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Elements and Performance Criteria

1. Prepare to blueprint engine
   • Job requirements are determined from workplace instructions
   • Information is sourced, procedures and methods are analysed, and appropriate tools are selected for machining and blueprinting engines
   • Tools and measuring equipment are selected and checked for serviceability
   • Hazards associated with the work are identified and risks are managed
   • Cylinder block and cylinder head are prepared for blueprinting according to safety and environmental requirements
2. Measure components
   • Measurements, clearances and tolerances are sourced and interpreted from manufacturer and component supplier literature
   • Components are measured and clearances and tolerances are calculated according to workplace procedures
3. Machine components
   • Components are adjusted or machined to meet manufacturer and component supplier specifications according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures
   • Dummy assembly of engine is performed as required and clearances and tolerances are calculated according to workplace procedures
   • Further machining is carried out as required to achieve required clearances and tolerances
   • Engine is assembled according to job requirements and clearances, and tolerances are calculated again
   • Bright surfaces are treated with rust prevention solution and component is prepared for further process or storage according to workplace procedures
   • Blueprinting schedule documentation is completed according to workplace procedures
4. Complete blueprinting and machining process
   • Final inspection is made to ensure finished work complies with workplace requirements
   • 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
5. Prepare to blueprint engine
   • Job requirements are determined from workplace instructions
   • Information is sourced, procedures and methods are analysed, and appropriate tools are selected for machining and blueprinting engines
   • Tools and measuring equipment are selected and checked for serviceability
   • Hazards associated with the work are identified and risks are managed
   • Cylinder block and cylinder head are prepared for blueprinting according to safety and environmental requirements
6. Measure components
   • Measurements, clearances and tolerances are sourced and interpreted from manufacturer and component supplier literature
   • Components are measured and clearances and tolerances are calculated according to workplace procedures
7. Machine components
   • Components are adjusted or machined to meet manufacturer and component supplier specifications according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures
   • Dummy assembly of engine is performed as required and clearances and tolerances are calculated according to workplace procedures
   • Further machining is carried out as required to achieve required clearances and tolerances
   • Engine is assembled according to job requirements and clearances, and tolerances are calculated again
   • Bright surfaces are treated with rust prevention solution and component is prepared for further process or storage according to workplace procedures
   • Blueprinting schedule documentation is completed according to workplace procedures
8. Complete blueprinting and machining process
   • Final inspection is made to ensure finished work complies with workplace requirements
   • 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.

Preparation must include:	ensuring surfaces 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: procedures for selecting and using personal protective equipment (PPE) for: handling engine blocks and sub-assemblies using chemical cleaning agents operational risk assessment and treatments associated with: electrical safety of machinery machinery movement and operation environmental requirements, including procedures for trapping, storing and disposing of cleaning and lubricating fluids released during process.
Blueprinting schedule documentation must include:	record of work performed, including tolerances and clearances achieved.

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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:

machine and blueprint two of the following different engine components:

engine with multiple overhead camshafts

V configuration engine with at least six cylinders

multi-cylinder diesel engine.

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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 performing advanced machining and blueprinting of engine components, including:

procedures for selecting and using personal protective equipment (PPE) for:

handling engine blocks and sub-assemblies

using chemical cleaning agents

operational risk assessment and treatments associated with:

electrical safety of machinery

machinery movement and operation

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

procedures for preparing cylinder blocks and cylinder heads for blueprinting, including:

chemically cleaning engine components, including methods for avoiding damage or loss of components

chasing threads to remove debris with correct grade tap

hardness testing components

pressure testing cylinder heads

checking cylinder heads for bend on both sides

checking cylinder heads for minimum thickness

checking valve guides, valve stems, collets and valve springs for wear

testing engine block, including sonic testing and crack testing

dummy assembling engines, including reasons for dummy assembling engines

procedures for blueprinting cylinder blocks, including:

line boring main tunnels to produce datum

fitting bearings and checking crush

measuring main bearing tunnel with bearings fitted

grinding crankshaft to suit bearings and to achieve desired clearance and phasing consistency

sleeving lifter bores to centre line of camshaft and checking lifter to bore clearance and alignment to camshaft

fitting camshaft bearings and checking running clearances

squaring up deck to crankshaft tunnel to ensure crankshaft is parallel to block

fitting torque plate to bore and hone

honing cylinders to desired surface finish, matching individual pistons to respective bores

setting ring end gap

achieving consistent piston height for desired compression ratio and checking rotational clearance

procedures for blueprinting connecting rods, including:

shot peening connecting rods

preparing rod for re-sizing, including removing and locating dowels as required

selecting bolts

tensioning and re-sizing tunnel, maintaining centre-to-centre height

checking little end running clearance

removing bushes and checking parent bore of rod and bush fitment

pin fitting rod, maintaining centre-to-centre height and running clearance

checking alignment of rod

fitting up bearings, checking crush and running clearance

resizing connecting rods and fitting new bolts to ensure centre-to-centre length and alignment is correct

procedures to blueprint cylinder heads, including:

methods for achieving optimum airflow, including limitations of cylinder head modifications

machining for larger valves, including identifying machining shifts in castings

operating flow bench

porting for improved air flow and to balance combustion chambers

calculating capacity of individual combustion chambers and machining combustion chambers to achieve consistency

calculating compression ratio

selecting camshaft

setting valve heights

calculating installed height of valve springs and seat pressure

calculating valve spring open height and pressure

calculating valve spring solid height and coil bind clearance

calculating spring retainer to stem seal clearance

dialling camshaft

machining pistons to achieve desired compression ratio

setting rocker geometry, including length and sweep

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-grinding operations, including rust protection of machined surfaces.

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