NZ Certificate in Electric Vehicle Automotive Engineering (Level 5) Theory Assessment

Under NZQA 3915 graduate outcomes, what is an EV Level 5 technician expected to do regarding workshop leadership?

• AOversee team responsibilities and ensure compliance with legislative and company safety r…
• BPerform only basic oil changes without supervisory duties
• CDelegate all HV safety solely to external consultants
• DFocus exclusively on sales without monitoring high-voltage hazards

A junior technician attempts HV battery service without completing voltage verification. Correct Level 5 leadership response?

• AStop work immediately, complete full isolation and zero-voltage verification, then retrai…
• BAllow completion if insulated gloves were worn
• CContinue because the 12 V battery was disconnected
• DDocument success without correction to meet deadline

When introducing DC fast-charge diagnostic equipment to a NZ EV workshop, what must a Level 5 technician ensure under HSWA?

• ARisk assessment, operator training, documented safe-work procedures, and maintained equip…
• BImmediate use without training to meet customer deadlines
• CRemoval of HV warning signage to reduce customer anxiety
• DBypassing charge port interlocks for faster testing

A workshop KPI shows rising comebacks on EV charging repairs. Best first action as technical leader?

• AReview diagnostic evidence, repair documentation, and technician workflow to identify sys…
• BBlame customers for misusing charge cables
• CReduce diagnostic time targets to increase throughput
• DStop using scan tools to avoid false codes

Which record best demonstrates HSWA compliance when overseeing traction battery removal?

• ACompleted job card with isolation steps, voltage verification readings, PPE used, and tec…
• BVerbal confirmation only with no written evidence
• CCustomer signature on a sales invoice alone
• DSocial media post showing the removed pack

Under the Health and Safety at Work Act 2015, who holds the primary duty to ensure EV workshop risks are managed?

• AThe PCBU (person conducting a business or undertaking)
• BOnly the apprentice on the job
• CThe vehicle manufacturer exclusively
• DCustomers who drop off vehicles

A technician reports recurring near-misses with unsecured EVs on hoists during battery service. Level 5 monitoring duty?

• AInvestigate root cause, reinforce hoist positioning and lock procedures, and escalate unr…
• BIgnore near-misses because no injury occurred
• CAllow one-wheel support if the HV job is quick
• DDisable hoist safety locks to speed lifting

NZQA 3915 states graduates are NOT recognised as manufacturer-specific technicians. What does this mean in practice?

• AOEM brand training and authorisation may still be required for warranty HV work despite h…
• BThe qualification is invalid for any EV repair work
• CGraduates may never work on electric vehicles
• DManufacturer procedures do not apply to NZQA graduates

Before assigning a technician their first unsupervised HV isolation on a BEV, what should a Level 5 leader verify?

• ADemonstrated competency against documented procedures, appropriate PPE, and understanding…
• BThat they have watched a single online video
• COnly that they hold a full driver licence
• DThat the customer approved the repair cost

An EV workshop plans to store removed traction battery modules indoors. Key HSWA consideration?

• AAssess fire, thermal runaway, and ventilation risks; follow manufacturer storage guidance…
• BStore anywhere convenient without risk assessment
• CStack modules against the lunchroom wall
• DDisable all smoke detectors to avoid false alarms

What is the MITO EV Level 5 training fee published on the official programme page?

• A$1,118 excluding GST (fixed, non-refundable)
• B$682 excluding GST
• C$1,189 excluding GST
• DFree with no employer involvement

How many NZQA credits does qualification 3915 comprise?

• A70 credits at Level 5
• B80 credits at Level 5
• C240 credits at Level 4
• D50 credits at Level 3

A Level 5 technician mentors staff on customer communication during HV repairs. Best practice?

• AExplain scope, safety delays for proper isolation, and realistic timelines without overpr…
• BPromise same-hour HV battery replacement regardless of parts
• CTell customers HV systems are safe to touch during service
• DAvoid documenting customer discussions

Entry to NZQA 3915 typically requires which prior qualification?

• AAutomotive Engineering qualification at Level 4 or equivalent skills and knowledge
• BNo automotive background required
• CClass 5 heavy vehicle licence only
• DUniversity engineering degree only

A BEV exhibits reduced acceleration with an inverter over-temperature code. Live data shows coolant at 95°C at the inverter outlet. Likely cause?

• ACooling system fault causing inverter thermal derating and reduced torque output
• BLow wiper fluid level
• CWorn brake pads only
• DIncorrect tyre pressure on one wheel

What does a resolver on a permanent-magnet synchronous motor (PMSM) provide to the inverter?

• ARotor position feedback for correct commutation timing and torque control
• BFuel injection timing
• CExhaust gas temperature
• DAutomatic transmission shift points

Regenerative braking contribution drops to zero but friction brakes work normally. Inverter coolant temperature reads high. Diagnosis?

• AInverter thermal protection limiting regen to preserve semiconductors
• BFlat 12 V battery alone causing total regen loss
• CWorn wiper blades
• DLow engine oil on a pure BEV

A traction motor produces a grinding noise under load with an inverter phase-current imbalance code. First check?

• AMotor winding integrity, inverter IGBT phase outputs, and resolver alignment per OEM proc…
• BReplace the 12 V battery without testing
• CAdjust wheel alignment only
• DDrain and refill windscreen washer fluid

During a road test, a BEV shudders when transitioning from regen to friction braking. Most likely system interaction?

• ABlending calibration fault between regenerative and hydraulic braking systems
• BIncorrect engine idle speed
• CClogged fuel filter
• DWorn spark plugs

What is the typical function of a DC link capacitor in an EV inverter?

• ASmooth DC bus voltage and supply stable energy during switching events
• BStore long-term energy like the traction battery
• CFilter engine oil contaminants
• DPressurise the air brake system

An AWD BEV has rear-drive inverter fault but front drive works. Customer reports vibration at highway speed. Related diagnostic focus?

• ATorque distribution and disabled rear axle regen/drive causing driveline imbalance
• BCarburettor mixture
• CTiming belt stretch
• DManual clutch slip

Live data shows motor RPM increasing but vehicle speed static with no park brake applied. Suspected fault area?

• AMechanical disconnect, reduction gear damage, or driveshaft/CV failure despite motor rota…
• BCorrect normal operation
• CLow tyre tread only
• DDirty air filter on a BEV

A hybrid in EV mode suddenly reverts to engine power with a motor inverter fault code. Safe next step?

• AFollow OEM fault procedure; do not continue HV motor diagnosis until codes and interlocks…
• BImmediately open the inverter cover while driving
• CRemove the service plug while the vehicle is moving
• DBypass the motor coolant pump

Field weakening in a PMSM drive system is used to achieve what?

• AHigher motor speeds above base speed by reducing flux, trading torque for speed
• BLower fuel consumption in diesel engines
• CIncreased exhaust back-pressure
• DManual gear downshifting

Oscilloscope capture on a three-phase motor lead shows one phase with significantly lower voltage amplitude. Likely fault?

• AOpen or high-resistance connection, failed IGBT leg, or damaged motor winding on that pha…
• BNormal balanced operation
• CLow windscreen washer fluid
• DIncorrect radio station preset

A BEV driver reports whining noise that changes with motor torque demand. Noise disappears in neutral (no torque). Focus?

• AElectromagnetic or mechanical noise from motor, reduction gear, or inverter under load
• BExhaust leak
• CFuel pump cavitation
• DDistributor cap tracking

What safety precaution applies before rotating an EV traction motor by hand during bench diagnosis?

• AEnsure HV system is isolated and motor cannot generate hazardous voltage as a generator
• BSpin rapidly to test bearing noise without isolation
• CApply 400 V externally to test rotation
• DRemove all PPE for dexterity

An inverter reports DC bus over-voltage during hard regen on a downhill drive. Expected control response?

• AReduce regen torque or activate braking resistor/grid to limit DC bus voltage rise
• BIncrease regen to maximum regardless of voltage
• COpen the traction battery contactors while driving
• DDisable friction brakes completely

A dual-motor BEV uses torque vectoring. A yaw-rate sensor fault appears. Likely system impact?

• AReduced or disabled torque vectoring; stability control may limit differential torque
• BImproved fuel economy
• CIncreased engine compression
• DAutomatic transmission slip

Hybrid vehicle motor-generator unit (MGU) will not crank the ICE for start. 12 V system normal, HV contactors closed. Check?

• AMGU inverter commands, resolver signal, ICE mechanical seizure, and hybrid control module…
• BSpark plug gap on a diesel hybrid only
• CCarburettor float level
• DManual choke setting

What indicates a failing traction motor bearing during a lift test with wheels free to rotate?

• ARoughness, play, or abnormal noise when rotating the motor/gearbox assembly by hand
• BPerfectly silent and smooth rotation only at exactly 3000 RPM
• CIncreased fuel trim on both banks
• DHigher exhaust CO levels

Inverter coolant pump runs continuously at maximum speed with no drive demand. Possible cause?

• ACoolant temperature sensor fault, control module strategy, or actual overheating condition
• BNormal behaviour with no possible fault
• CLow washer fluid triggering pump
• DWorn brake discs commanding pump speed

A technician measures AC ripple on the DC bus after inverter replacement. Reading exceeds OEM limit. Action?

• AInvestigate capacitor installation, bus bar torque, and inverter grounding before releasi…
• BIgnore ripple as irrelevant to EV operation
• COnly check tyre pressures
• DClear codes without further testing

Single-pedal driving mode increases regen when lifting off the accelerator. Customer reports abrupt deceleration. Adjustment focus?

• ARegen level settings, brake blending calibration, and driver mode software parameters
• BEngine timing advance
• CManual clutch adjustment
• DCarburettor idle mixture

What is the primary reason EV inverters use IGBT or SiC power semiconductors?

• AEfficient high-frequency switching to convert DC battery voltage to controlled AC for the…
• BTo generate spark for petrol combustion
• CTo pressurise power steering fluid
• DTo operate halogen headlamps only

A BEV shows "HV system fault" with isolation resistance below 500 Ω/V. First safe diagnostic action?

• ADo not touch HV components; follow OEM insulation fault procedure with rated PPE and insu…
• BProbe battery terminals with bare hands wearing cloth gloves
• CDrive at maximum speed to clear the fault
• DBypass the interlock circuit permanently

BMS live data shows one cell group consistently 0.15 V below others at moderate SOC. Likely concern?

• AWeak or failing cell group requiring further load testing and possible module service
• BNormal identical balance on all cells always
• CLow engine oil pressure
• DClogged air filter only

What does State of Health (SOH) typically represent in a traction battery?

• ARemaining useful capacity or degradation compared to new battery condition
• BCurrent vehicle road speed
• CTyre tread depth percentage
• DEngine coolant temperature

Traction battery thermal management uses liquid cooling. Coolant temperature spread across modules is 15°C during fast charge. Diagnosis?

• ACooling flow restriction, pump fault, or blocked cooling plate requiring thermal system i…
• BPerfectly normal with no possible issue
• CLow wiper fluid causing thermal spread
• DIncorrect wheel alignment

Before opening a serviceable battery pack enclosure, mandatory safety steps include?

• AOEM isolation procedure, voltage verification, appropriate PPE, and fire/emergency plan i…
• BOpening immediately to save time
• CUsing only standard 12 V test light on orange cables
• DRemoving all ventilation from the workshop

A hybrid NiMH pack shows rapid SOC swing under light load. Internal resistance reads elevated. Interpretation?

• ABattery degradation increasing voltage sag and reducing effective capacity
• BBrand new battery behaviour
• CTyre under-inflation only
• DCorrect normal NiMH behaviour at all times

What is the purpose of a pre-charge circuit in a traction battery contactor system?

• ALimit inrush current when closing main contactors by charging DC link capacitors through…
• BIncrease fuel pressure to injectors
• CEngage the starter motor pinion
• DOpen the exhaust valve

BMS reports insulation fault only when humidity is high. Likely cause?

• AMoisture ingress at pack seal, connector, or HV cable boot causing intermittent leakage
• BNormal weather with no fault
• CLow brake fluid only
• DIncorrect radio antenna

A technician must transport a damaged lithium-ion module internally. Best practice?

• AUse OEM-approved fire-rated container, secure upright, label as damaged HV battery, and f…
• BPlace loose in the boot without labeling
• CTape terminals and throw in general waste skip
• DSubmerge in fresh water permanently

Cell balancing in a Li-ion BMS during charging primarily achieves what?

• AEqualises individual cell or group voltages to prevent over-voltage on weaker strings
• BIncreases engine RPM
• CAdjusts wheel camber
• DChanges automatic transmission shift maps

After a minor collision affecting the battery pack underside, what must be assessed before HV re-energisation?

• AStructural damage, coolant leaks, isolation resistance, and BMS fault status per OEM insp…
• BOnly cosmetic paint on the bonnet
• CWiper blade length
• DSeat fabric colour

Live data shows contactors commanded closed but no DC current to inverter. Pre-charge status stuck incomplete. Suspect?

• APre-charge resistor failure, capacitor fault, or BMS inhibiting main contactor closure
• BCorrect normal sleep mode only
• CLow tyre pressure
• DDirty cabin air filter