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 dismantling and evaluation methods and techniques appropriate to the circumstances

complete preparatory activity in a systematic manner

complete the dismantling and evaluation of a range of engine blocks and sub-assemblies

measure and check work against manufacturer and component supplier specifications

evaluate components according to workplace requirements and specifications

determine required repair procedures

complete the dismantling and evaluation of engine blocks and sub-assembly components within workplace timeframes

complete work without damage to tools and equipment or injury to persons.

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. Performance is demonstrated consistently over a period of time and in a suitable range of contexts.

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 engine blocks appropriate to the workplace, including those with and without cylinder sleeves

equipment and hand, air and power tools appropriate to dismantling and evaluating engine blocks and sub-assembly components

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:

dismantle engine blocks without causing damage to components

clean parts using appropriate solutions and procedures

identify components for re-use or replacement

check for abnormal wear and defects

check for conformance to specifications

measure to specified tolerances and dimensions

identify repair procedures

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

apply accurate measurements

calculate component dimensions

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

take, locate, download and view digital images

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 pullers

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

dismantling methods and procedures, including:

reasons for selecting the chosen tools, techniques and equipment

hazards and fluid control measures associated with the removal of engines and engine components, including housekeeping

pre-evaluation checks to determine suitability of component to be re-used

reasons for checking endfloats before disassembly

cleaning solutions and cleaning procedures of components

use of pullers, presses and specialised tools, and the application of heat to dismantle components, such as gears, pulleys and dowels

procedures for recording the facing directions of pistons, connecting rods, main and big-end caps and positions of removable counterweights and counterweight shafts assemblies

precautions to be aware of when removing the connecting rod cap in relation to snap-broken rods

removing crankshaft and identifying main bearing caps that have lost register

removing dry and wet sleeves

dismantling pistons from connecting rods

removing camshaft bearings and balance/idler shaft bearings

removing welsh plugs and oil gallery plugs

removing diesel injection pumps

dismantling components that have seized, bent or broken, including seized stud and bolt removal

measuring, testing and evaluating procedures, including:

characteristics of surface finishes and wear patterns as applied to cylinder bores, crankshafts, pistons, gears, cam followers, camshafts, bearings and bushes, block facings, parting faces of connecting rod and main bearing caps

crack testing components

testing hardness of alloy cylinder blocks, pistons, crankshaft journals and camshaft followers

straightness of shafts

taper, ovality and wear of:

crankshaft and camshaft journals

main bearing and connecting rod tunnels

cylinder bores in conventional engine blocks and the parent bores of engine blocks with dry sleeves

camshaft lobe lift

main bearing tunnels for alignment

connecting rod alignment and little-end bore size

cylinder block flatness and deck height

piston ring land clearance, piston skirt wear and gudgeon pin to piston clearance

cylinder liner register in both the upper and lower parts of the cylinder block

oil pump for serviceability

idler gear hub to bearing clearance

Australian standards relating 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 may 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 dismantling engine components

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

Tools and measuring equipment may include:

depth micrometers

dial bore gauges

dial indicators

inside and outside micrometers

pullers

other specialised tools.

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 are to include:

clean-up management

dust and noise minimisation

waste management.

Sub-assemblies include:

balance shafts

bearings

belts and pulleys

camshafts

chains

connecting rods

crankshafts

cylinder barrels

cylinder head assemblies

cylinder liners (wet and dry)

gears

idler shafts

oil pumps

pistons

rings.

Positions of auxiliary equipment may include:

clamps

missing parts

mounting brackets

position of sensors.