The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

The evidence required to demonstrate competency in this unit must be relevant to workplace operations and satisfy all of the requirements of the performance criteria and required skills and knowledge.

A person who demonstrates competency in this unit must be able to:

observe safety procedures and requirements

select methods and techniques for assembling engine blocks and sub-assemblies appropriate to the circumstances

complete the assembly of multi-cylinder blocks, including:

measuring and checking against manufacturer and component supplier specifications

carrying out assembly to manufacturer and component supplier requirements without causing damage to components, tools or systems

complete workplace and equipment records.

Context of, and specific resources for assessment

Competency is to be assessed in the workplace or a simulated workplace environment that accurately reflects performance in a real workplace setting.

Assessment is to occur:

using standard workplace practices and procedures

following safety requirements

applying environmental constraints.

Assessment is to comply with relevant:

regulatory requirements

Australian standards

industry codes of practice.

The following resources must be made available for the assessment of this unit:

appropriate worksite

multi-cylinder engines appropriate to the workplace, including in-line multi-cylinder engine and vee-configuration multi-cylinder engine blocks

fixed and portable hand, air and power tools, lifting equipment, torque wrench, measuring equipment and other equipment appropriate to assembling engine blocks and sub-assemblies

specifications and work instructions.

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of this Training Package.

Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with application of required skills and knowledge.

Assessment methods must be by direct observation of tasks and include questioning on required skills and knowledge to ensure its correct interpretation and application.

Assessment must confirm that competency is able not only to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

Competence in this unit may be assessed in conjunction with other units which together form part of a holistic work role.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

Assessment processes and techniques must be culturally sensitive and appropriate to the language and literacy capacity of the candidate and the work being performed.

Required skills

technical skills to:

clean parts using appropriate solutions and procedures

determine size and suitability of replacement components

measure to specified tolerances and dimensions

use appropriate tools for assembling engine blocks and sub-assemblies

perform necessary machining operations for assembling engine blocks and sub-assemblies

communication skills to:

follow oral instructions

work as part of a team

literacy skills to:

understand quality procedures

read, interpret and follow job instructions, specifications, standard operating procedures, charts, lists, drawings and other applicable reference documents

obtain and record measurements

document required repairs and parts

numeracy skills to use mathematical ideas and techniques to:

assess tolerances and clearances

calculate component dimensions to the required tolerances

problem-solving skills to:

prevent time and material wastage

plan and sequence operations

self-management skills to:

select and use appropriate equipment, materials, processes and procedures

follow workplace documentation, such as codes of practice and operating procedures

technology skills to use communication devices and computerised equipment to search and gather supporting material

Required knowledge

WHS regulations and requirements, equipment, material and personal safety requirements, including:

personal protective equipment (PPE) for handling engine blocks and sub-assemblies and using chemical cleaning agents

correct operation of specialised equipment, such as heating torches, ovens and presses

procedures for handling freezing substances, such as liquid nitrogen

manual-handling techniques, including:

using machinery for lifting engine blocks and engine components

using slings, chains and other lifting equipment according to safe work practices

procedures for clearance testing and adjusting or machining components, including:

piston to connecting rod big-end alignment

big-end bearing crush with bearing blue

piston ring end gap, back clearance and side clearance

bearing crush with bearing blue and measuring clearances

semi-flanged thrust bearings

finished camshaft bearings and measuring clearances

camshafts and cam followers

camshaft endfloat

crankshaft endfloat

gear backlash

oil pump sealing and pick-up oil piping

procedures for assembling processes and components, including:

reasons for and methods of producing a clean assembly space

performing a final wash of components prior to re-assembly

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

Australian standards relevant to engine reconditioning

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Workplace instructions include:

computer-generated instructions

verbal instructions

written instructions.

Information may include:

Australian standards

engineer’s design specifications and instructions

instructions issued by authorised workplace or external persons

workplace specifications and requirements

regulatory and legislative requirements relating to the automotive industry, including Australian Design Rules

safe work procedures relating to the operation of machinery associated with assembling engines

verbal, written and graphical instructions, signage, work schedules, plans, specifications, work bulletins, memos, material safety data sheets (MSDS), diagrams or sketches.

Appropriate tooling options may include:

comparator gauges

ring compressors

hand tooling

plasti-gauge

power tooling

torque wrenches.

Tools and measuring equipment may include:

clamps

dial indicators

inside and outside micrometers

lifting equipment.

WHS requirements may include:

individual state or territory regulatory requirements

operational risk assessment and treatments associated with:

electrical safety

machinery movement and operation

manual and mechanical lifting and shifting

toxic substances

working in proximity to others and site visitors

PPE required by legislation, regulations, codes of practice and workplace policies and procedures.

Environmental requirements include:

clean-up management

dust and noise minimisation

waste management.

Technical information may include:

manufacturer or supplier component specifications.

Support equipment includes:

assembly bench

assembly trolleys

engine stands

lifting equipment.

Facilities include:

dedicated engine assembly room

dust and gas exhaust units.

Pre-assembly cleaning includes:

removing machining residue

ensuring gasket faces are clean and oil and water passageways are clear using tools, such as a rifle brush.

Engine components include:

engine blocks, sleeves, crankshafts, camshafts, camshaft followers, piston and connecting rod assemblies, timing chains and gears, oil pumps, oil squirters and coolers

other variables, including ancillary systems and components, such as:

cooling systems

exhaust systems

fuel systems.

Replacement component parts may include:

bearing sets

gasket sets

oil pumps

piston rings

pistons

seals

sleeves

timing chains and gears.

Clearances and tolerances that are measured include:

back clearance and side clearance

bearing to journal clearances

endfloats

gear backlashes

parent bore to dry sleeve fit

piston ring end-gap

piston to bore clearance

sleeve heights.

Clearances and tolerances that are adjusted include:

adjusting gear backlash

machining semi-finished thrust bearings

machining piston protrusion and valve pockets

pin-boring connecting rod little-ends.

Assembling engine sub-assemblies includes:

assembling, aligning and fitting:

air brake compressors

oil coolers

oil pumps

pistons.

Assembling engine blocks includes:

fitting finished dry interference and slip-fit sleeves, chrome sleeves and wet sleeves

fitting crankshafts, piston assemblies, camshafts, camshaft followers, push rods, oil pumps, timing gears and timing chains

fitting balance weights and timing gears to crankshafts

fitting covers, seals, housings, flywheels and forced air induction assemblies.