Western Cape Education Department

Directorate: Curriculum FET

Mechanical Technology
Automotive

REVISION BOOKLET
TERM 1

2023

Grade 11

This revision program is designed to assist you in revising the critical content and
skills covered during the 1st term. The purpose is to prepare you to understand the
key concepts and to provide you with an opportunity to establish the required
standard and the application of the knowledge necessary to succeed in the NCS
examination.
The revision program covers the following topics:
Generic Topics
• Safety
• Tools
• Engines
Specific Topics
• Engines

It is important to prepare yourself by practice answering questions from past

papers.
You can ask your teacher to give you some previous year question papers to use
as a guide to help you prepare for your final exam:
There are also lessons on various grade 11 topics on the WCED e-Portal.
(https://wcedeportal.co.za/)
 LIST OF CONTENTS

No Topic Page

1. Structure of question paper 2

2. Safety 4

3. Tools (Generic) 5

4. Engines 6

5. Questions and answers 6 - 12

6. General comments 13

Final Examination Weighting in Automotive

MECHANICAL TECHNOLOGY – AUTOMOTIVE GRADE 11

SECTION A (GENERIC)
QUESTION CONTENT MARKS
1 Multiple-choice (Generic) 20
2 Safety (Generic) 20
3 Tools and Equipment (Generic) 25
4 Maintenance (Generic) 20
TOTAL SECTION A: 85

MECHANICAL TECHNOLOGY – AUTOMOTIVE GRADE 11

SECTION B (SPECIFIC)
QUESTION CONTENT MARKS
5 Tools 15
6 Engines 30
7 Forces 20
8 Maintenance 15
9 Systems and Control 30
10 Terminology 5
TOTAL SECTION B 115
GRAND TOTAL 200

Instructions and Information

1. Read ALL the questions carefully.
2. Answer ALL the questions.
3. Number the answers correctly according to the numbering system used in this
question paper.
4. Start EACH question on a NEW page.
5. Show ALL calculations and units. Round off final answers to TWO decimal
places.
6. Candidates may use non-programmable scientific calculators and drawing
instruments.
7. The value of gravitational acceleration should be taken as 10 m/s.
8. All dimensions are in millimetres, unless stated otherwise in the question.
9. Write neatly and legibly.
10. A formula sheet is attached at the end of the question paper.

Final examination: At the end of each academic year every learner is required to
write a final examination, which is compiled in such a way that it represents the
entire theoretical content covered throughout the year. The final examination
paper accounts for 50% of the learner’s promotion mark and is internally set,
marked, and moderated.
Formal assessments should cater for a range of cognitive levels and learners’
abilities as shown below:

Cognitive Levels Percentage of Task

Lower order: knowledge 30%

Middle order: comprehension and application 50%

Higher order: analysis, evaluation, and synthesis 20%

GRADES 10 – 11 ASSESSMENT REQUIREMENTS

% OF FINAL
ASSESSMENT TERM TERM TERM TERM PROMOTION MARK
TASKS 1 2 3 4 MARK Weighting

Assignment 1 250 total

Control Test 1 10 converted
to mark
25
Mid-year 1 15 out of
examination 100
  
Phase 1 Phase 2 Phase 3 250 total
Practical (Any (Any (Any
converted
Assessment maintenance maintenance maintenance
25 to mark
Task (PAT) skills task) skills task) skills task)
Phase 1 – Phase 4 out of
100

Final examination 1 50 200

TOTAL – PROMOTION MARK 400
Mechanical Technology (Automotive)
Grade 11
Revision pack
Term 1

Topic 1: Safety (Generic).

In this section, work through the content. The things you need to know the are the
following:
First Aid:
• HIV/AIDS Awareness
• Knowledge of basic First Aid measures

OHS Act:
Analyse the OHS Act and regulations where applicable.

Machine-specific safety measures when dealing with:

• Grinding machines (portable, bench and surface)
• Cutting machines (drilling machines, power saw, band saw)
• Hydraulic operated equipment – hydraulic press

Occupational Health and Safety

➢ This is a very open-ended type of topic and learners need to ensure that
they read every question very carefully with understanding.
➢ Learners must make sure their answers are short and to the point. They must
remember the examiner/marker must understand what they trying to say in
their answer.
➢ Many learners do not look at mark allocation of questions and only give
one fact for a two-mark question.
➢ The duties of the employer and the employee in the workplace is very
important and learners must know it.
➢ The following concepts which was also done in grade 10 is not always
answered well:
• Unsafe actions – this refer to a specific ACTION that can lead to an injury or
cause damage.

Remember an unsafe action is any activity that is conducted that may

threaten the health and safety of workers

• Unsafe conditions – this refer to a CONDITION that might lead to an injury or

cause damage
An unsafe condition refers to a condition that is likely to cause harm,
damage or injury to property or persons.
 ➢ You need to be familiar with the National policies and procedures dealing
with HIV/AIDS - go through this and understand what it means
➢ You need to be familiar with knowledge of basic first aid.
➢ You need to analyse the OHS Act and regulations where applicable to
tools and machinery.
➢ The different safety signs used in workshop is critical to know and
understand – you need to know the different colour codes and types and
shape of these signs.
➢ Personal protective gear and its uses is also very important.

Topic 2: Tools (Generic)

The principles and functions of the following purpose-made tooling and

equipment:
• Stocks and dies (characteristics and drill sizes)
• Grinding machines (portable, bench)
• Cutting machines (drilling machines, power saw, horizontal band saw)
• Guillotine machine (manual and power driven)
• Press machines

➢ You need to be able to label the sketches of the all purpose-made tooling
and equipment.
➢ You need to understand the working principles and functions of all the
above-mentioned purpose-made tooling and equipment.

Topic 3: Tools (Specific)

The principles and functions of the following purpose-made tooling and

equipment:

• Dial indicators
• Telescopic gauges
• Torque wrenches
• Outside, inside micrometers and vernier caliper (simple readings from the
instruments, use of attachments)

➢ You need to be able to label the sketches of the dial indicator, outside
micrometer and the vernier caliper.
➢ You need to be able to know the functions of all precision measuring
instruments and where they are used or applied.
➢ You need to be able to know how to read and sketch readings on the
micrometers.
Examples

1. What is the reading on the outside micrometer, shown below?

Answer: 6 + 0,5 + 0,15 = 6.65 mm

2. What is the reading displayed on the inside micrometer, below?

Answer: 150 + 7 + 0,5 + 0,11 = 157,61mm

Topic 4: Engines (Specific)

C.I. Engines:
Combustion chamber designs for direct and indirect injection.

Injector:
Function, construction, operation, and types of nozzles

Valve assemblies:
• Identify various overhead valve arrangements
• Identify various camshafts arrangements: SOHC (single) and DOHC (double)
• Cam followers – mechanical and hydraulic
• Valve timing diagram – necessity for lead, lag and overlap
• Continuously variable valve timing (CVVT) system
• Purpose and importance of valve clearance
• Timing gears, chains, belt drives and tensioners.
Questions

1. What is the average compression ratio for compression ignition engines?

2. Describe what is meant by swirling.
3. Describe what is meant by squish.
4. Define direct injection.
5. State the advantages of direct injection.
6. State the disadvantages of direct injection.
7. Define indirect injection.
8. State the advantages of indirect injection.
9. State the disadvantages of indirect injection.
10. Label the two drawings below, that illustrates the difference between a
direct and indirect injection combustion chamber.

Direct Injection Indirect injection

11. What is the function of the glow plug in the indirect combustion chamber?

CI Engines

Model answers
1. The ratio of between 16:1 and 22:1.
2. Swirling means, imparting a spiral movement to air.
3. Squish occurs during the compression stroke. The raised piston edges move
towards the cylinder head and in the process, air is forced towards the
combustion chamber at an increasing rate.
4. Fuel is injected directly into the cylinder from above the piston so that
combustion occurs in the space between the piston and the cylinder head.
5. • Easier starting because less heat is lost during compression stroke.
• Glow plugs are not required for cold starting.
• increased thermal efficiency results in relatively lower fuel consumption.
6. • Due to increased mean effective pressure, combustion knock may occur
more frequently and be more pronounced.
• Increased injection pressure places more stress on the injector pump, which
means a larger drain of engine power.
• Injector nozzle vapour holes are very small and tend to block and wear
out.
7. Indirect injection is when the fuel is injected into a pre-combustion chamber
in the cylinder head and not directly into the cylinder.
8. • The engine can attain higher revolutions and develop more power.
• lower injection pressure is required
• The engine operation is smoother and less noisy.
• A lower grade of fuel may be used.
9. Starting problems are experienced when engines are cold.
10.
Direct injection Indirect Injection
A Injector Piston
B Piston Combustion Chamber
C Combustion Chamber Glow plug
D Injector

11. The fresh air charge is heated by means of glow plugs in the combustion
chambers.
 Injectors

1. Name two advantages and disadvantages of a common rail injection

system.
2. State the function of the injector.
3. State four requirements of an efficient injector.
4. Make four drawings to illustrate the differences between the various injector
nozzles.

Model answers

1 Advantages of a common rail system

• More accurate timing and phasing of injectors.
• Much quieter engine operation.
• Higher engine speeds possible.
• Better fuel consumption.

Disadvantages of a common rail system

• Electric injectors are expensive to manufacture.

• Electronic systems are not as robust as mechanical ones.

2. The function of the injector is to break down the metered quantity of fuel from
the injector pump and atomise it into such a condition that it will readily mix
with the air in the combustion chamber, and inject the fuel under high
pressure into the highly compressed, heated and turbulent air charge in the
combustion chamber.

3 The pressure under which injection occurs must be high enough to:
• atomise the liquid fuel as thoroughly as possible.
• deliver the correct spray pattern.
• inject the atomised fuel with sufficient penetration into the combustion
chamber.
• inject the atomised fuel in the direction of the required section of the
combustion chamber.
4.

Single-hole Multi-hole Pintle-type Pintaux-type

Valve assemblies:

➢ Know the advantages and two disadvantages of each of the different

valve arrangements:
1. Name four camshaft arrangements.
2. State the function of the cam follower.
3. Describe what is meant by the following:
3.1 Valve lead.
3.2 Valve lag.
3.3 Valve overlap

4. What is the purpose of valve clearance?

5. Name two disadvantages of each of the following:

5.1 Excessive valve clearance.

5.2 Insufficient valve clearance.

6. Why must timing chains be tensioned?

7. Mention two advantages and two disadvantages of cam belts

Model answers

1.

• Single overhead camshaft in the centre with rockers to open the valves.
(OHC)

• Single overhead camshaft on the side with rockers to open the valves. (OHC)
 • Double overhead camshafts mounted directly above the valve stems. One
of the camshafts activates the intake valves, while the other activates the
exhaust valves. (DOHC)
• The low camshaft on the side of the cylinder block as in the case of the
overhead-valve engine. (OHV)

2.
• Cam followers convert the reciprocating movement of the cams on the
camshaft into a reciprocating movement of the valves.
• Mechanical cylinder-type cam follower with adjustable screw and lock nut
as used on the side- valve engine.
• Mechanical open-cylinder-type as used on overhead-valve engines.
• Mechanical mushroom type, which is used on overhead-valve as well as
side-valve engines.
• Hydraulic cam followers which are mainly used on overhead-valve engines.

3.1 A valve leads when it opens before the piston reaches T.D.C. or B.D.C.

3.2 A valve lags when is closes after the piston reached T.D.C. or B.D.C.

3.3 Valve overlap is the number of degrees of crankshaft rotation, while

both intake and exhaust valves of one cylinder remain open.
4. Valve clearance is essential to provide for expansion in the valve
mechanism such that the valve will be properly closed and kept closed by
the valve spring at all temperatures.
5.1 Disadvantages of excessive valve clearance.

• Noisy engine operation.

• Excessive wear on the components in the valve mechanism.

• Loss of power due to disturbed valve timing. The valves open later and
close earlier. The valves therefore do not remain open long enough.

5.2 Disadvantages effect of insufficient valve clearance

• The valves will overheat and burn because the valves will not rest against
the valve seats to be cooled.

• Further burning of valves will occur because the valves are not closing
properly, with consequent loss in pressure and power.

• Loss of power is also caused because the valve timing is disturbed. The
valves open earlier and close later. The valves therefore remain open too
long.

6. Timing chains have the tendency to stretch and the rollers over the link pins
are subjected to wear. This tendency results in noisy operation and
excessive slackness in the chain drive will also affect the accuracy of the
valve timing. There is also the danger of the timing chain jumping one or
two teeth of the timing gear.
7. Advantages
• Timing belts are quieter than chains
• They are positioned outside the engine where they are not in contact with
the engine lubricating oil.
• Inexpensive

Disadvantages
• They also have a shorter lifetime than chains.
• They need regular replacing around 80,000 to 100,000 kilometres.
• Correct adjustments of tensioners are important to avoid problems.
General comments on the answering of questions
(a) Learners must always start each question on a new page as indicated in the
instructions.
(b) Learners have difficulty expressing themselves when responding to
describe/explain type of questions. It is important for learners to explain or
describe concepts in a logical sequence, e.g. Explain the difference
between direct and indirect injection on a CI engine.
(c) Learners should be careful not giving general responses that are incorrect
instead of specific responses. E.g. learners should be able to distinguish the
differences when observing safety precautions on specific machines.
(d) In a question that counts two marks, learners only provided one response
instead of two. Learners must be able to derive the number of facts that they
should state from the mark allocation of the question.
(e) Learners should not only rely on activities that are in the textbooks but
alternative questions on all cognitive levels for all the topics should be
developed by themselves.
(f) It is recommended that learners study drawings and sketches until they
know all the labels of all the parts.

(g) It is important that all topics should be covered sufficiently by learners in

order to prepare themselves for any type of questions on a specific topic.

(h) It is important that labels should always be indicated on all drawings.

(i) Learners have difficulty explaining practical applications, theoretically.