Application
This unit describes the performance outcomes required to dismantle and evaluate an engine block and its sub-assemblies as part of an engine repair or reconditioning process. It involves preparing for the task, dismantling and evaluating the engine blocks and sub-assemblies, determining required repair action, and completing workplace processes and documentation.
It applies to those working in the automotive service and repair industry. The engine blocks and sub-assemblies include those in vehicles from all sectors of the industry.
No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.
Elements and Performance Criteria
Elements Elements describe the essential outcomes. | Performance Criteria Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold and italicised text is used, further information is detailed in the range of conditions section. |
1. Prepare to dismantle engine block and sub-assembly | 1.1 Job requirements are determined from workplace instructions 1.2 Engine block and sub assembly dismantling information is sourced and interpreted 1.3 Tools and measuring equipment are selected and checked for serviceability 1.4 Hazards associated with the work are identified and risks are managed 1.5 Engine is set up for dismantling using appropriate lifting equipment and avoiding fluid spillage according to safety and environmental requirements 1.6 Engine block and sub-assembly are cleaned according to safety and environmental procedures and relevant Australian standards, and positions of auxiliary equipment are recorded, including photographic evidence |
2. Dismantle engine block and sub-assembly | 2.1 Covers and ancillary components are removed, cleaned and stored according to workshop procedures 2.2 Engine block and sub-assembly are dismantled according to safety requirements and laid out in a logical order using approved methods, tools and equipment 2.3 Component parts are cleaned using appropriate cleaning agents for the type of material and kept in a logical order in preparation for evaluation |
3. Determine repair procedures | 3.1 Engine block and sub-assembly are inspected, measured and tested against manufacturer specifications and tolerances and according to workplace procedures and safety requirements 3.2 Engine block and sub-assembly are evaluated and repair requirements are determined and reported according to workplace procedures |
4. Complete dismantle and evaluation processes | 4.1 Final inspection is made to ensure finished work complies with workplace requirements 4.2 Bright surfaces are treated with rust prevention solution and engine block and sub-assembly are prepared for further process or storage according to workplace procedures 4.3 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 4.4 Workplace documentation is processed according to workplace procedures |
Evidence of Performance
Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unit’s elements, performance criteria, range of conditions and foundation skills:
dismantle and evaluate the following three different engine blocks and their sub-assemblies:
in-line engine block
V configuration engine block
diesel engine block with sleeves.
Evidence of Knowledge
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.
Assessment Conditions
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.
Foundation Skills
This section describes those language, literacy, numeracy and employment skills that are essential to performance and are not explicit in the performance criteria.
Skills | Description |
Learning skills to: | locate appropriate sources of information efficiently. |
Reading skills to: | identify and interpret engine component specifications from workshop literature interpret safe operating procedures for engine component rebuild machinery from operating manuals and signs. |
Writing skills to: | legibly and accurately fill out workplace documentation when making recommendations. |
Numeracy skills to: | interpret numerical information in manufacturer specifications, workshop literature, and machinery dials, gauges and computer readouts use basic mathematical operations, including addition and subtraction, to: convert metric dimensions to imperial, and imperial dimensions to metric calculate tolerances and clearances. |
Planning and organising skills to: | select best tooling option for the work and sequence components to reduce time and material wastage. |
Technology skills to: | use metric and imperial precision measuring equipment. |
Range Statement
This section specifies work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. Bold italicised wording, if used in the performance criteria, is detailed below.
Safety and environmental requirements must include: | work health and safety (WHS) and occupational health and safety (OHS) requirements, 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. |
Inspecting, measuring and testing must include: | applying surface finishes and wear patterns 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: connecting rods crankshaft camshaft cylinder block surface camshaft and main bearing tunnels main bearing caps hardness testing: alloy cylinder blocks, pistons, crankshaft journals and camshaft followers checking 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 checking: 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 upper and lower parts of cylinder block oil pump for serviceability idler gear hub to bearing clearance. |
Sectors
Technical - Manufacture
Competency Field
Mechanical Miscellaneous