and label ALL the parts. The piston direction must be indicated by means of arrows.

(7) [20]

(11040651) -6- T1160(E)(A16)T


QUESTION 4 4.1 Indicate whether the following statements are TRUE or FALSE. Choose the

answer and write only 'true' or 'false' next to the question number (4.1.1–4.1.5) in the ANSWER BOOK.

4.1.1 An engine crane can be used to remove both engine and the gear

box of the motor car.

4.1.2 Compression rings form a gas-tight seal to enable the air fuel

mixture to be compressed.

4.1.3 During the induction stroke of a two stroke diesel engine the piston

moves upwards.

4.1.4 The main disadvantage of the front engine front wheel drive is

minimal rear tyre wear.

4.1.5 Lubricating oil helps to carry away heat from the moving parts of

the engine.

(5 × 1) (5) 4.2 Name THREE functions of engine oil used in an internal combustion engine. (3) 4.3 Give THREE reasons for high oil consumption by an engine. (3) 4.4 Name THREE functions of tyres on a vehicle. (3) 4.5 DIAGRAM SHEET 2, FIGURE 5 shows an oil pump. Name the parts labelled

(A–F) in the ANSWER BOOK.

(6) [20] QUESTION 5 5.1 State THREE good sawing techniques using a hacksaw. (3) 5.2 State TWO safety measurers to be taken when working on a grinding

machine.

(2) 5.3 State THREE reasons that cause accidents in the workshop due to poor

housekeeping.

(3) 5.4 Make a neat labelled sketch of a hydrometer. (5)

(11040651) -7- T1160(E)(A16)T


5.5 Illustrations (5.5.1–5.5.7) show various tools used in the workshop. Name the

tools as marked in the ANSWER BOOK.

5.5.1

5.5.2

5.5.3

5.5.4

5.5.5

5.5.6

(11040651) -8- T1160(E)(A16)T


5.5.7

(7 × 1) (7) [20]

TOTAL: 100

(11040651) -9- T1160(E)(A16)T


DIAGRAM SHEET 1

FIGURE 1

FIGURE 2

FIGURE 3

-1-

(11040651) -10- T1160(E)(A16)T


DIAGRAM SHEET 2

FIGURE 4

FIGURE 5

-2-



APRIL EXAMINATION


10 APRIL 2015


MARKING GUIDELINE



QUESTION 1 1.1 1.1.1 C 1.1.2 D 1.1.3 D 1.1.4 C 1.1.5 D 1.1.6 C 1.1.7 D 1.1.8 A 1.1.9 A 1.1.10 D

(10 × 10 (10) 1.2 A – exhaust stroke

B – power stroke C – spark plug D – exhaust port/outlet port E – crankshaft F – mixture of air and fuel G – Inlet port

(7) 1.3 1.3.1 Diamond point. 1.3.2 Torque wrench. 1.3.3 The feeler gauge.

(3 × 1) (3) [20]

QUESTION 2 2.1 2.1.1 To connect the piston to the crankshaft. 2.1.2 To drive air through the radiator core. 2.1.3 To help the engine reach its normal running temperature/to

maintain operating temperature.

2.1.4 To deliver an adequate volume of oil around the engine at a

suitable pressure.

2.1.5 To ignite the spark on fuel air mixture.

(5 × 1) (5)



2.2 A – big end bearing

B – timing chain gear C – balance weight D – oil hole E – rear flange F – main journal

(6) 2.3 Switch off the engine, a car must be on level ground, take out oil dip stick and

wipe oil off, then put dip stick back, remove and check.

(4) 2.4 A – adjusting bar

B – alternator C – fan D – fan belt E – pulley

(5) [20] QUESTION 3 3.1 Worn out oil rings

Weak oil pump.

Wrongly placed oil rings.

(3) 3.2 It provides a vacuum in order to draw fuel charge into the cylinder.

It compresses the mixture in the cylinder.

It holds the expanding gas at the top off the piston.

It transmits energy during power stroke to crankshaft.

It moves up and down the cylinder and exhaust the burnt fuel charge.

It conducts heat from the piston to the cooled cylinder walls. (Any 3 × 1)

(3) 3.3 A – flywheel

B – clutch plate C – crankshaft D – pressure plate E – release lever F – thrust bearing G –spring

(7)



3.4 The blower supplies air into the cylinder which is at low pressure. The influx

air is compressed. The inlet port is open. Because of high cylinder pressure, most of the spent gas is emitted through the open exhaust port. At the same time the air blows out the remaining spent gases.

(7)

[20] QUESTION 4 4.1 4.1.1 True 4.1.2 True 4.1.3 False 4.1.4 False 4.1.5 True (5 × 1) (5) 4.2 Reduces power loss by reducing friction.

Reduces wear in moving parts.

Assists in cooling hot components.

Assists in cooling pistons and rings against cylinder walls.

Absorbs shock and reduces noise between moving parts.

Maintains internal cleanliness.

Reduces rusting and corrosion of components. (Any 3 × 1)

(3)



4.3 External oil leaks.

Oil levels too high.

Faulty crankshaft ventilation system.

Worn rings/valve stem seals.

Oil pressure too high. (Any 3 × 1)

(3) 4.4 Absorb road shocks.

To provide comfortable, quiet run of the vehicle

To give safe operating to maximum speed.

To offer minimum rolling resistance to motion.

To support the weight of the vehicle and distribute it evenly over the road.

To provide friction between the tyre and the road for traction.

It provides an air cushion between the road and the car wheels. (Any 3 × 1)

(3) 4.5 A – outer rotor

B – drive shaft C – Inner rotor D – casing E – Outlet F – Inlet

(6) [20] QUESTION 5 5.1 Cut slowly using full length of the blade.

Do not apply too much downward pressure on the blade.

Insert the blade with the teeth pointing to the front.

The blade must be properly tensioned.

After use, slack the blade.

Use the correct blade for the job. (Any 3 × 1)

(3) 5.2 Safety goggles must all times be used.

Work rest must always be in place; gap between rest and wheel is ± 2 mm.

Grading wheels must be balanced.

Work piece should not be knocked.

Permanent transparent shield be mounted above work area.

Sides of the grinding wheels should not be used for grinding.

Work piece should not be pressed too hard against the grinder. (Any 2 × 1)

(2) 5.3 Negligence of person involved.

Ignorance of the danger involved.

Fooling about, playing, jokes.

Tiredness or day dreaming.

Failure to take adequate precaution.

Lack of skills through inadequate training.

Untidy or obstructed working area. (Any 3 × 1)

(3)



5.4

(5)

5.5 5.5.1 lead light 5.5.2 ring spanner 5.5.3 side cutter 5.5.4 ratchet handle 5.5.5 feeler gauge 5.5.6 ring squeezer 5.5.7 cooling system pressure tester (7)

[20]

TOTAL: 100


T1140(E)(N11)T




(11040651)

11 November 2014 (Y-Paper) 13:00–16:00


(11040651) -2- T1140(E)(N11)T






Answer ALL the questions. Read ALL the questions carefully. Number the answers according to the numbering system used in this question paper. ALL sketches must be provided with the necessary labels. Correct spelling and terminology are important. Start each question on a NEW page. Write neatly and legibly.

(11040651) -3- T1140(E)(N11)T




1.1.1 One of the advantages of good housekeeping is … A

B C D

poor ventilation. hazardous atmospheric conduction. inadequate supports. keeping work areas neat and orderly.

1.1.2 Safety signs used in industries are classified into groups or

designations. State the designation that PV stands for:

A

B C D

Warning signs Information signs Prohibitive signs Fire-equipment warning signs

1.1.3 The most common hammer used in an automotive workshop is a

…

A

B C D

ball-peen hammer. soft-face hammer. lump hammer. mallet hammer.

1.1.4 The … change(s) the reciprocating movement of the piston into

rotary motion.

A

B C D

connecting rod crankshaft piston rings compression rings

1.1.5 The timing chain is the connection between the … A

B C D

camshaft and crankshaft. big-end bearing and crankshaft. small-end bearing and crankshaft. timing cover and gasket.

1.1.6 A measuring instrument which is both accurate and versatile: A

B C D

The telescopic gauge The dial gauge The feeler gauge The plastigauge

(11040651) -4- T1140(E)(N11)T


1.1.7 The correct sequence of strokes in a four-stroke petrol engine is:

A B C D

Power, Induction, Exhaust and Compression strokes Induction, Compression, Power and Exhaust strokes Compression, Exhaust, Power and Induction strokes Induction, Power, Compression and Exhaust strokes

1.1.8 Dilution of motor oil can be very detrimental to an engine and its components. One cause of engine dilution of motor oil is …

A B C D

varnish formation. reduction of oil viscosity. low oil pressure. leaking injection.

1.1.9 One of the causes of engine overheating is …

A B C D

air cooling of oil. water cooling of oil. exhaust restriction. bypass of valve.

1.1.10 One of the advantages of a tubeless tyre is …

A B C D

radial ply. cross ply. less vibration. ply rating.

(10 × 1)

(10)

1.2 FIGURE 1 shows a sketch of the parts of an internal combustion engine. Name the labelled parts (A–I) in the ANSWER BOOK.

(9)

FIGURE 1

(11040651) -5- T1140(E)(N11)T


1.3 Name ONE defect on a motor vehicle that can be caused by a faulty lead-

acid battery.

(1) [20]

QUESTION 2 2.1 FIGURE 2 below shows a sketch of the parts of an internal combustion

engine. Name the labelled parts (A–F) in the ANSWER BOOK.

(6)

FIGURE 2 2.2 Give TWO reasons for low oil pressure, although there is enough oil in the

sump.

(2) 2.3 Name TWO types of lubricating systems in the engine of a motor vehicle. (2) 2.4 Make a large neat sketch of a hydrometer suitable to measure the density of

the electrolyte in the battery.

(5) 2.5 Name TWO methods to connect a battery. (2) 2.6 Name THREE causes of excessive sulphation. (3)

[20]

(11040651) -6- T1140(E)(N11)T


QUESTION 3 3.1 Every engine cylinder normally contains two valves per cycle (one inlet valve

and one exhaust valve). In most of today's motor cars, multi-valve technology is used. Make a neat sketch of a valve and indicate all valve parts.

(6)

3.2 Name the TWO types of piston rings. (2) 3.3 Give TWO reasons why a timing guide is important. (2) 3.4 FIGURE 3 below shows the parts of an internal combustion engine.

Name the labelled parts (A–H)

(8)

FIGURE 3

3.5 State ONE function of each of the following engine components: 3.5.1

3.5.2

Crankshaft Flywheel

(1) (1) [20]

(11040651) -7- T1140(E)(N11)T


QUESTION 4


4.1.1 4.1.2 4.1.3 4.1.4 4.1.5

Add water to the battery before doing a hydrometer test. Oil or grease present on the linings causes slip in clutch. Electrolyte consists of sulphuric acid and distilled water. One of the tyre's purposes is to offer the maximum rolling resistance to the motion. The connecting rod changes reciprocating movement into rotary movement of the piston.

(5 × 1)

(5)

4.2 State THREE functions of the clutch as used between the engine and gearbox.

(3)

4.3 State THREE safety precautions that a mechanic must take to ensure his/her personal safety in the workshop.

(3)

4.4 State FOUR causes of accidents in the workshop. (4)

4.5 State FIVE causes of rattles, ticks or knocks inside the bell housing. It happens when the engine is started and the clutch operated.

(5) [20]

QUESTION 5

5.1 Make a neat, labelled sketch of TWO 12 V batteries connected in parallel. Clearly indicate the total voltage available from this arrangement. (2 x 2)

(4)

5.2 FIGURE 4 below shows two sketches of tyre-ply constructions. Name the ply constructions shown in each of the sketches (A and B) in the ANSWER BOOK.

(2)

FIGURE 4

(11040651) -8- T1140(E)(N11)T


5.3 State TWO reasons why correct tyre pressure should be maintained. (2) 5.4 State THREE advantages of tubeless tyres. (3) 5.5 FIGURE 5 below shows various tools used in the workshop.

Name the tools marked (5.5.1–5.5.9)

5.5 5.5.1

5.5.2

5.5.3

5.5.4

(11040651) -9- T1140(E)(N11)T


5.5.5

5.5.6

5.5.7

(11040651) -10- T1140(E)(N11)T


5.5.8

5.5.9

(9) [20]

FIGURE 5

TOTAL: 100





11 NOVEMBER 2014


MARKING GUIDELINE



QUESTION 1 1.1 1.1.1

1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10

D C A B A B B D C C

(10 × 1)

(10)

1.2 A – Dipstick

B – Oil pump C – Strainer D – Sump E – Oil-filler cap F – Oil-pressure switch G – Oil filter H – Oil I – Oil drain plug (9 x 1)

(9)

1.3 Difficult to start

Engine fails to crank (Any 1 x 1)

(1) [20]

QUESTION 2 2.1 A – Cylinder head

B – Piston C – Connecting rod D – Big-end bearing E – Crankshaft F – Bearing caps (6 x 1)

(6)

2.2 Weak oil pump

Cracked cylinder head

Weak compression (Any 2 x 1)

(2)

2.3 Splash system

Pressure system

(2)



2.4 FIGURE 1 (hydrometer structure) (5)

FIGURE 1 2.5 Series connection of battery

Parallel connection of battery

(2)


Local chemical action in the cells Insufficient or infrequent charging The electrolyte level being too low The specific gravity of the electrolyte being too low (Any 3 × 1)

(3) [20]

QUESTION 3 3.1 FIGURE 2 (valve structure) (6)

FIGURE 2



3.2 Oil rings and compression rings (2) 3.3 To prevent the chain belt from sleeking against lamina cover

To ensure that the chain belt stays on the sprockets

(2)

3.4 A – Camshaft

B – Tensioner C – Timing belt D – Connecting rod E – Camshaft F – Camshaft G – Valve H – Piston (8 x 1)

(8)

3.5 3.5.1

3.5.2

Crankshaft

Provides a constant turning force to the wheels

Changing reciprocating movement of piston into rotary motion

Distributes oil from main journal bearings to big end of the connecting rod (Any of the above)

Flywheel * It smoothes the engine. * It serves as a mounting surface for the clutch and pressure plate. * It engages the starter motor to crank the engine.

(Any of the above)

(1)

(1) [20]


4.1.2 4.1.3 4.1.4 4.1.5

True

True True False False

(5 × 1)

(5)

4.2 To transmit the torque smoothly from running engine

To allow gear changing when the vehicle is in motion

To give temporary neutral when the engine is running for gear selection

(3)



4.3 Safety shoes must be worn all the time.

No loose cloth, sleeves, long hair in the workshop

Safety goggles or welding helmets must be worn.

Facial mask for asbestos dust from brake shoes

Ear guards must be worn when working in a noisy place.

Gloves must be worn when working with acids.

A creeper to protect your body from cold floor (Any 3 x 1)

(3)

4.4 Negligence; ignorance of the danger involved; fooling about tiredness or

daydreaming; failure to use correct equipment; lack of skills through inadequate training; untidy or obstructed equipment. (Any 4 x 1)

(4)

4.5 Release-lever broken spring

Gearbox input shaft-bearing damaged Release bearing worn or damaged Input shaft splines of clutch excessively worn Broken or loose shock spring of clutch plate

(5) [20]

QUESTION 5 5.1 FIGURE 3 (battery parallel connection) (4)

PARALLEL CIRCUIT The two 12 V batteries are connected in parallel to form a 12 V battery that will last longer and have a greater cranking capacity than one 12 V battery. This arrangement is used on smaller trucks with a diesel engine that is difficult to start. The two batteries will supply sufficient current to the 12 V starter motor to start the engine.

FIGURE 3 5.2 A – Radial ply; B – Cross ply (2) 5.3 Longer tyre life; assures vehicle safety; comfortable ride

Prevent excessive heat built-up; proper tyre inflation allows full tyre area to touch the road (Any 2 x 1)

(2)

5.4 Cheap to produce and assemble; keep pressure for a longer period;

increase safety; they are lighter in mass; cooler turning (Any 3 × 1)

(3)



5.5 5.5.1

5.5.2 5.5.3 5.5.4 5.5.5 5.5.6 5.5.7 5.5.8 5.5.9

Trolley jack Hacksaw Ring squeezer Veneer calliper Centre punch Vice grip (pipe pliers) Outside micrometer Lead light Clamp screw (9 x 1)

(9) [20]

TOTAL: 100


T1130(E)(J21)T

AUGUST EXAMINATION



(11040651)

21 July 2014 (Y-Paper) 13:00–16:00


(11040651) -2- T1130(E)(J21)T





INSTRUCTIONS AND INFORMATION 1. 2. 3. 4. 5. 6. 7. 8.

Answer ALL the questions. Read ALL the questions carefully. Number the answers according to the numbering system used in this question paper. ALL sketches must be provided with the necessary labels. Correct spelling and terminology are important. Start each question on a NEW page. Marks indicated are percentages. Write neatly and legibly.

(11040651) -3- T1130(E)(J21)T




1.1.1 Two 12 volt batteries connected in parallel produce … volts. A

B C D

12 18 24 6

1.1.2 The main function of the crankshaft is to … A

B C D

drive the clutch assembly. drive the gearbox. convert the reciprocating motion of the piston to rotary motion. convert the combustion pressure to mechanical power.

1.1.3 The correct sequence of strokes of a two-cylinder four-stroke

engine is:

A

B C D

Compression, induction, power, exhaust Induction, compression, power Induction, compression, power, exhaust Induction, compression, power, transfer

1.1.4 Tyres should be inflated to the recommended pressure when they

are …

A

B C D

carrying a load. hot. cold. at operating temperature.

1.1.5 An engine that overheats can cause … A

B C D

engine seizure. a cracked cylinder head. bearing failure. All of above

1.1.6 Completely removing a radiator pressure cap while an engine is

hot can cause …

A

B C D

a cracked engine block. a blocked radiator. a sudden, violent burst of steam. warped valves.

(11040651) -4- T1130(E)(J21)T


1.1.7 The ... is the correct tool to loosen cylinder head bolts. A

B C D

power bar torque wrench speed brace ratchet

1.1.8 The most accurate mechanical measuring instrument is the … A

B C D

vernier calliper. micrometer. dial gauge. steel rule.

1.1.9 If a fire brakes out in a workshop, you should not … A

B C D

identify the most suitable fire extinguisher. correctly operate the suitable fire extinguisher. locate fire fighting equipment and alarms in the workshop. open all doors and windows.

1.1.10 Used engine oil should be disposed of by … A

B C D

dumping it in an open field. pouring it down the drain. putting it in the rubbish bin. recycling.

(10 x 1)

(10)

1.2 FIGURE 1 below shows a sketch of an engine.

Name the parts labelled A–E by writing only the answer next to the letter (A–E) in the ANSWER BOOK.

FIGURE 1 (5)

A C

B

E

D

(11040651) -5- T1130(E)(J21)T


1.3 FIGURE 2 below shows various signs.

Name the sign illustrated in each sketch by writing only the answer next to the question number (1.3.1–1.3.3) in the ANSWER BOOK.

1.3.1

1.3.2

1.3.3

FIGURE 2 (3 x 2)

(6) [21]

QUESTION 2

2.1 FIGURE 3 below shows the internal parts of the internal combustion engine.

Name the parts labelled A–F by writing only the answer next to the letter (A–F) in the ANSWER BOOK.

FIGURE 3 (6)

F E

(11040651) -6- T1130(E)(J21)T


2.2 State the functions of the following: 2.2.1 Flywheel 2.2.2 Valve-stem oil seal 2.2.3 Crankshaft

(3 x 1)

(3) 2.3 Name the special tools needed in each of the following cases: 2.3.1 When raising a vehicle so that a wheel can be changed 2.3.2 To insert a piston into a cylinder 2.3.3 To locate leaks in the vehicle cooling system 2.3.4 To check/measure the density of electrolyte in the battery

(4 x 1)

(4) 2.4 Explain in detail the compression stroke of the four-stroke petrol (spark

ignition) engine. In your explanation refer to the position of the pistons, valves and characteristics of the mixture charge and direction of piston movement.

(8) [21]

QUESTION 3

3.1 Make a large, neat, sectional sketch of a four-stroke diesel engine during power stroke. Name all the parts of the engine and indicate the direction of the piston travel.

(5)

3.2 FIGURE 4 below shows a front engine, front-wheel drive. Name the parts labelled A–F by writing only the answer next to the letter (A–F) in the ANSWER BOOK.

FIGURE 4 (6)

A

B

C

D

E

F

(11040651) -7- T1130(E)(J21)T


3.3 Explain in detail what happens in a single-plate helical spring clutch assembly when the clutch pedal is depressed.

(5)

3.4 Give TWO disadvantages of a front engine, front-wheel drive arrangement. (2)

3.5 Give TWO advantages of a rear engine, rear-wheel drive arrangement. (2) [20]

QUESTION 4


4.1.1 An engine overheat can be caused by a cracked cylinder head.

4.1.2 The correct sequence of a two-stroke four-cylinder engine is compression, induction, power and exhaust.

4.1.3 The main function of a crankshaft is to convert reciprocating motion of the piston into rotary. (3 x 1)

(3)

4.2 Name FIVE types of oil pumps that may be used in an internal combustion engine.

(5)

4.3 Name TWO oil additives. (2)

4.4 Write down what SAE 40 W/50 stand for. (3)

4.5 FIGURE 5 shows a cooling system of an internal combustion engine.

Name the parts (A–E) by writing only the answer next to the letter (A–E) in the ANSWER BOOK.

FIGURE 5 (5) [18]

(11040651) -8- T1130(E)(J21)T


QUESTION 5

5.1 FIGURE 6 below shows a measuring instrument. Name the instrument and name the parts labelled A–D by writing only the answer next to the letter (A–D) in the ANSWER BOOK.

FIGURE 6 (5) 5.2 Describe how a battery is replaced in a vehicle. (3)

5.3 State TWO functions of a tyre in a vehicle. (2)

5.4 State THREE advantages of a tubeless tyre. (3)

5.5 FIGURE 7 below shows various tools used in a workshop. Name the tools by writing only the answer next to the question number (5.5.1–5.5.7) in the ANSWER BOOK.

5.5.1

5.5.2

5.5.3

A

B

C

D

(11040651) -9- T1130(E)(J21)T


5.5.4

5.5.5

5.5.6

5.5.7

FIGURE 7 (7) [20]

TOTAL: 100



AUGUST EXAMINATION


21 JULY 2014


MARKING GUIDELINE

MARKING GUIDELINE -2- T1130(E)(J21)T MOTOR TRADE THEORY N1



1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10

A C C D D C A B D D (10 x 1)

(10)

1.2 A – Adjusting bar

B – Alternator C – Radiator fan D – Fan belt E – Pulley (5 x 1)

(5)

1.3 1.3.1

1.3.2 1.3.3

Warning of moving machinery hazard Respiratory protection Use safety goggles

(3 x 2)

(6) [21]

QUESTION 2 2.1 A – Camshaft pulley

B – Belt [toothed]. C – Distributor drive pulley D – Jockey pulley belt/tensions E – Crankshaft pulley F – Inlet/outlet

(6)

2.2 2.2.1 Flywheel

It smoothes out engine speed and keeps the crankshaft spirit.

It serves as a mounting surface for clutch and pressure plate.

It engages the startor motor to crank the engine. (Any 1 x 1)

(1)

2.2.2 Valve-stem oil seal

It prevents oil on the valve stem from running into combustion chamber.

It prevents oil on the valve stem to cause engine to smoke. (Any 1 x 1)

(1)



2.2.3 Crankshaft

It provides a constant turning force to the wheels.

It changes the reciprocating movement of piston into rotary.

It distributes oil from the main bearing journals to the big end journals of the connecting rod. (Any 1 x 1)

(1)

2.3 2.3.1

2.3.2 2.3.3 2.3.4

Jack Ring squeezer Pressure tester Hydrometer (4 x 1)

(4)

2.4 Piston is moving upwards

Both inlet and outlet valves are closed

Petrol

Air is compressed (4 x 2)

(8) [21]

QUESTION 3 3.1

(5)

3.2 A Drive shaft

B Gear box C Clutch D Engine E Final drive F CV joints (Any 6 x 1)

(6)



3.3 Pressure plate is forced towards the flywheel by means of series of helical

coil springs which provide clamping force

Three to four release levers pivot so that they engage with the release bearing at one end and pressure plate at the other lever

The pressure plate moves back the springs again to release the force on the driven plate when the clutch is operated to disengage.

(5)

3.4 Increases wear on front tyres

Heavy feel of steering

High maintenance costs

High initial cost due to complicated drive arrangement (Any 2 x 1)

(2)

3.5 Light steering of the vehicle

Very good traction

Engine noise kept to a minimum

High efficiency transmission (Any 2 x 1)

(2) [20]


4.1.2 4.1.3

True False True

(3)

4.2 Geary type

Eccentric rotor type

Internal gear type

Sliding type

Plunger type

(5)

4.3 Viscosity index improves; oil body; fluidity; detergent dispersant; corrosion

and rust inhibition; pour point depression; oxidation inhibitors; foaming resistance; resistance to carbon formation; extreme pressure resistance.

(2)

4.4 SAE 40W/50

SAE – Society of Automatic Engineers W - Winter condition 50 - Operation temperature

(3)

4.5 Radiator

Radiator fan

Cooling air

Water pump

Water jackets

(5) [18]



QUESTION 5 5.1 Hydrometer

Rubber bulb

Float

Weight

Rubber pipe

(5)

5.2 Use two spanners to loosen the terminal

Remove the earth terminal first

Use spread clamps for terminals which are stuck

Do not put battery on the paint work of a vehicle

Clean the battery terminals

Tighten securely and coat terminal with grease

Use two open-end spanners to tighten clamp nuts

Top up level of electrolyte if necessary (Any 3 x 1)

(3)

5.3 It provides an air cushion between road and car wheels

It absorbs shocks resulting from irregularities in the road It provides frictional contact for good traction To support the weight of the vehicle To offer maximum rolling resistance to motion To give safe operation up to the maximum speed To give a comfortable ride To provide quiet, straight ahead running and freedom from skidding on cornering and braking (Any 2 x 1)

(2)

5.4 Cheap to produce and assemble

Keeps its pressure for a longer period

Increases safety

Lighter in mass

Cooler running (Any 3 x 1)

(3)

5.5 Punch

Rug spanner

Torque wrench

Allen key

Phillips screw driver

Engineering vice

Trestle (7 x 1)

(7) [20]

TOTAL: 100

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