Individuals must be able to demonstrate knowledge of:
work health and safety (WHS) and occupational health and safety (OHS) requirements relating to reconditioning engine cylinder heads, including:
operational risk assessment and treatments associated with:
electrical safety of power tools
manual and mechanical lifting and shifting equipment
toxic cleaning substances
selecting and using personal protective equipment (PPE) for handling engine cylinder heads and using specialised equipment
environmental requirements, including procedures for trapping, storing and disposing of cleaning fluids and machining waste released during reconditioning process
procedures for removing cylinder head from engine block
dismantling methods and procedures relating to cylinder heads
cleaning methods and procedures relating to cylinder heads
procedures for measuring, testing and evaluating cylinder heads, including:
hardness of aluminium alloy cylinder heads and re-hardening aluminium alloy cylinder heads
visual inspections
cylinder head testing, including:
dye penetrant for alloy cylinder heads
wet and dry magnetic particle for cast iron cylinder heads
vacuum for valve leakage
pressure for porosity
inspecting valve guides and valve seats
procedures for measuring, testing and evaluating associated parts, including inspecting camshafts, valves, valve springs, valve spring seats, valve spring retainers, collets and lash caps, rocker arms, rocker shafts and pushrods
procedures for repairing cylinder heads and associated components, including:
heat treating aluminium alloy cylinder heads
straightening cylinder heads
repairing cracks in cylinder heads
welding aluminium alloy and cast iron cylinder heads
types of surface finishes for different cylinder head gaskets
surfacing cylinder heads, including manifold faces
repairing valve guides, valve seats, rocker arms and rocker shafts
replacing valve guides
cutting valve seats to required angles
re-facing valves in valve re-facer
setting valve stem protrusion
setting valve masking heights in diesel cylinder heads
fitting injector tubes and setting injector protrusion
cleaning cylinder heads of residue and swarf, including removing residue from bead cleaning
procedures for assembling cylinder heads, including:
refitting welsh plugs and oil gallery plugs, valves, springs, spring seats, retainers, collets lash caps, camshafts, rocker gear, cam followers and associated components
reasons for setting valve timing before fitting cylinder head to block
evaluating and setting rocker arm geometry
preparing cylinder block to accept cylinder head
fitting head gaskets and cylinder heads to engine blocks
tightening procedures for cylinder head bolts
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 test procedures, including machined surface 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 cylinder heads that they have reconditioned, 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
precision measuring equipment relevant to the engine component and work process
three different multi-cylinder engine cylinder heads as specified in the performance evidence
fixed and portable hand, air and power tools, lifting equipment and material suitable for reconditioning cylinder heads.