NZ Certificate in Light Automotive Engineering (Level 4) Theory Assessment

Under New Zealand HSWA 2015, what is a Level 4 technician's duty when monitoring workshop safety?

• AIdentify hazards, report risks to the PCBU, and ensure controls are followed by supervise…
• BIgnore minor hazards if production targets are behind schedule
• CDelegate all safety monitoring solely to WorkSafe inspectors
• DRely on customers to report workshop hazards before servicing begins

Before working on a hybrid vehicle high-voltage system in a New Zealand workshop, what must be completed first?

• AFollow manufacturer isolation procedure, verify zero voltage, and use appropriate PPE and…
• BDisconnect the 12 V battery only and begin component removal immediately
• CSpray water on orange cables to dissipate residual charge
• DAsk a colleague to hold insulated gloves while you probe live terminals

What is the minimum legal tread depth for passenger car tyres at the principal grooves under NZ WoF requirements?

• A1.5 mm
• B3.0 mm
• C0.5 mm
• D4.0 mm

When must a New Zealand automotive workshop conduct a risk assessment under HSWA principles?

• AWhen introducing new equipment, processes, or high-risk tasks such as HV battery removal
• BOnly after a serious harm notification to WorkSafe
• COnce every ten years regardless of process changes
• DOnly when requested by a customer in writing

A Level 4 technician notices an apprentice bypassing a wheel chock on a rolling road. What is the correct response?

• AStop the task, correct the unsafe practice, and reinforce the workshop safe-work procedure
• BAllow it once if the vehicle is only idling at low speed
• CReport the apprentice to NZTA instead of the workshop supervisor
• DIgnore it if the apprentice has completed Level 2 theory

Which document must be available in a NZ workshop before using a new brake-cleaning solvent?

• ACurrent Safety Data Sheet (SDS) with hazard controls and PPE requirements
• BThe vehicle owner's insurance policy
• CA WoF inspection checklist only
• DThe apprentice's school report

What is the purpose of a workshop JSA (Job Safety Analysis) before driveline removal on a raised vehicle?

• ABreak the task into steps, identify hazards at each step, and define controls before work…
• BCalculate the customer's invoice total including GST
• CDetermine the correct tyre pressure for the WoF retest
• DRecord engine compression readings for the service history

When storing removed HV battery modules in a NZ workshop, what control is required?

• ASegregated, labelled quarantine area with fire-suppression planning per manufacturer and…
• BStack modules under the parts bench with other metal scrap
• CPlace modules in the general staff lunch area for visibility
• DSubmerge modules in water to prevent thermal runaway

A workshop noise survey shows exposure above the WorkSafe action level. What should the PCBU implement?

• AHearing conservation controls such as engineering changes, rotation, and hearing protecti…
• BIgnore results if staff prefer not to wear earmuffs
• CIncrease radio volume so technicians can hear over machinery
• DRemove all power tools from the workshop permanently

During EV service, orange HV cables are found with damaged insulation. What is the correct Level 4 action?

• AQuarantine the vehicle, tag out the system, and follow manufacturer repair or replacement…
• BWrap damaged section with general cloth tape and continue the service
• CCut the cable and twist the conductors together temporarily
• DTest the circuit with a test lamp connected to the damaged section

A near-miss occurs when a hoist arm slips but no injury results. Under HSWA monitoring practice, what should happen?

• AInvestigate root cause, record the event, and update controls before resuming similar lif…
• BTake no action because no injury occurred
• CWait for WorkSafe to initiate an investigation before changing procedures
• DDiscard the hoist without documenting the incident

What does a wet compression test that rises significantly compared to a dry test typically indicate?

• APoor piston ring sealing or cylinder wall wear
• BA faulty oxygen sensor only
• CIncorrect ignition timing with no internal wear
• DExcessive fuel pressure at the rail

An engine shows low compression on one cylinder only. What is the most logical next test?

• ALeak-down test to identify whether valves, rings, or gasket are leaking
• BReplace all spark plugs before further testing
• CAdjust wheel alignment to correct the misfire
• DFlush the radiator and retest compression

A timing chain rattle on cold start that fades when warm most often suggests:

• AWorn chain tensioner or stretched timing chain
• BLow brake fluid level in the master cylinder
• CA clogged cabin air filter
• DUnder-inflated spare tyre in the boot

A four-cylinder engine has compression readings of 1200, 1180, 650, and 1190 kPa. What is the most likely fault?

• AMechanical problem in cylinder 3 such as burnt valve, broken ring, or head gasket leak
• BUniform wear across all cylinders requiring only an oil change
• CA global fuel filter restriction affecting one cylinder
• DIncorrect tyre rotation pattern

If static compression ratio is 10:1 and a cylinder sweeps 500 cc, what is approximate clearance volume?

• A50 cc
• B5000 cc
• C5 cc
• D250 cc

Oil analysis shows elevated iron and aluminium particles after a turbocharger failure. What does this support?

• AInternal wear from debris circulated through the lubrication system after turbo failure
• BNormal additive package breakdown only
• CContamination from incorrect coolant type in the washer bottle
• DWoF tread depth below 1.5 mm on rear tyres

A DI petrol engine misfires under load with carbon fouling on the intake valves. What is the most probable cause at Level 4 diagnosis?

• AOil vapour and blow-by depositing on valves because port fuel wash is absent in direct in…
• BWorn brake pads transferring material to intake valves
• CLow power-steering fluid aeration
• DIncorrect rear fog lamp bulb wattage

What does a fuel trim reading of +25% long-term on a petrol engine most commonly indicate?

• AThe ECM is adding fuel to compensate for a lean condition such as unmetered air or low fu…
• BThe engine is running rich and the ECM is removing fuel
• CThe catalytic converter is new and causing enrichment
• DThe alternator is overcharging and enriching the mixture

A petrol vehicle fails emissions for high HC with normal CO and O2. What should be checked first?

• AIgnition system misfire causing unburned fuel
• BOverfilled engine oil only
• CRear wiper motor current draw
• DSpare wheel balance weights

A turbo diesel shows black smoke under acceleration with boost pressure 40 kPa below specification. What is the leading diagnosis?

• ABoost leak, stuck VGT vanes, or restricted intake/exhaust causing insufficient air
• BExcessive power-steering assist pressure
• CCabin pollen filter oversize
• DUnder-torqued wheel nuts on the front axle

An EVAP system small leak code appears after fuel cap replacement. What is the correct diagnostic sequence?

• AVerify cap quality, smoke-test the EVAP circuit, and inspect purge/vent valves and lines
• BReplace the catalytic converter immediately
• CAdjust camber to zero on all wheels
• DDrain engine oil to minimum level

A GDI engine shows P0171 and hissing at the intake manifold gasket. What confirms the fault?

• ASmoke test or propane enrichment showing RPM change at the gasket seam
• BMeasuring tyre tread depth at 1.5 mm WoF limit
• CChecking brake disc thickness only
• DReading transmission fluid colour

A diesel particulate filter regenerates frequently but soot load remains high. What advanced fault is most likely?

• AFailed differential pressure sensor, leaking injectors, or short-trip driving preventing…
• BCorrect tyre pressures on all four corners
• CNew wiper blades installed correctly
• DFresh cabin deodoriser in the vents

Vibration under hard acceleration in a FWD vehicle is most commonly caused by:

• AWorn inner CV joint allowing plunging imbalance
• BLow engine oil level only
• CA dirty cabin air filter
• DIncorrect clock spring rotation count

A clunk when shifting from reverse to drive in an AWD SUV often indicates:

• AExcessive driveshaft or differential lash from worn U-joints or mount isolation
• BLow washer fluid in the reservoir
• CA burnt-out number plate lamp
• DOverfilled coolant expansion tank only

During a road test, a humming noise changes with vehicle speed but not engine RPM in neutral. What system is implicated?

• AWheel bearing, tyre, or final-drive/driveshaft rotating with road speed
• BIntake manifold vacuum leak at idle
• CFaulty MAF sensor scaling only
• DLow brake fluid causing pedal fade

A propshaft centre bearing failure is suspected. What symptom supports this diagnosis?

• AVibration increasing with speed and noise from the bearing support area
• BEngine overheating at motorway speeds only
• CIntermittent wipers during cornering
• DABS lamp flashing at every stop

An AWD transfer case binds on tight turns on dry pavement. What is the likely cause?

• AIncorrect or viscous coupling fluid, or driving with mismatched tyre diameters
• BLow engine compression on one cylinder
• CFaulty rear demister grid only
• DWorn windscreen wiper rubbers

A RWD ute shudders on take-off with a single-cardan joint at steep angle. What is the correct repair direction?

• AReduce joint angle with ride-height correction or fit a double-cardan joint as specified
• BIncrease propshaft angle by lowering the differential
• CRemove the centre bearing to stiffen the shaft
• DFit smaller diameter tyres on the front only without calculation

Differential oil is metallic glitter with a whine under load. What Level 4 conclusion is justified?

• AInternal gear or bearing damage requiring differential strip inspection
• BNormal additive sparkle requiring no action
• CTyre tread at exactly 2.0 mm causing gear noise
• DLow cabin humidity affecting lube viscosity

An automatic transmission slips in third gear only with no codes. What should be checked first?

• AFluid level, condition, and pressure test per workshop manual
• BBrake pad thickness on rear axle
• CPower antenna mast lubrication
• DSpare tyre age code

A manual gearbox pops out of fifth gear under light load. What is the most likely internal fault?

• AWorn synchro or detent spring on fifth gear
• BLow engine coolant level
• CFaulty rear fog lamp switch
• DUndercharged air conditioning system

ATF smells burnt and is dark brown after towing a heavy trailer up a long grade. What does this indicate?

• ATransmission overheating and clutch material breakdown requiring fluid service and fault…
• BNormal ATF colour for all vehicles regardless of use
• CWoF tread minimum of 1.5 mm has been exceeded
• DCorrect tyre rotation every 10 000 km

A DCT shudders from rest with a P0900 series clutch actuator code. What is the logical repair path?

• ADiagnose clutch actuator circuit, verify fluid, and perform clutch adaptation if within s…
• BReplace all four tyres with the smallest available size
• CAdjust headlamp aim only
• DDrain engine oil to minimum mark

CVT exhibits high RPM with slow vehicle acceleration and whining. Live data shows high pulley ratio error. What is likely?

• ABelt slip from worn pulleys/belt or low/incorrect CVT fluid
• BLow brake fluid causing ratio error
• CFaulty number plate lamp earth
• DOverinflated spare tyre

After clutch replacement on a manual AWD, a vibration appears at 3000 RPM. What is the most probable installation error?

• ADual-mass flywheel misalignment, incorrect clutch disc orientation, or failing to reset D…
• BUsing the correct gearbox oil grade specified by OEM
• CTorquing wheel nuts to specification
• DSetting tyre pressures to placard values

Using Ohm's law, what is the current through a 12 Ω heated seat element at 12 V?

• A1 A
• B144 A
• C0.08 A
• D24 A

A circuit draws 12 A at 12 V through a supply wire with 0.05 Ω total resistance. What is the voltage drop across the wire?

• A0.6 V
• B6.0 V
• C0.12 V
• D2.4 V

What is the correct first step when diagnosing an intermittent open circuit in a vehicle wiring harness?

• AWiggle-test the harness while monitoring voltage or resistance at the load
• BReplace the alternator without measurement
• CIncrease fuse rating to stop blowing
• DDisconnect the battery and spray water on connectors

A headlamp is dim on low beam only. Voltage at the lamp is 9 V with 12.4 V at the battery. What is indicated?

• AExcessive voltage drop in the supply or ground path for that circuit
• BPerfect wiring with no resistance
• COvercharged battery causing low lamp voltage
• DCorrect operation for all halogen lamps

What wire repair practice meets typical OEM expectations in a NZ light vehicle workshop?

• ASolder and heat-shrink with correct gauge and sealed connector, following EWD splice loca…
• BTwist wires together and tape with general cloth tape only
• CSplice with mismatched thinner wire to save copper
• DJoin high-current cables with a household wire nut

A fuse repeatedly blows when the rear demister is switched on. What diagnostic approach is correct?

• AMeasure demister grid amperage and inspect for damaged element shorts to body
• BFit a fuse twice the rated value permanently
• CIgnore because demisters are non-essential
• DDisconnect the ABS module to reduce load

CAN bus communication errors appear after body repair. All modules show high error counters. What is the first wiring check?

• ACAN H and CAN L continuity, termination, and short/open between pairs at repaired splice…
• BEngine oil viscosity grade only
• CTyre rotation direction markings
• DPower steering fluid colour

A starter motor circuit shows 11.8 V at battery and 8.0 V at starter during cranking. Cable resistance is suspected. If cranking current is 200 A, what is approximate cable plus connection resistance?

• A0.019 Ω
• B1.9 Ω
• C0.19 Ω
• D19 Ω

Two CAN nodes fail to communicate after a connector refit. Resistance between CAN H and CAN L at the DLC is 120 Ω. What does this suggest?

• AMissing termination—only one 120 Ω module terminator is present instead of two parallel 6…
• BPerfect network with both terminators active
• CShort circuit between battery positive and CAN L
• DOpen circuit on the starter motor positive cable

A BCM controls interior lights that stay on with all doors closed. What should be verified first?

• ADoor jamb switch inputs and BCM live data for door-ajar status
• BEngine compression on all cylinders
• CTransmission fluid colour only
• DSpare wheel pressure