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Elements and Performance Criteria

1. Prepare to dismantle engine
   • Job requirements are determined from workplace instructions
   • Dismantling information is sourced and interpreted
   • Dismantling options are analysed and those most appropriate to the circumstances are selected
   • Hazards associated with the work are identified and risks are managed
   • Dismantling tools and equipment are selected and checked for serviceability
2. Dismantle and evaluate engine and components
   • Engine and relevant components are dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements, and without causing unnecessary damage to components or systems
   • Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
   • Components are measured and compared with manufacturer specifications and serviceability is determined
   • Component repair method is determined
   • Unserviceable parts are identified and replacement parts sourced
3. Carry out overhaul
   • Overhaul information is sourced and interpreted
   • Overhaul options are analysed and those most appropriate to the circumstances are selected
   • Overhaul tools and equipment are selected and checked for serviceability
   • Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or systems
4. Assemble engine and components
   • Engine is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
   • Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
   • Assembly of engine is completed within workplace timeframes and without causing damage to other components or systems
   • Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
5. Complete work processes
   • Final inspection is made to ensure work is to workplace expectations and engine is presented ready for use or storage
   • Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
   • Tools and equipment are checked and stored according to workplace procedures
   • Workplace documentation is processed according to workplace procedures
6. Prepare to dismantle engine
   • Job requirements are determined from workplace instructions
   • Dismantling information is sourced and interpreted
   • Dismantling options are analysed and those most appropriate to the circumstances are selected
   • Hazards associated with the work are identified and risks are managed
   • Dismantling tools and equipment are selected and checked for serviceability
7. Dismantle and evaluate engine and components
   • Engine and relevant components are dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements, and without causing unnecessary damage to components or systems
   • Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
   • Components are measured and compared with manufacturer specifications and serviceability is determined
   • Component repair method is determined
   • Unserviceable parts are identified and replacement parts sourced
8. Carry out overhaul
   • Overhaul information is sourced and interpreted
   • Overhaul options are analysed and those most appropriate to the circumstances are selected
   • Overhaul tools and equipment are selected and checked for serviceability
   • Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or systems
9. Assemble engine and components
   • Engine is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
   • Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
   • Assembly of engine is completed within workplace timeframes and without causing damage to other components or systems
   • Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
10. Complete work processes
    • Final inspection is made to ensure work is to workplace expectations and engine is presented ready for use or storage
    • Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
    • Tools and equipment are checked and stored according to workplace procedures
    • Workplace documentation is processed according to workplace procedures

Range Statement

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.

Safety and environmental requirements must include:

work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures for using: specialised engine overhaul tools, equipment and machinery chemicals and toxic substances manual and mechanical lifting equipment environmental requirements, including procedures for trapping, storing and disposing of fluids released from engines.

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Performance Evidence

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:

overhaul two different multi-cylinder engines, including one engine with cylinder sleeves.

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Knowledge Evidence

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to overhauling engines and associated components, including procedures for:

using personal protective equipment (PPE) when handling engines and using chemical cleaning agents

using slings, chains and other lifting equipment and machinery

using specialised equipment, including heating torches, ovens and presses

handling freezing substances, including liquid nitrogen

environmental requirements, including procedures for trapping, storing and disposing of fluids released from engines

types, characteristics and operating principles of engines and associated engine components

engine overhaul procedures, including:

methods for cleaning and preparing engine for overhaul

engine dismantling procedures

engine and engine component inspection, measuring and evaluation procedures, including:

non-destructive testing procedures, including dye penetrant testing and magnetic particle testing

methods for measuring and calculating tolerances and clearances

engine and engine component repair and adjustment procedures, including:

engine cylinder head and block machining

engine crankshaft and camshaft grinding

engine cylinder and engine sleeve fitting, boring and honing

engine bearing tunnel and connecting rod repair

engine component heat treating, straightening and reclamation

engine component balancing

engine assembly procedures, including procedures for tolerance measuring and calculating and adjusting components, including:

piston to connecting rod big-end alignment

big-end bearing to crankshaft journal clearance

big-end bearing crush with bearing blue

piston ring end gap, back clearance and side clearance

main bearing to crankshaft journal clearance

main bearing crush with bearing blue

semi-flanged thrust bearings to crankshaft clearance

finished camshaft bearings to camshaft clearance

camshafts and cam followers

camshaft end float

crankshaft end float

gear backlash

oil pump sealing and pick-up oil piping

component assembly procedures and processes, including:

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

post-overhaul testing procedures for engines.

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