Individuals must be able to demonstrate knowledge of:
work health and safety (WHS) and occupational health and safety (OHS) requirements relating to overhauling engines and associated components, including procedures for:
using personal protective equipment (PPE) when handling engines and using chemical cleaning agents
using slings, chains and other lifting equipment and machinery
using specialised equipment, including heating torches, ovens and presses
handling freezing substances, including liquid nitrogen
environmental requirements, including procedures for trapping, storing and disposing of fluids released from engines
types, characteristics and operating principles of engines and associated engine components
engine overhaul procedures, including:
methods for cleaning and preparing engine for overhaul
engine dismantling procedures
engine and engine component inspection, measuring and evaluation procedures, including:
non-destructive testing procedures, including dye penetrant testing and magnetic particle testing
methods for measuring and calculating tolerances and clearances
engine and engine component repair and adjustment procedures, including:
engine cylinder head and block machining
engine crankshaft and camshaft grinding
engine cylinder and engine sleeve fitting, boring and honing
engine bearing tunnel and connecting rod repair
engine component heat treating, straightening and reclamation
engine component balancing
engine assembly procedures, including procedures for tolerance measuring and calculating and adjusting components, including:
piston to connecting rod big-end alignment
big-end bearing to crankshaft journal clearance
big-end bearing crush with bearing blue
piston ring end gap, back clearance and side clearance
main bearing to crankshaft journal clearance
main bearing crush with bearing blue
semi-flanged thrust bearings to crankshaft clearance
finished camshaft bearings to camshaft clearance
camshafts and cam followers
camshaft end float
crankshaft end float
gear backlash
oil pump sealing and pick-up oil piping
component assembly procedures and processes, including:
welsh plugs and oil gallery plugs
piston and connecting rod assemblies
big-end bearings
piston rings to pistons
main bearings and thrust washers
semi-flanged thrust bearings
crankshafts, including protection measures for crankshaft journals, bearings, rings and bores
finished camshaft bearings
camshafts and cam followers
timing gears
chains and tensioners
oil pumps, oil squirters and oil pump pick-ups
balance shafts
fitting ancillary components, including covers and seals, housings, diesel fuel injection pumps, oil coolers, crankshaft pulleys, flywheels and bell housings
post-overhaul testing procedures for 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 engines 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:
mechanical repair workplace or simulated workplace
workplace instructions
manufacturer engine specifications
two different multi-cylinder engines requiring overhaul, including an engine with cylinder sleeves
tools, equipment and materials appropriate for overhauling and adjusting engines.