Individuals must be able to demonstrate knowledge of:
work health and safety (WHS) and occupational health and safety (OHS) requirements relating to performing advanced machining and blueprinting of engine components, including:
procedures for selecting and using personal protective equipment (PPE) for:
handling engine blocks and sub-assemblies
using chemical cleaning agents
operational risk assessment and treatments associated with:
electrical safety of machinery
machinery movement and operation
environmental requirements, including procedures for trapping, storing and disposing of cleaning and lubricating fluids released during process
procedures for preparing cylinder blocks and cylinder heads for blueprinting, including:
chemically cleaning engine components, including methods for avoiding damage or loss of components
chasing threads to remove debris with correct grade tap
hardness testing components
pressure testing cylinder heads
checking cylinder heads for bend on both sides
checking cylinder heads for minimum thickness
checking valve guides, valve stems, collets and valve springs for wear
testing engine block, including sonic testing and crack testing
dummy assembling engines, including reasons for dummy assembling engines
procedures for blueprinting cylinder blocks, including:
line boring main tunnels to produce datum
fitting bearings and checking crush
measuring main bearing tunnel with bearings fitted
grinding crankshaft to suit bearings and to achieve desired clearance and phasing consistency
sleeving lifter bores to centre line of camshaft and checking lifter to bore clearance and alignment to camshaft
fitting camshaft bearings and checking running clearances
squaring up deck to crankshaft tunnel to ensure crankshaft is parallel to block
fitting torque plate to bore and hone
honing cylinders to desired surface finish, matching individual pistons to respective bores
setting ring end gap
achieving consistent piston height for desired compression ratio and checking rotational clearance
procedures for blueprinting connecting rods, including:
shot peening connecting rods
preparing rod for re-sizing, including removing and locating dowels as required
selecting bolts
tensioning and re-sizing tunnel, maintaining centre-to-centre height
checking little end running clearance
removing bushes and checking parent bore of rod and bush fitment
pin fitting rod, maintaining centre-to-centre height and running clearance
checking alignment of rod
fitting up bearings, checking crush and running clearance
resizing connecting rods and fitting new bolts to ensure centre-to-centre length and alignment is correct
procedures to blueprint cylinder heads, including:
methods for achieving optimum airflow, including limitations of cylinder head modifications
machining for larger valves, including identifying machining shifts in castings
operating flow bench
porting for improved air flow and to balance combustion chambers
calculating capacity of individual combustion chambers and machining combustion chambers to achieve consistency
calculating compression ratio
selecting camshaft
setting valve heights
calculating installed height of valve springs and seat pressure
calculating valve spring open height and pressure
calculating valve spring solid height and coil bind clearance
calculating spring retainer to stem seal clearance
dialling camshaft
machining pistons to achieve desired compression ratio
setting rocker geometry, including length and sweep
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
post-grinding operations, including rust protection of machined surfaces.
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 components that they have machined and blueprinted, 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
two different multi-cylinder engines as specified in the performance evidence requiring machining and blueprinting
precision measuring equipment, including:
dial bore gauges
dial indicators
inside and outside metric and imperial micrometers
inside and outside spring calipers
fixed and portable hand, air and power tools
lifting equipment
material suitable for machining and blueprinting the engine components.