Mechanical Technology May-June 2023 (Automotive) Eng

SENIOR CERTIFICATE EXAMINATIONS/
NATIONAL SENIOR CERTIFICATE EXAMINATIONS
MECHANICAL TECHNOLOGY: AUTOMOTIVE
2023
MARKS: 200
TIME: 3 hours
This question paper consists of 17 pages and a 2-page formula sheet.
Copyright reserved Please turn over

Mechanical Technology: Automotive 2 DBE/2023
SC/NSC
INSTRUCTIONS AND INFORMATION
1. Write your centre number and examination number in the spaces provided on
the ANSWER BOOK.
2. Read ALL the questions carefully.
3. Answer ALL the questions.
4. Number the answers correctly according to the numbering system used in this
question paper.
5. Start EACH question on a NEW page.
6. Show ALL calculations and units. Round off final answers to TWO decimal
places.
7. Candidates may use non-programmable scientific calculators and drawing

instruments.
8. The value of gravitational acceleration should be taken as 10 m/s 2.
9. All dimensions are in millimetres, unless stated otherwise in the question.
10. Write neatly and legibly.
11. A formula sheet is attached at the end of the question paper.
12. Use the criteria below to assist you in managing your time.
TIME
QUESTION CONTENT MARKS
IN MINUTES
GENERIC
1 Multiple-choice Questions 6 6
2 Safety 10 10
3 Materials 14 14
SPECIFIC
4 Multiple-choice Questions 14 10
5 Tools and Equipment 23 20
6 Engines 28 25
7 Forces 32 25
8 Maintenance 23 20
9 Systems and Control (Automatic Gearbox) 18 20
Systems and Control (Axles, Steering
10 32 30
Geometry and Electronic)
TOTAL 200 180

SC/NSC
QUESTION 1: MULTIPLE-CHOICE QUESTIONS (GENERIC)

Various options are provided as possible answers to the following questions. Choose
the answer and write only the letter (A–D) next to the question numbers
(1.1 to 1.6) in the ANSWER BOOK, e.g. 1.7 E.
1.1 Which ONE of the following safety precautions is applicable to the bench
grinder?
A Oil the surface of the machine.
B Remove all guards when grinding.
C Wear safety goggles when grinding.
D Ensure that the machine is on. (1)
1.2 What does the Occupational Health and Safety Act state regarding HIV/Aids
awareness?
A All employers must make sure that the workplace is safe, and that
employees are not at risk of contracting HIV.
B It does not contain common guidelines on how employers, employees
and trade unions should respond to persons with HIV in the workplace.
C Employers may demote or promote an employee based on his/her
HIV status.
D Employers can simply dismiss a person who has HIV. (1)
1.3 Which ONE of the following procedures is applicable when applying basic
medical treatment?
A Examine the injured person.
B Remove the object from the wound.
C Use an oily substance or lotion on a burn.
D Phone the insurance company. (1)
1.4 Why is steel heated slowly to a certain temperature during heat treatments?
To ensure that …
A high heat is obtained.
B the room temperature is correct.
C a uniform temperature is obtained.
D the safety process is correct. (1)
1.5 Which ONE of the following is an example of case-hardening?
A Frying pans
B Gears
C Wheel rims
D Chisels (1)
1.6 What does the term quenching rate during heat treatment mean?
A Cooling rate
B Heating rate
C Tempering rate
D Hardening rate (1)
[6]

SC/NSC
QUESTION 2: SAFETY (GENERIC)
2.1 Which safety precaution must be adhered to after the work on any machine is
completed? (1)
2.2 Give TWO reasons why the space between the tool rest and the grinding
wheel on a bench grinder must not exceed 3 mm. (2)
2.3 Identify the workshop layouts shown in FIGURES 2.3.1 and 2.3.2 below.
2.3.1
FIGURE 2.3.1 (1)
2.3.2
FIGURE 2.3.2 (1)
2.4 State ONE type of personal protective equipment that must be worn when
working on a hydraulic press machine. (1)
2.5 State ONE function of the safety guard on a portable angle grinder. (1)
2.6 State ONE safety precaution, other than environmental safety, that must be
observed when using a shearing machine/guillotine. (1)
2.7 State TWO safety precautions that must be adhered to when storing
gas cylinders. (2)
[10]

SC/NSC
QUESTION 3: MATERIALS (GENERIC)
3.1 Why is tempering of steel done after hardening? (2)
3.2 Give ONE reason for EACH of the following heat-treatment processes on
steel:
3.2.1 Case hardening (2)
3.2.2 Annealing (2)
3.3 Explain how to conduct a spark test to identify the type of steel. (2)
3.4 Explain how you will conduct the following tests:
3.4.1 Filing test (2)
3.4.2 Bend test (2)
3.5 What sound do the following materials make when performing a sound test?
3.5.1 Low-carbon steel (1)
3.5.2 High-carbon steel (1)

[14]

SC/NSC
QUESTION 4: MULTIPLE-CHOICE QUESTIONS (SPECIFIC)
Various options are provided as possible answers to the following questions. Choose
the answer and write only the letter (A–D) next to the question numbers
(4.1 to 4.14) in the ANSWER BOOK, e.g. 4.15 E.
4.1 During which test should the crankshaft be locked to prevent the engine from
turning?
A Compression test
B Exhaust gas analysis
C Cylinder leakage test
D Computerised diagnostic scan (1)
4.2 Which wheel alignment angles are measured using the bubble gauge?
A Caster, camber and toe

B Caster, camber and king pin inclination
C Toe-in, toe-out and Ackermann angle
D Camber, Ackermann angle and king pin inclination (1)
4.3 FIGURE 4.3 below shows the position of the crankpins in a four-stroke inline
engine. Identify the number of cylinders for the crankpin positions shown.
FIGURE 4.3
A Twin-cylinder in-line engine

B Three-cylinder in-line engine
C Eight-cylinder in-line engine
D Five-cylinder in-line engine (1)
4.4 An intercooler is used to …
A prevent the turbocharger from overheating.

B prevent the supercharger from overheating.
C cool air that is compressed by the supercharger or turbocharger.
D cool the different parts of an engine. (1)

SC/NSC
4.5 The combustion chamber volume is also known as the …
A swept volume.
B clearance volume.
C total volume.
D firing volume. (1)
4.6 The engine capacity of a four-cylinder 1 600 cm3 engine is …
A 400 ml.
B 1,6 ml.
C 1 600 ml.
D 40 ml. (1)
4.7 Which ONE of the following determines brake power using a clamping device
with the brake arm?
A Electrical dynamometer
B Pröny brake
C Chassis dynamometer
D Hand brake (1)
4.8 Which ONE of the following is a cause of high carbon dioxide readings in the
exhaust gas?
A Vacuum leaks
B Exhaust system leaks
C Nearly ideal air-fuel ratio
D Engine overheating (1)
4.9 The coolant of an engine cooling system is a mixture of …
A antifreeze and water.

B soluble oil and water.
C soap and water.
D hydraulic fluid and water. (1)
4.10 Which ONE of the following components is part of an automatic gearbox?
A Water pump
B Oil pump
C Gas pump
D Fuel pump (1)

SC/NSC
4.11 The hydraulic pistons in an automatic gearbox control the …
A oil pump.
B valve body.
C gearshift lever mechanism.
D multi-disc clutches. (1)
4.12 Feathered tyre wear is caused by …
A incorrect toe setting.

B incorrect camber setting.
C wheel bounce.
D worn shock absorbers. (1)
4.13 Which component of the alternator controls the charging level of the battery?
A Stator
B Rectifier
C Regulator
D Slip ring (1)
4.14 The amount of fuel injected decreases when the …
A engine speed increases.

B fuel pressure regulator does not open.
C the fuel filter is blocked.
D engine is cold. (1)
[14]

SC/NSC
QUESTION 5: TOOLS AND EQUIPMENT (SPECIFIC)
5.1 With reference to the engine cylinder compression test, answer the following
questions:
5.1.1 Give a reason for conducting the test. (2)
5.1.2 Name TWO types of compression tests. (2)
5.1.3 Give TWO reasons for low compression in a cylinder. (2)
5.2 FIGURE 5.2 below shows a cylinder leakage tester. Answer the questions
that follow.
A D
FIGURE 5.2
5.2.1 Label components AD. (4)
5.2.2 Why is pressurised air blown into the cylinder during the cylinder
leakage test? (2)
5.3 State THREE precautions when performing an exhaust gas analysis. (3)
5.4 Name THREE vehicle systems that can be scanned by the on-board
diagnostic scanner. (3)
5.5 State TWO faults which could be identified while performing dynamic wheel
balancing. (2)
5.6 Describe in THREE steps how to perform dynamic wheel balancing after a
wheel has been checked and set up on the wheel balancer. (3)
[23]

SC/NSC
QUESTION 6: ENGINES (SPECIFIC)
6.1 FIGURE 6.1 below shows a component of a four-cylinder in-line (straight)

engine. Answer the questions that follow.
FIGURE 6.1
6.1.1 Identify the component. (1)
6.1.2 What is the main function of the component? (2)
6.1.3 Which part of the component is drilled to balance it? (1)
6.1.4 Explain static balance of this component. (2)
6.2 FIGURE 6.2 below shows a vibration damper that is mounted on an internal
combustion engine. Answer the questions that follow.
FIGURE 6.2
6.2.1 Where on an engine is a vibration damper normally mounted? (1)
6.2.2 What is the function of a vibration damper? (1)
6.3 Name THREE different types of engine cylinder configurations. (3)

SC/NSC
6.4 Give TWO reasons why the power strokes of an engine are often spaced at
equal intervals. (2)
6.5 State THREE methods to determine the firing order of an engine. (3)
6.6 Answer the following questions about turbochargers:
6.6.1 Explain the term boost. (2)
6.6.2 Name the TWO types of turbochargers. (2)
6.7 Answer the following questions about superchargers:
6.7.1 Give TWO reasons why superchargers are fitted to engines. (2)
6.7.2 Name TWO mechanical drive systems used to turn superchargers. (2)
6.8 What does a twin-charging forced induction system consist of? (2)
6.9 State TWO advantages of using a twin-charging forced induction system on

an engine. (2)
[28]

SC/NSC
QUESTION 7: FORCES (SPECIFIC)
7.1 Define swept volume of an internal combustion engine. (2)
7.2 State THREE methods that can be used to increase the compression ratio of
an internal combustion engine. (3)
7.3 In an internal combustion engine the bore diameter is 90 mm and the stroke
length is 100 mm. The compression ratio is 10,5 : 1.
Calculate the following:
7.3.1 The swept volume of a single cylinder in cm3 (3)
7.3.2 The original clearance volume of a single cylinder in cm 3 (3)
7.3.3 The new bore diameter in mm if the compression ratio is increased

to 11 : 1. The clearance volume and stroke length remain
unchanged. (7)
7.4 The following data refers to a two-cylinder two-stroke engine which was
tested with a Pröny brake:
Engine speed during the test: 2 000 r/min

Mean effective pressure: 900 kPa
Bore diameter: 84 mm
Stroke length: 86 mm
Brake arm length: 0,4 m
Scale reading: 25 kg
Calculate the following:
7.4.1 Indicated power in kW (7)
7.4.2 Brake power in kW (5)
7.4.3 Mechanical efficiency (2)

[32]

SC/NSC
QUESTION 8: MAINTENANCE (SPECIFIC)
8.1 TABLE 8.1 below shows the results of the gas analysis of an internal
combustion engine. Complete TABLE 8.1 by giving ONE cause and ONE
appropriate corrective measure for EACH given cause.
NOTE: Write only the answer next to the question numbers

(8.1.1 to 8.1.4) in the ANSWER BOOK.
FAULTS (DEFECTS) POSSIBLE CORRECTIVE

CAUSES MEASURES
High oxygen (O2) reading 8.1.1 8.1.2
High hydrocarbon (HC) reading 8.1.3 8.1.4
TABLE 8.1 (4)
8.2 Explain why the following procedures are conducted on an internal

combustion engine during a compression test:
8.2.1 Remove the high-tension lead. (1)
8.2.2 Unplug the fuel-injection system. (1)
8.2.3 Fully open the throttle valve. (1)
8.2.4 Record the readings. (1)
8.3 State the cause of and suggest an appropriate corrective measure for the
following cylinder leakage test results:
8.3.1 Hissing sound at the air intake (2)
8.3.2 Hissing sound at the dipstick (2)
8.4 State THREE causes of a high oil-pressure reading on an internal

combustion engine. (3)
8.5 A fuel pressure test is conducted on an engine.
8.5.1 State TWO manufacturer's specifications required before the fuel

pressure test can be conducted. (2)
8.5.2 Where on the vehicle is the fuel-pressure tester inserted? (1)
8.5.3 Why may the rubber pipe on the fuel pressure tester not be worn
away? (1)
8.6 State FOUR causes of pressure drop during a cooling system pressure test. (4)
[23]

SC/NSC
QUESTION 9: SYSTEMS AND CONTROL (AUTOMATIC GEARBOX) (SPECIFIC)
9.1 A vehicle is fitted with an automatic gearbox. Explain how the following
problems are solved:
9.1.1 The vehicle needs to be towed over a long distance (1)
9.1.2 Slippage occurs inside a torque converter (1)
9.1.3 The automatic gearbox oil overheats (1)
9.1.4 Gearshift lever position is selected before starting the vehicle (1)
9.1.5 Identify the correct type of oil to use in the gearbox (1)
9.2 FIGURE 9.2 below shows a torque converter.
FIGURE 9.2
Which components of the torque converter are described in

QUESTIONS 9.2.1 to 9.2.3 below?
9.2.1 The driving member that is driven by the crankshaft (1)
9.2.2 It is splined to the gearbox input shaft (1)
9.2.3 It increases the torque under load (1)
9.3 Which component of the valve body is directly connected to the gear lever in
an automatic transmission? (1)
9.4 State TWO advantages of the epicyclic gear system in the transmission of a
motor vehicle. (2)

SC/NSC
9.5 FIGURE 9.5 below shows the gear system of an automatic gearbox.
Answer the questions that follow.
Brake band 2 Brake band 1

Annulus 1
Annulus 2
Planet carrier
Input shaft
Output shaft
Sun gear 2 Sun gear 1
Planet gear 2 Planet gear 1
FIGURE 9.5
9.5.1 Identify the gear system in FIGURE 9.5 above. (1)
9.5.2 Explain, in the CORRECT sequence, how reverse gear is obtained

in this gear system. Use the labels in FIGURE 9.5 to assist you in
your explanation. (5)
9.6 Which component circulates the oil through an automatic gearbox? (1)
[18]

SC/NSC
QUESTION 10: SYSTEMS AND CONTROL (AXLES, STEERING GEOMETRY

AND ELECTRONICS) (SPECIFIC)
10.1 State TWO features required for a well-designed steering system. (2)
10.2 FIGURE 10.2 below shows a wheel alignment angle. Answer the questions
that follow.
FRONT
B A
FIGURE 10.2
10.2.1 Label A–C. (3)
10.2.2 Identify angle D. (1)
10.2.3 What is the purpose of wheel alignment angle D? (2)
10.3 Wheel bounce (hop) and wheel wobble (shimmy) are symptoms of
unbalanced wheels.
Answer the questions below.
10.3.1 Draw a neat labelled sketch to show wheel bounce (hop). (2)
10.3.2 Draw a neat labelled sketch to show wheel wobble (shimmy). (2)
10.3.3 Explain the difference between wheel wobble and wheel bounce. (2)
10.4 Name TWO materials that are used to coat the monolith in a catalytic
convertor. (2)

SC/NSC
10.5 State TWO functions of EACH of the following sensors:
10.5.1 Lambda (2)
10.5.2 TPS (2)
10.5.3 MAF (2)
10.6 Briefly explain the operation of the common rail direct-injection system
(CRDI). (3)
10.7 Explain how current is generated in an alternator. (3)
10.8 State TWO tests performed on an alternator stator by using a multimeter. (2)
10.9 State TWO positions where an electrical fuel pump is placed in a modern
motor vehicle. (2)
[32]
TOTAL: 200
Copyright reserved
SC/NSC
FORMULA SHEET FOR MECHANICAL TECHNOLOGY: AUTOMOTIVE
1. F  ma
Where:
m = Mass
a = Acceleration
2. Work done  Force  Displacement OR W Fs
Force  Displacement Fs

3. Power  OR P
Time t
4. Torque  Force  Radius OR T Fr
5. IP  P  L  A  N  n
Where:
IP  Indicated power
P  Mean effective pressure
L  Stroke length
A  Area of piston crown
N  Number of power strokes per second
n  Number of cylinders
6. BP = 2 π N T
Where:
BP  Brake power
N  Revolution s per second
T  Torque
7. Brake power with Pröny brake = 2  π  N  F  R
Where:
BP  Brake power
N  Revolution s per second
F  Force
R  Brake arm length

SC/NSC
BP
8. Mechanical efficiency =  100%
IP
SV  CV
9 Compression ratio 
CV
Where:
SV  Swept volume
CV  Clearance volume
πD 2
10. SV = L
4
Where:
D  Bore diameter
L  Stroke length
SV
11. CV =
CR - 1
Product of teeth on driven gears

12. Gear ratio =
Product of teeth on driver gears
Copyright reserved

Mechanical Technology May-June 2023 (Automotive) Eng

Uploaded by

Copyright:

Available Formats

Mechanical Technology May-June 2023 (Automotive) Eng

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Mechanical Technology May-June 2023 (Automotive) Eng

Uploaded by

Copyright:

Available Formats

SENIOR CERTIFICATE EXAMINATIONS/

NATIONAL SENIOR CERTIFICATE EXAMINATIONS

MECHANICAL TECHNOLOGY: AUTOMOTIVE

This question paper consists of 17 pages and a 2-page formula sheet.

Copyright reserved Please turn over

INSTRUCTIONS AND INFORMATION

2. Read ALL the questions carefully.

3. Answer ALL the questions.

5. Start EACH question on a NEW page.

7. Candidates may use non-programmable scientific calculators and drawing

8. The value of gravitational acceleration should be taken as 10 m/s 2.

9. All dimensions are in millimetres, unless stated otherwise in the question.

10. Write neatly and legibly.

11. A formula sheet is attached at the end of the question paper.

Copyright reserved Please turn over

QUESTION 1: MULTIPLE-CHOICE QUESTIONS (GENERIC)

Copyright reserved Please turn over

QUESTION 2: SAFETY (GENERIC)

FIGURE 2.3.1 (1)

FIGURE 2.3.2 (1)

Copyright reserved Please turn over

QUESTION 3: MATERIALS (GENERIC)

3.1 Why is tempering of steel done after hardening? (2)

3.2.1 Case hardening (2)

3.2.2 Annealing (2)

3.4 Explain how you will conduct the following tests:

3.4.1 Filing test (2)

3.4.2 Bend test (2)

3.5.1 Low-carbon steel (1)

3.5.2 High-carbon steel (1)

Copyright reserved Please turn over

QUESTION 4: MULTIPLE-CHOICE QUESTIONS (SPECIFIC)

A Caster, camber and toe

A Twin-cylinder in-line engine

4.4 An intercooler is used to …

A prevent the turbocharger from overheating.

Copyright reserved Please turn over

4.5 The combustion chamber volume is also known as the …

4.6 The engine capacity of a four-cylinder 1 600 cm3 engine is …

4.9 The coolant of an engine cooling system is a mixture of …

A antifreeze and water.

4.10 Which ONE of the following components is part of an automatic gearbox?

Copyright reserved Please turn over

4.11 The hydraulic pistons in an automatic gearbox control the …

4.12 Feathered tyre wear is caused by …

A incorrect toe setting.

4.14 The amount of fuel injected decreases when the …

A engine speed increases.

Copyright reserved Please turn over

QUESTION 5: TOOLS AND EQUIPMENT (SPECIFIC)

5.1.1 Give a reason for conducting the test. (2)

5.1.2 Name TWO types of compression tests. (2)

5.1.3 Give TWO reasons for low compression in a cylinder. (2)

5.2.1 Label components AD. (4)

Copyright reserved Please turn over

QUESTION 6: ENGINES (SPECIFIC)

6.1 FIGURE 6.1 below shows a component of a four-cylinder in-line (straight)

6.1.1 Identify the component. (1)

6.1.2 What is the main function of the component? (2)

6.1.3 Which part of the component is drilled to balance it? (1)