Individuals must be able to demonstrate knowledge of:
work health and safety (WHS) and occupational health and safety (OHS) requirements relating to dismantling and evaluating engine blocks and sub-assemblies, including operational risk assessment and treatments associated with:
electrical equipment used in dismantling and evaluating engine blocks and sub-assemblies
manual and mechanical lifting and shifting equipment
toxic cleaning substances
environmental requirements, including procedures for trapping, storing and disposing of cleaning fluids released during the process
manual handling techniques, including those relating to:
using machinery for lifting engine blocks and engine components
using slings, chains and other lifting equipment according to safe work practices
dismantling methods and procedures, including:
reasons for selecting chosen tools, techniques and equipment
hazards and fluid control measures associated with removal of engines and engine components, including housekeeping
procedures for recording positions of components, including photographic evidence
pre-evaluation checks to determine suitability of component to be re-used
reasons for checking end float before disassembly
cleaning solutions and cleaning procedures for components
use of pullers, presses and specialised tools, and application of heat to dismantle components, including gears, pulleys and dowels
procedures for recording facing directions of pistons, connecting rods, main and big end caps, and positions of removable counterweights and counterweight shaft assemblies
precautions to be used when removing connecting rod cap
removing crankshaft and identifying main bearing caps that have lost register
removing dry and wet sleeves
dismantling pistons from connecting rods
removing camshaft bearings and balance/idler shaft bearings
removing welsh plugs and oil gallery plugs
removing diesel injection pumps
dismantling components that have seized, bent or broken, including seized stud and bolt removal
inspection, measurement and testing procedures, including:
characteristics of surface finishes and wear patterns as applied to:
cylinder bores, crankshafts, pistons, gears, cam followers, and camshafts
bearings and bushes
block facings
parting faces of connecting rod
main bearing caps
crack testing components
testing hardness of alloy cylinder blocks, pistons, crankshaft journals and camshaft followers
straightness of shafts
taper, ovality and wear of:
crankshaft and camshaft journals
main bearing and connecting rod tunnels
cylinder bores in conventional engine blocks and parent bores of engine blocks with dry sleeves
camshaft lobe lift
straightness of shafts
main bearing tunnels for alignment
connecting rod alignment and little end bore size
cylinder block flatness and deck height
piston ring land clearance, piston skirt wear and gudgeon pin to piston clearance
cylinder liner register in both the upper and lower parts of the cylinder block
oil pump for serviceability
idler gear hub to bearing clearance
requirements of Australian standards relevant to engine reconditioning, including:
AS 4182 Automotive repairs – Code of practice for reconditioning reciprocating spark ignition engines
AS 4427 Automotive repairs – Code of practice for reconditioning reciprocating compression ignition engines.
Assessors must satisfy NVR/AQTF assessor requirements.
Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.
Assessment must include direct observation of tasks.
Where assessment of competency includes third-party evidence, individuals must provide evidence that links them to the engine blocks and sub-assemblies that they have dismantled and evaluated, e.g. repair orders.
Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application.
The following resources must be made available:
automotive repair workplace or simulated workplace
workplace instructions
manufacturer engine specifications
AS 4182 Automotive repairs – Code of practice for reconditioning reciprocating spark ignition engines
AS 4427 Automotive repairs – Code of practice for reconditioning reciprocating compression ignition engines
three different multi-cylinder engine blocks specified in the performance evidence
precision measuring equipment, including:
dial bore gauges
dial indicators
inside and outside metric and imperial micrometers
fixed and portable hand, air and power tools and lifting equipment suitable for dismantling and evaluating engine blocks and sub-assemblies.