Assessor Resource

AURHTF002
Diagnose and repair heavy vehicle diesel fuel injection systems

Assessment tool

Version 1.0
Issue Date: March 2024


This unit describes the performance outcomes required to diagnose and repair faults in the diesel fuel injection systems of heavy vehicles and machinery. It involves preparing for the task, selecting the correct diagnostic procedure, carrying out the diagnosis and the repair, performing post-repair testing, and completing workplace processes and documentation.

It applies to those working in the automotive service and repair industry. The diesel fuel injection systems include those in agricultural machinery, heavy commercial vehicles, marine vessels or mobile plant machinery. The unit does not apply to electronic compression ignition engine management systems.

No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)



Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

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 diagnose and repair diesel fuel injection system

1.1 Job requirements are determined from workplace instructions

1.2 Diagnostic information is sourced and interpreted

1.3 Diagnostic options are analysed and those most appropriate to the circumstances are selected

1.4 Hazards associated with the work are identified and risks are managed

1.5 Diagnostic tools and equipment are selected and checked for serviceability

2. Diagnose diesel fuel injection system

2.1 Engine tune adjustments are checked and rectified as required according to manufacturer specifications and workplace procedures

2.2 Diagnostic tests are carried out according to manufacturer specifications, workplace procedures, and environmental and safety requirements

2.3 Faults are identified from diagnostic test results and causes of faults are determined

2.4 Diagnosis findings, including recommendations for necessary repairs or adjustments, are reported according to workplace procedures

3. Repair diesel fuel injection system

3.1 Repair information is sourced and interpreted

3.2 Repair options are analysed and those most appropriate to the circumstances are selected

3.3 Repair tools, equipment and materials are selected and checked according to manufacturer procedures

3.4 Repairs and component replacements and adjustments are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or systems

3.5 Post-repair testing is carried out according to workplace procedures to confirm fault rectification, and any further problems detected as having been introduced during the repair process are rectified

4. Complete work processes

4.1 Final inspection is made to ensure work is to workplace expectations and system or vehicle is presented ready for use

4.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

4.3 Tools and equipment are checked and stored according to workplace procedures

4.4 Workplace documentation is processed according to workplace procedures

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:

diagnose and repair a fault in two different heavy vehicle diesel fuel injection systems, completing the following with each system:

testing the low pressure fuel supply

removing and refitting a low pressure fuel pump

removing, refitting and timing a diesel high pressure pump

removing, refitting and testing injectors

bleeding a diesel fuel injection system.

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to diagnosing and repairing vehicle diesel fuel injection systems, including procedures for:

working with:

high fuel pressures

stored fuel pressures

high voltage diesel fuel injectors

engine start-up and shut-down

environmental requirements, including procedures for trapping, storing and disposing of diesel fuel released from injection systems

operating principles of diesel fuel injection systems and associated components, including:

phases of combustion

composition of diesel fuel

application, purpose and operation of diesel fuel injection systems and components, including:

low pressure fuel supply systems, including:

fuel pumps

filters and separators

high pressure diesel fuel injection systems, including:

distributor type injection pumps

in-line injection pumps

electronic unit injection (EUI)

hydraulic electronic unit injection (HEUI)

high pressure injection (HPI)

injectors

diagnostic testing procedures for diesel fuel injection systems, including:

assessing exhaust smoke

testing low pressure fuel systems

testing injector opening pressure, back leakage, nozzle leakage and spray pattern

assessing air induction systems

measuring individual cylinder exhaust temperature to determine underperforming cylinders

repair procedures for diesel fuel injection systems, including procedures for:

dismantling, cleaning, adjusting and reassembling conventional injectors

removing, installing and timing high pressure injection pumps

adjusting and tuning mechanical unit injection systems

bleeding fuel systems

post-repair testing procedures for diesel fuel injection systems, including procedures for:

checking fuel system leakage

assessing engine performance.

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 heavy vehicle diesel fuel injection systems that they have worked on, 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 heavy vehicle diesel fuel injection system specifications

two different heavy vehicles with faults in their diesel fuel injection systems

diagnostic equipment for diesel fuel injection systems

tools, equipment and materials appropriate for repairing and adjusting heavy vehicle diesel fuel injection systems.


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)


Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

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 diagnose and repair diesel fuel injection system

1.1 Job requirements are determined from workplace instructions

1.2 Diagnostic information is sourced and interpreted

1.3 Diagnostic options are analysed and those most appropriate to the circumstances are selected

1.4 Hazards associated with the work are identified and risks are managed

1.5 Diagnostic tools and equipment are selected and checked for serviceability

2. Diagnose diesel fuel injection system

2.1 Engine tune adjustments are checked and rectified as required according to manufacturer specifications and workplace procedures

2.2 Diagnostic tests are carried out according to manufacturer specifications, workplace procedures, and environmental and safety requirements

2.3 Faults are identified from diagnostic test results and causes of faults are determined

2.4 Diagnosis findings, including recommendations for necessary repairs or adjustments, are reported according to workplace procedures

3. Repair diesel fuel injection system

3.1 Repair information is sourced and interpreted

3.2 Repair options are analysed and those most appropriate to the circumstances are selected

3.3 Repair tools, equipment and materials are selected and checked according to manufacturer procedures

3.4 Repairs and component replacements and adjustments are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or systems

3.5 Post-repair testing is carried out according to workplace procedures to confirm fault rectification, and any further problems detected as having been introduced during the repair process are rectified

4. Complete work processes

4.1 Final inspection is made to ensure work is to workplace expectations and system or vehicle is presented ready for use

4.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

4.3 Tools and equipment are checked and stored according to workplace procedures

4.4 Workplace documentation is processed according to workplace procedures

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 requirements must include:

work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures for:

working with:

high fuel pressures

stored fuel pressures

high voltage diesel fuel injectors

engine start-up and shut-down.

Environmental requirements must include:

procedures for trapping, storing and disposing of diesel fuel released from injection systems.

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:

diagnose and repair a fault in two different heavy vehicle diesel fuel injection systems, completing the following with each system:

testing the low pressure fuel supply

removing and refitting a low pressure fuel pump

removing, refitting and timing a diesel high pressure pump

removing, refitting and testing injectors

bleeding a diesel fuel injection system.

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to diagnosing and repairing vehicle diesel fuel injection systems, including procedures for:

working with:

high fuel pressures

stored fuel pressures

high voltage diesel fuel injectors

engine start-up and shut-down

environmental requirements, including procedures for trapping, storing and disposing of diesel fuel released from injection systems

operating principles of diesel fuel injection systems and associated components, including:

phases of combustion

composition of diesel fuel

application, purpose and operation of diesel fuel injection systems and components, including:

low pressure fuel supply systems, including:

fuel pumps

filters and separators

high pressure diesel fuel injection systems, including:

distributor type injection pumps

in-line injection pumps

electronic unit injection (EUI)

hydraulic electronic unit injection (HEUI)

high pressure injection (HPI)

injectors

diagnostic testing procedures for diesel fuel injection systems, including:

assessing exhaust smoke

testing low pressure fuel systems

testing injector opening pressure, back leakage, nozzle leakage and spray pattern

assessing air induction systems

measuring individual cylinder exhaust temperature to determine underperforming cylinders

repair procedures for diesel fuel injection systems, including procedures for:

dismantling, cleaning, adjusting and reassembling conventional injectors

removing, installing and timing high pressure injection pumps

adjusting and tuning mechanical unit injection systems

bleeding fuel systems

post-repair testing procedures for diesel fuel injection systems, including procedures for:

checking fuel system leakage

assessing engine performance.

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 heavy vehicle diesel fuel injection systems that they have worked on, 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 heavy vehicle diesel fuel injection system specifications

two different heavy vehicles with faults in their diesel fuel injection systems

diagnostic equipment for diesel fuel injection systems

tools, equipment and materials appropriate for repairing and adjusting heavy vehicle diesel fuel injection systems.

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Job requirements are determined from workplace instructions 
Diagnostic information is sourced and interpreted 
Diagnostic options are analysed and those most appropriate to the circumstances are selected 
Hazards associated with the work are identified and risks are managed 
Diagnostic tools and equipment are selected and checked for serviceability 
Engine tune adjustments are checked and rectified as required according to manufacturer specifications and workplace procedures 
Diagnostic tests are carried out according to manufacturer specifications, workplace procedures, and environmental and safety requirements 
Faults are identified from diagnostic test results and causes of faults are determined 
Diagnosis findings, including recommendations for necessary repairs or adjustments, are reported according to workplace procedures 
Repair information is sourced and interpreted 
Repair options are analysed and those most appropriate to the circumstances are selected 
Repair tools, equipment and materials are selected and checked according to manufacturer procedures 
Repairs and component replacements and adjustments are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or systems 
Post-repair testing is carried out according to workplace procedures to confirm fault rectification, and any further problems detected as having been introduced during the repair process are rectified 
Final inspection is made to ensure work is to workplace expectations and system or vehicle is presented ready for use 
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 
Tools and equipment are checked and stored according to workplace procedures 
Workplace documentation is processed according to workplace procedures 
Job requirements are determined from workplace instructions 
Diagnostic information is sourced and interpreted 
Diagnostic options are analysed and those most appropriate to the circumstances are selected 
Hazards associated with the work are identified and risks are managed 
Diagnostic tools and equipment are selected and checked for serviceability 
Engine tune adjustments are checked and rectified as required according to manufacturer specifications and workplace procedures 
Diagnostic tests are carried out according to manufacturer specifications, workplace procedures, and environmental and safety requirements 
Faults are identified from diagnostic test results and causes of faults are determined 
Diagnosis findings, including recommendations for necessary repairs or adjustments, are reported according to workplace procedures 
Repair information is sourced and interpreted 
Repair options are analysed and those most appropriate to the circumstances are selected 
Repair tools, equipment and materials are selected and checked according to manufacturer procedures 
Repairs and component replacements and adjustments are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or systems 
Post-repair testing is carried out according to workplace procedures to confirm fault rectification, and any further problems detected as having been introduced during the repair process are rectified 
Final inspection is made to ensure work is to workplace expectations and system or vehicle is presented ready for use 
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 
Tools and equipment are checked and stored according to workplace procedures 
Workplace documentation is processed according to workplace procedures 

Forms

Assessment Cover Sheet

AURHTF002 - Diagnose and repair heavy vehicle diesel fuel injection systems
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Assessment Record Sheet

AURHTF002 - Diagnose and repair heavy vehicle diesel fuel injection systems

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Assessment task 1: [title] Result: Competent Not yet competent

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