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Elements and Performance Criteria

1. Prepare to undertake metal building procedures
   • Job requirements are determined from workplace instructions
   • Information is sourced, procedures and methods are analysed, and appropriate tools are selected for rebuilding engine components
   • Tools and measuring equipment are selected and checked for serviceability
   • Hazards associated with the work are identified and risks are managed
   • Engine component is prepared for appropriate metal application method according to workplace procedures and safety and environmental requirements
2. Apply metal to engine component
   • Metal application process is used to rebuild damaged engine component according to workplace procedures and safety requirements, and following machinery safe operating procedures
   • Engine component is measured to ensure compliance with specifications
   • Metal application process is completed in readiness for further repair according to workplace procedures and safety requirements, and following machinery safe operating procedures
3. Perform necessary machining to rebuild component
   • Machining is carried out according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures
   • Component is measured to ensure compliance with manufacturer specifications
   • Machining operations are completed according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and following machinery safe operating procedures
4. Complete rebuild processes
   • Component surfaces are finished to manufacturer specifications and within allowable tolerances according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures
   • Final inspection is made to ensure finished work complies with workplace requirements
   • Bright surfaces are treated with rust prevention solution and engine component 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
5. Prepare to undertake metal building procedures
   • Job requirements are determined from workplace instructions
   • Information is sourced, procedures and methods are analysed, and appropriate tools are selected for rebuilding engine components
   • Tools and measuring equipment are selected and checked for serviceability
   • Hazards associated with the work are identified and risks are managed
   • Engine component is prepared for appropriate metal application method according to workplace procedures and safety and environmental requirements
6. Apply metal to engine component
   • Metal application process is used to rebuild damaged engine component according to workplace procedures and safety requirements, and following machinery safe operating procedures
   • Engine component is measured to ensure compliance with specifications
   • Metal application process is completed in readiness for further repair according to workplace procedures and safety requirements, and following machinery safe operating procedures
7. Perform necessary machining to rebuild component
   • Machining is carried out according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures
   • Component is measured to ensure compliance with manufacturer specifications
   • Machining operations are completed according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and following machinery safe operating procedures
8. Complete rebuild processes
   • Component surfaces are finished to manufacturer specifications and within allowable tolerances according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures
   • Final inspection is made to ensure finished work complies with workplace requirements
   • Bright surfaces are treated with rust prevention solution and engine component 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

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.

Measuring equipment must include:	dial indicators inside and outside metric and imperial micrometers.
Safety and environmental requirements must include:	work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures: selecting and using personal protective equipment (PPE) safely operating welding, metal spraying and hard chroming machinery environmental requirements, including procedures for trapping, storing and disposing of cooling and lubricating fluids released during the machining process.

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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:

repair a cast iron cylinder head

repair a crack in an aluminium alloy cylinder head

build up camshaft lobes or journals by welding, metal spraying and hard chroming, and machine to specifications

build up crankshaft journals or thrust surfaces or bearing faces by welding, metal spraying and hard chroming, and machine to specifications.

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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 applying metal to rebuild engine components, including procedures for :

selecting and using personal protective equipment (PPE)

safely operating welding, metal spraying and hard chroming machinery

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

procedures for identifying existing heat treatment processes, including nitriding, Tufftriding and induction hardening

specific welding procedures, including:

manual metal arc welding (MMAW)

gas metal arc welding (GMAW)

gas tungsten arc welding (GTAW)

flux core

metal spraying

submerged arc

procedures for hard chrome application

repair operations for components, including:

crankshaft journals

camshaft journals and lobes

seal areas

crankshaft nose and keyway

pulley retaining thread damage

crankshaft radius treatment, including:

shot peening

radius rolling

deep fillet radius rolling

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 operations, including rust protection of machined surfaces.

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