Assessor Resource

AURTTM009
Fit sleeves and bore and hone engine cylinders

Assessment tool

Version 1.0
Issue Date: April 2024


This unit describes the performance outcomes required to fit sleeves to restore engine cylinder blocks and to bore and hone the sleeves to specific tolerances. It involves preparing for the task, assessing damage and determining required repair action, boring, sleeving and honing engine cylinders, and completing workplace processes and documentation.

It applies to those working in the automotive service and repair industry. The engines 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.

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 bore engine cylinder

1.1 Job requirements are determined from workplace instructions

1.2 Engine block, boring and sleeving information is sourced and interpreted

1.3 Tools and measuring equipment for boring are selected and checked for serviceability

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

1.5 Engine cylinder is measured and calibration requirements for boring are determined

1.6 Engine cylinder block is prepared for boring, and reboring machine is prepared to accept engine cylinder block according to manufacturer specifications and workplace procedures

1.7 Engine cylinder block is correctly positioned and clamped, and limit stop is set according to manufacturer specifications and workplace procedures

2. Bore engine cylinder

2.1 Cutting tools are mounted and positioned, and worn and damaged cutting tools are identified and replaced or sharpened

2.2 Boring operations are carried out at correct speeds and feed rates according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures

2.3 Engine cylinder is measured to ensure compliance with specifications

2.4 Boring operations are completed to required specifications and honing allowances according to workplace procedures and safety requirements, and following machinery safe operating procedures

3. Prepare to sleeve engine cylinder

3.1 Tools and equipment for sleeving are selected, checked and prepared for operation according to manufacturer specifications and workplace procedures

3.2 Measuring and calibration requirements for sleeving are determined and required sleeve is selected

3.3 Engine cylinder block or barrel is prepared for sleeving according to manufacturer specifications and workplace procedures

4. Sleeve engine cylinder

4.1 Sleeving operations are carried out according to workplace procedures and safety requirements, and following machinery safe operating procedures

4.2 Sleeves are measured to ensure compliance with specifications, including sleeve protrusion

4.3 Sleeves are bored as required to required specifications and honing allowances according to workplace procedures and safety requirements, and following machinery safe operating procedures

5. Prepare to hone engine cylinder

5.1 Bored engine block is cleaned of residue and swarf according to manufacturer specifications and workplace procedures

5.2 Tools and equipment for honing are selected, checked and prepared for operation according to manufacturer specifications and workplace procedures

5.3 Clearances are measured and honing requirements are determined

5.4 Honing machine is prepared to accept engine cylinder block according to manufacturer specifications and workplace procedures

5.5 Engine cylinder block is positioned and securely clamped, and required hone stroke is set according to manufacturer specifications and workplace procedures

5.6 Hone stones are selected and speed is set to achieve required finish and cross hatch

6. Hone engine cylinder

6.1 Engine cylinder is honed at correct speed and rate to required finish according to workplace procedures and safety requirements and following machinery safe operating procedures

6.2 Engine cylinder is measured to ensure compliance with specifications

6.3 Honing operations are completed to required piston to bore clearance according to workplace procedures and safety requirements and following machinery safe operating procedures

6.4 Engine cylinder block is thoroughly cleaned of residual honing oil according to workplace procedures

7. Complete sleeving, boring and honing processes

7.1 Final inspection is made to ensure finished work complies with workplace requirements

7.2 Bright surfaces are treated with rust prevention solution and engine cylinder block is prepared for further process or storage according to workplace procedures

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

7.4 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:

work on three different engine blocks as follows:

bore one engine block to accept parallel liners with correct interference fit

bore one engine block to accept flanged liners with correct interference fit

bore and hone the cylinders of a different multi-cylinder engine block to achieve correct piston to bore clearance.

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to fitting sleeves and boring and honing engine cylinders, including:

procedures for selecting and using personal protective equipment (PPE) for:

handling engine cylinder blocks

using boring and honing machines

using chemical cleaning and lubricating agents

safe operating procedures for boring and honing machinery, including:

electrical safety of boring and honing machinery

boring and honing machinery movement and operation

environmental requirements, including procedures for trapping, storing and disposing of cleaning and lubricating fluids released during the machining process

types and application of sleeves, including:

dry sleeves, including:

interference fit parallel sleeve

interference fit flanged sleeves

chrome type finished-to-size dry flanged sleeves

wet sleeves, including:

flanged

stepped

sleeve fitting procedures, including:

interference sleeves, including fitting parallel sleeves to step in parent bore

wet sleeves

checking sleeve height

types, characteristics and limitations of honing and boring machines, including:

types and grades of boring tools

types and grades of honing stones

hand-held and machine-operated hones

tool sharpening methods, including:

maintaining sharpness of tool throughout boring operations

compensation methods for tool wear throughout boring operations

boring methods and procedures, including:

determining required size of bore, including honing allowance

preparing engine cylinder block for boring, and setting engine cylinder block into boring machine, including jigs, rails and clamps

setting boring tool to correct diameter, locking boring tool, and setting limit stop

reasons for taking a test cut

speed and feed rates of boring tool for differing materials, including alloysil or nicolsil, and for bore diameters

methods for setting speed and feed rate of boring tools

honing methods and procedures, including:

cleaning engine cylinder block before and after honing

preparing portable and stationary honing machines, setting engine cylinder block into honing machine, and setting hone stroke

setting honing speeds and feed rates to achieve required finish

methods of measuring bores for taper, ovality and barrelling

types and application of cleaning, lubricating and protective agents, including:

material suitability

application of lubricating agents for different speeds and feed rates of boring machines and honing machines

hazards associated with chemical cleaning and lubricating agents

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-repair procedures, including rust protection.

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 cylinders 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 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 as specified in the performance evidence

engine boring and honing machines

precision measuring equipment, including:

dial bore gauges

dial indicator gauges

inside and outside metric and imperial micrometers.

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 bore engine cylinder

1.1 Job requirements are determined from workplace instructions

1.2 Engine block, boring and sleeving information is sourced and interpreted

1.3 Tools and measuring equipment for boring are selected and checked for serviceability

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

1.5 Engine cylinder is measured and calibration requirements for boring are determined

1.6 Engine cylinder block is prepared for boring, and reboring machine is prepared to accept engine cylinder block according to manufacturer specifications and workplace procedures

1.7 Engine cylinder block is correctly positioned and clamped, and limit stop is set according to manufacturer specifications and workplace procedures

2. Bore engine cylinder

2.1 Cutting tools are mounted and positioned, and worn and damaged cutting tools are identified and replaced or sharpened

2.2 Boring operations are carried out at correct speeds and feed rates according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures

2.3 Engine cylinder is measured to ensure compliance with specifications

2.4 Boring operations are completed to required specifications and honing allowances according to workplace procedures and safety requirements, and following machinery safe operating procedures

3. Prepare to sleeve engine cylinder

3.1 Tools and equipment for sleeving are selected, checked and prepared for operation according to manufacturer specifications and workplace procedures

3.2 Measuring and calibration requirements for sleeving are determined and required sleeve is selected

3.3 Engine cylinder block or barrel is prepared for sleeving according to manufacturer specifications and workplace procedures

4. Sleeve engine cylinder

4.1 Sleeving operations are carried out according to workplace procedures and safety requirements, and following machinery safe operating procedures

4.2 Sleeves are measured to ensure compliance with specifications, including sleeve protrusion

4.3 Sleeves are bored as required to required specifications and honing allowances according to workplace procedures and safety requirements, and following machinery safe operating procedures

5. Prepare to hone engine cylinder

5.1 Bored engine block is cleaned of residue and swarf according to manufacturer specifications and workplace procedures

5.2 Tools and equipment for honing are selected, checked and prepared for operation according to manufacturer specifications and workplace procedures

5.3 Clearances are measured and honing requirements are determined

5.4 Honing machine is prepared to accept engine cylinder block according to manufacturer specifications and workplace procedures

5.5 Engine cylinder block is positioned and securely clamped, and required hone stroke is set according to manufacturer specifications and workplace procedures

5.6 Hone stones are selected and speed is set to achieve required finish and cross hatch

6. Hone engine cylinder

6.1 Engine cylinder is honed at correct speed and rate to required finish according to workplace procedures and safety requirements and following machinery safe operating procedures

6.2 Engine cylinder is measured to ensure compliance with specifications

6.3 Honing operations are completed to required piston to bore clearance according to workplace procedures and safety requirements and following machinery safe operating procedures

6.4 Engine cylinder block is thoroughly cleaned of residual honing oil according to workplace procedures

7. Complete sleeving, boring and honing processes

7.1 Final inspection is made to ensure finished work complies with workplace requirements

7.2 Bright surfaces are treated with rust prevention solution and engine cylinder block is prepared for further process or storage according to workplace procedures

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

7.4 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.

Calibration requirements must include:

determining:

piston to bore clearance

sizes of cut

required honing allowance.

Safety and environmental requirements must include:

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

procedures for selecting and using personal protective equipment (PPE) for:

handling engine cylinder blocks

using boring and honing machines

using chemical cleaning and lubricating agents

safe operating procedures for boring and honing machinery, including:

electrical safety of boring and honing machinery

boring and honing machinery movement and operation

environmental requirements, including procedures for trapping, storing and disposing of cleaning and lubricating fluids released during the machining process.

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:

work on three different engine blocks as follows:

bore one engine block to accept parallel liners with correct interference fit

bore one engine block to accept flanged liners with correct interference fit

bore and hone the cylinders of a different multi-cylinder engine block to achieve correct piston to bore clearance.

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to fitting sleeves and boring and honing engine cylinders, including:

procedures for selecting and using personal protective equipment (PPE) for:

handling engine cylinder blocks

using boring and honing machines

using chemical cleaning and lubricating agents

safe operating procedures for boring and honing machinery, including:

electrical safety of boring and honing machinery

boring and honing machinery movement and operation

environmental requirements, including procedures for trapping, storing and disposing of cleaning and lubricating fluids released during the machining process

types and application of sleeves, including:

dry sleeves, including:

interference fit parallel sleeve

interference fit flanged sleeves

chrome type finished-to-size dry flanged sleeves

wet sleeves, including:

flanged

stepped

sleeve fitting procedures, including:

interference sleeves, including fitting parallel sleeves to step in parent bore

wet sleeves

checking sleeve height

types, characteristics and limitations of honing and boring machines, including:

types and grades of boring tools

types and grades of honing stones

hand-held and machine-operated hones

tool sharpening methods, including:

maintaining sharpness of tool throughout boring operations

compensation methods for tool wear throughout boring operations

boring methods and procedures, including:

determining required size of bore, including honing allowance

preparing engine cylinder block for boring, and setting engine cylinder block into boring machine, including jigs, rails and clamps

setting boring tool to correct diameter, locking boring tool, and setting limit stop

reasons for taking a test cut

speed and feed rates of boring tool for differing materials, including alloysil or nicolsil, and for bore diameters

methods for setting speed and feed rate of boring tools

honing methods and procedures, including:

cleaning engine cylinder block before and after honing

preparing portable and stationary honing machines, setting engine cylinder block into honing machine, and setting hone stroke

setting honing speeds and feed rates to achieve required finish

methods of measuring bores for taper, ovality and barrelling

types and application of cleaning, lubricating and protective agents, including:

material suitability

application of lubricating agents for different speeds and feed rates of boring machines and honing machines

hazards associated with chemical cleaning and lubricating agents

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-repair procedures, including rust protection.

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 cylinders 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 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 as specified in the performance evidence

engine boring and honing machines

precision measuring equipment, including:

dial bore gauges

dial indicator gauges

inside and outside metric and imperial micrometers.
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 
Engine block, boring and sleeving information is sourced and interpreted 
Tools and measuring equipment for boring are selected and checked for serviceability 
Hazards associated with the work are identified and risks are managed 
Engine cylinder is measured and calibration requirements for boring are determined 
Engine cylinder block is prepared for boring, and reboring machine is prepared to accept engine cylinder block according to manufacturer specifications and workplace procedures 
Engine cylinder block is correctly positioned and clamped, and limit stop is set according to manufacturer specifications and workplace procedures 
Cutting tools are mounted and positioned, and worn and damaged cutting tools are identified and replaced or sharpened 
Boring operations are carried out at correct speeds and feed rates according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures 
Engine cylinder is measured to ensure compliance with specifications 
Boring operations are completed to required specifications and honing allowances according to workplace procedures and safety requirements, and following machinery safe operating procedures 
Tools and equipment for sleeving are selected, checked and prepared for operation according to manufacturer specifications and workplace procedures 
Measuring and calibration requirements for sleeving are determined and required sleeve is selected 
Engine cylinder block or barrel is prepared for sleeving according to manufacturer specifications and workplace procedures 
Sleeving operations are carried out according to workplace procedures and safety requirements, and following machinery safe operating procedures 
Sleeves are measured to ensure compliance with specifications, including sleeve protrusion 
Sleeves are bored as required to required specifications and honing allowances according to workplace procedures and safety requirements, and following machinery safe operating procedures 
Bored engine block is cleaned of residue and swarf according to manufacturer specifications and workplace procedures 
Tools and equipment for honing are selected, checked and prepared for operation according to manufacturer specifications and workplace procedures 
Clearances are measured and honing requirements are determined 
Honing machine is prepared to accept engine cylinder block according to manufacturer specifications and workplace procedures 
Engine cylinder block is positioned and securely clamped, and required hone stroke is set according to manufacturer specifications and workplace procedures 
Hone stones are selected and speed is set to achieve required finish and cross hatch 
Engine cylinder is honed at correct speed and rate to required finish according to workplace procedures and safety requirements and following machinery safe operating procedures 
Engine cylinder is measured to ensure compliance with specifications 
Honing operations are completed to required piston to bore clearance according to workplace procedures and safety requirements and following machinery safe operating procedures 
Engine cylinder block is thoroughly cleaned of residual honing oil according to workplace procedures 
Final inspection is made to ensure finished work complies with workplace requirements 
Bright surfaces are treated with rust prevention solution and engine cylinder block is prepared for further process or storage according to workplace procedures 
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 
Workplace documentation is processed according to workplace procedures 
Job requirements are determined from workplace instructions 
Engine block, boring and sleeving information is sourced and interpreted 
Tools and measuring equipment for boring are selected and checked for serviceability 
Hazards associated with the work are identified and risks are managed 
Engine cylinder is measured and calibration requirements for boring are determined 
Engine cylinder block is prepared for boring, and reboring machine is prepared to accept engine cylinder block according to manufacturer specifications and workplace procedures 
Engine cylinder block is correctly positioned and clamped, and limit stop is set according to manufacturer specifications and workplace procedures 
Cutting tools are mounted and positioned, and worn and damaged cutting tools are identified and replaced or sharpened 
Boring operations are carried out at correct speeds and feed rates according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures 
Engine cylinder is measured to ensure compliance with specifications 
Boring operations are completed to required specifications and honing allowances according to workplace procedures and safety requirements, and following machinery safe operating procedures 
Tools and equipment for sleeving are selected, checked and prepared for operation according to manufacturer specifications and workplace procedures 
Measuring and calibration requirements for sleeving are determined and required sleeve is selected 
Engine cylinder block or barrel is prepared for sleeving according to manufacturer specifications and workplace procedures 
Sleeving operations are carried out according to workplace procedures and safety requirements, and following machinery safe operating procedures 
Sleeves are measured to ensure compliance with specifications, including sleeve protrusion 
Sleeves are bored as required to required specifications and honing allowances according to workplace procedures and safety requirements, and following machinery safe operating procedures 
Bored engine block is cleaned of residue and swarf according to manufacturer specifications and workplace procedures 
Tools and equipment for honing are selected, checked and prepared for operation according to manufacturer specifications and workplace procedures 
Clearances are measured and honing requirements are determined 
Honing machine is prepared to accept engine cylinder block according to manufacturer specifications and workplace procedures 
Engine cylinder block is positioned and securely clamped, and required hone stroke is set according to manufacturer specifications and workplace procedures 
Hone stones are selected and speed is set to achieve required finish and cross hatch 
Engine cylinder is honed at correct speed and rate to required finish according to workplace procedures and safety requirements and following machinery safe operating procedures 
Engine cylinder is measured to ensure compliance with specifications 
Honing operations are completed to required piston to bore clearance according to workplace procedures and safety requirements and following machinery safe operating procedures 
Engine cylinder block is thoroughly cleaned of residual honing oil according to workplace procedures 
Final inspection is made to ensure finished work complies with workplace requirements 
Bright surfaces are treated with rust prevention solution and engine cylinder block is prepared for further process or storage according to workplace procedures 
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 
Workplace documentation is processed according to workplace procedures 

Forms

Assessment Cover Sheet

AURTTM009 - Fit sleeves and bore and hone engine cylinders
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

AURTTM009 - Fit sleeves and bore and hone engine cylinders

Student name:

Student ID:

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

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

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