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Elements and Performance Criteria

  1. Prepare to assemble engine block and sub-assembly
  2. Check engine block and sub-assembly clearances and tolerances
  3. Assemble engine block and engine sub-assembly
  4. Complete assembly process
  5. Prepare to assemble engine block and sub-assembly
  6. Check engine block and sub-assembly clearances and tolerances
  7. Assemble engine block and engine sub-assembly
  8. Complete assembly process

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.

Tools must include:

fixed and portable hand, air and power tools

lifting equipment

torque wrench

material suitable for assembling engine block.

Pre-assembly cleaning must include:

removing machining residue

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

Safety and environmental requirements must include:

work health and safety (WHS) and occupational health and safety (OHS) requirements, including operational risk assessment and treatments associated with:

power tool electrical safety

manual and mechanical lifting and shifting equipment

toxic cleaning substances

environmental requirements, including procedures for trapping, storing and disposing of cleaning fluids released during the assembly process.

Measuring clearances and tolerances must include:

back clearance and side clearance

bearing to journal clearance

end floats

piston ring end gap

piston to bore clearance.

Adjusting clearances and tolerances must include:

adjusting gear backlash

machining semi-finished thrust bearings

machining piston protrusion and valve pockets

pin-boring connecting rod little ends.

Assembled must include:

gaskets

seals.

Australian standards must include:

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.



Knowledge Evidence

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to assembling engine blocks and sub-assemblies, including procedures for:

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

correctly operating specialised equipment, including heating torches, ovens and presses

handling freezing substances, including 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

environmental requirements, including procedures for trapping, storing and disposing of cleaning fluids released during the assembly process

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

piston to connecting rod big end alignment

big end and main bearing crush with bearing blue

piston ring end gap, back clearance and side clearance

bearing to crankshaft clearances with plastigage and measuring and calculating clearances

semi-flanged thrust bearings

finished camshaft bearings and measuring clearances

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:

pre-assembly wash procedures for components

welsh plugs and oil gallery plugs

piston and connecting rod assemblies

big end bearings

piston rings to pistons, including procedures for using ring compressors

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

bell housings

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.