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Elements and Performance Criteria

1. Prepare to dismantle engine block and sub-assembly
   • Job requirements are determined from workplace instructions
   • Engine block and sub assembly dismantling information is sourced and interpreted
   • Tools and measuring equipment are selected and checked for serviceability
   • Hazards associated with the work are identified and risks are managed
   • Engine is set up for dismantling using appropriate lifting equipment and avoiding fluid spillage according to safety and environmental requirements
   • Engine block and sub-assembly are cleaned according to safety and environmental procedures and relevant Australian standards, and positions of auxiliary equipment are recorded, including photographic evidence
2. Dismantle engine block and sub-assembly
   • Covers and ancillary components are removed, cleaned and stored according to workshop procedures
   • Engine block and sub-assembly are dismantled according to safety requirements and laid out in a logical order using approved methods, tools and equipment
   • Component parts are cleaned using appropriate cleaning agents for the type of material and kept in a logical order in preparation for evaluation
3. Determine repair procedures
   • Engine block and sub-assembly are inspected, measured and tested against manufacturer specifications and tolerances and according to workplace procedures and safety requirements
   • Engine block and sub-assembly are evaluated and repair requirements are determined and reported according to workplace procedures
4. Complete dismantle and evaluation processes
   • Final inspection is made to ensure finished work complies with workplace requirements
   • Bright surfaces are treated with rust prevention solution and engine block and sub-assembly are 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 dismantle engine block and sub-assembly
   • Job requirements are determined from workplace instructions
   • Engine block and sub assembly dismantling information is sourced and interpreted
   • Tools and measuring equipment are selected and checked for serviceability
   • Hazards associated with the work are identified and risks are managed
   • Engine is set up for dismantling using appropriate lifting equipment and avoiding fluid spillage according to safety and environmental requirements
   • Engine block and sub-assembly are cleaned according to safety and environmental procedures and relevant Australian standards, and positions of auxiliary equipment are recorded, including photographic evidence
6. Dismantle engine block and sub-assembly
   • Covers and ancillary components are removed, cleaned and stored according to workshop procedures
   • Engine block and sub-assembly are dismantled according to safety requirements and laid out in a logical order using approved methods, tools and equipment
   • Component parts are cleaned using appropriate cleaning agents for the type of material and kept in a logical order in preparation for evaluation
7. Determine repair procedures
   • Engine block and sub-assembly are inspected, measured and tested against manufacturer specifications and tolerances and according to workplace procedures and safety requirements
   • Engine block and sub-assembly are evaluated and repair requirements are determined and reported according to workplace procedures
8. Complete dismantle and evaluation processes
   • Final inspection is made to ensure finished work complies with workplace requirements
   • Bright surfaces are treated with rust prevention solution and engine block and sub-assembly are 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.

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: electrical equipment used in dismantling and evaluating engine blocks and sub-assemblies 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 process.

Inspecting, measuring and testing must include:

applying surface finishes and wear patterns to: cylinder bores, crankshafts, pistons, gears, cam followers, and camshafts bearings and bushes block facings parting faces of connecting rod main bearing caps crack testing: connecting rods crankshaft camshaft cylinder block surface camshaft and main bearing tunnels main bearing caps hardness testing: alloy cylinder blocks, pistons, crankshaft journals and camshaft followers checking taper, ovality and wear of: crankshaft and camshaft journals main bearing and connecting rod tunnels cylinder bores in conventional engine blocks and parent bores of engine blocks with dry sleeves checking: camshaft lobe lift straightness of shafts 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 upper and lower parts of cylinder block oil pump for serviceability idler gear hub to bearing clearance.

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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:

dismantle and evaluate the following three different engine blocks and their sub-assemblies:

in-line engine block

V configuration engine block

diesel engine block with 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 dismantling and evaluating engine blocks and sub-assemblies, including operational risk assessment and treatments associated with:

electrical equipment used in dismantling and evaluating engine blocks and sub-assemblies

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 process

manual handling techniques, including those relating to:

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 chosen tools, techniques and equipment

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

procedures for recording positions of components, including photographic evidence

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

reasons for checking end float before disassembly

cleaning solutions and cleaning procedures for components

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

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

precautions to be used when removing connecting rod cap

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

inspection, measurement and testing procedures, including:

characteristics of surface finishes and wear patterns as applied to:

cylinder bores, crankshafts, pistons, gears, cam followers, and camshafts

bearings and bushes

block facings

parting faces of connecting rod

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 parent bores of engine blocks with dry sleeves

camshaft lobe lift

straightness of shafts

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

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.

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