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Elements and Performance Criteria

1. Prepare to bore engine cylinder
   • Job requirements are determined from workplace instructions
   • Engine block, boring and sleeving information is sourced and interpreted
   • Tools and measuring equipment for boring are selected and checked for serviceability
   • Hazards associated with the work are identified and risks are managed
   • Engine cylinder is measured and calibration requirements for boring are determined
   • Engine cylinder block is prepared for boring, and reboring machine is prepared to accept engine cylinder block according to manufacturer specifications and workplace procedures
   • Engine cylinder block is correctly positioned and clamped, and limit stop is set according to manufacturer specifications and workplace procedures
2. Bore engine cylinder
   • Cutting tools are mounted and positioned, and worn and damaged cutting tools are identified and replaced or sharpened
   • Boring operations are carried out at correct speeds and feed rates according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures
   • Engine cylinder is measured to ensure compliance with specifications
   • Boring operations are completed to required specifications and honing allowances according to workplace procedures and safety requirements, and following machinery safe operating procedures
3. Prepare to sleeve engine cylinder
   • Tools and equipment for sleeving are selected, checked and prepared for operation according to manufacturer specifications and workplace procedures
   • Measuring and calibration requirements for sleeving are determined and required sleeve is selected
   • Engine cylinder block or barrel is prepared for sleeving according to manufacturer specifications and workplace procedures
4. Sleeve engine cylinder
   • Sleeving operations are carried out according to workplace procedures and safety requirements, and following machinery safe operating procedures
   • Sleeves are measured to ensure compliance with specifications, including sleeve protrusion
   • Sleeves are bored as required to required specifications and honing allowances according to workplace procedures and safety requirements, and following machinery safe operating procedures
5. Prepare to hone engine cylinder
   • Bored engine block is cleaned of residue and swarf according to manufacturer specifications and workplace procedures
   • Tools and equipment for honing are selected, checked and prepared for operation according to manufacturer specifications and workplace procedures
   • Clearances are measured and honing requirements are determined
   • Honing machine is prepared to accept engine cylinder block according to manufacturer specifications and workplace procedures
   • Engine cylinder block is positioned and securely clamped, and required hone stroke is set according to manufacturer specifications and workplace procedures
   • Hone stones are selected and speed is set to achieve required finish and cross hatch
6. Hone engine cylinder
   • Engine cylinder is honed at correct speed and rate to required finish according to workplace procedures and safety requirements and following machinery safe operating procedures
   • Engine cylinder is measured to ensure compliance with specifications
   • Honing operations are completed to required piston to bore clearance according to workplace procedures and safety requirements and following machinery safe operating procedures
   • Engine cylinder block is thoroughly cleaned of residual honing oil according to workplace procedures
7. Complete sleeving, boring and honing processes
   • Final inspection is made to ensure finished work complies with workplace requirements
   • Bright surfaces are treated with rust prevention solution and engine cylinder block 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
8. Prepare to bore engine cylinder
   • Job requirements are determined from workplace instructions
   • Engine block, boring and sleeving information is sourced and interpreted
   • Tools and measuring equipment for boring are selected and checked for serviceability
   • Hazards associated with the work are identified and risks are managed
   • Engine cylinder is measured and calibration requirements for boring are determined
   • Engine cylinder block is prepared for boring, and reboring machine is prepared to accept engine cylinder block according to manufacturer specifications and workplace procedures
   • Engine cylinder block is correctly positioned and clamped, and limit stop is set according to manufacturer specifications and workplace procedures
9. Bore engine cylinder
   • Cutting tools are mounted and positioned, and worn and damaged cutting tools are identified and replaced or sharpened
   • Boring operations are carried out at correct speeds and feed rates according to workplace procedures and safety and environmental requirements, and following machinery safe operating procedures
   • Engine cylinder is measured to ensure compliance with specifications
   • Boring operations are completed to required specifications and honing allowances according to workplace procedures and safety requirements, and following machinery safe operating procedures
10. Prepare to sleeve engine cylinder
    • Tools and equipment for sleeving are selected, checked and prepared for operation according to manufacturer specifications and workplace procedures
    • Measuring and calibration requirements for sleeving are determined and required sleeve is selected
    • Engine cylinder block or barrel is prepared for sleeving according to manufacturer specifications and workplace procedures
11. Sleeve engine cylinder
    • Sleeving operations are carried out according to workplace procedures and safety requirements, and following machinery safe operating procedures
    • Sleeves are measured to ensure compliance with specifications, including sleeve protrusion
    • Sleeves are bored as required to required specifications and honing allowances according to workplace procedures and safety requirements, and following machinery safe operating procedures
12. Prepare to hone engine cylinder
    • Bored engine block is cleaned of residue and swarf according to manufacturer specifications and workplace procedures
    • Tools and equipment for honing are selected, checked and prepared for operation according to manufacturer specifications and workplace procedures
    • Clearances are measured and honing requirements are determined
    • Honing machine is prepared to accept engine cylinder block according to manufacturer specifications and workplace procedures
    • Engine cylinder block is positioned and securely clamped, and required hone stroke is set according to manufacturer specifications and workplace procedures
    • Hone stones are selected and speed is set to achieve required finish and cross hatch
13. Hone engine cylinder
    • Engine cylinder is honed at correct speed and rate to required finish according to workplace procedures and safety requirements and following machinery safe operating procedures
    • Engine cylinder is measured to ensure compliance with specifications
    • Honing operations are completed to required piston to bore clearance according to workplace procedures and safety requirements and following machinery safe operating procedures
    • Engine cylinder block is thoroughly cleaned of residual honing oil according to workplace procedures
14. Complete sleeving, boring and honing processes
    • Final inspection is made to ensure finished work complies with workplace requirements
    • Bright surfaces are treated with rust prevention solution and engine cylinder block 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.

Calibration requirements must include:

determining: piston to bore clearance sizes of cut required honing allowance.

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 cylinder blocks using boring and honing machines using chemical cleaning and lubricating agents safe operating procedures for boring and honing machinery, including: electrical safety of boring and honing machinery boring and honing machinery movement and operation environmental requirements, including procedures for trapping, storing and disposing of cleaning 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:

work on three different engine blocks as follows:

bore one engine block to accept parallel liners with correct interference fit

bore one engine block to accept flanged liners with correct interference fit

bore and hone the cylinders of a different multi-cylinder engine block to achieve correct piston to bore clearance.

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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 fitting sleeves and boring and honing engine cylinders, including:

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

handling engine cylinder blocks

using boring and honing machines

using chemical cleaning and lubricating agents

safe operating procedures for boring and honing machinery, including:

electrical safety of boring and honing machinery

boring and honing machinery movement and operation

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

types and application of sleeves, including:

dry sleeves, including:

interference fit parallel sleeve

interference fit flanged sleeves

chrome type finished-to-size dry flanged sleeves

wet sleeves, including:

flanged

stepped

sleeve fitting procedures, including:

interference sleeves, including fitting parallel sleeves to step in parent bore

wet sleeves

checking sleeve height

types, characteristics and limitations of honing and boring machines, including:

types and grades of boring tools

types and grades of honing stones

hand-held and machine-operated hones

tool sharpening methods, including:

maintaining sharpness of tool throughout boring operations

compensation methods for tool wear throughout boring operations

boring methods and procedures, including:

determining required size of bore, including honing allowance

preparing engine cylinder block for boring, and setting engine cylinder block into boring machine, including jigs, rails and clamps

setting boring tool to correct diameter, locking boring tool, and setting limit stop

reasons for taking a test cut

speed and feed rates of boring tool for differing materials, including alloysil or nicolsil, and for bore diameters

methods for setting speed and feed rate of boring tools

honing methods and procedures, including:

cleaning engine cylinder block before and after honing

preparing portable and stationary honing machines, setting engine cylinder block into honing machine, and setting hone stroke

setting honing speeds and feed rates to achieve required finish

methods of measuring bores for taper, ovality and barrelling

types and application of cleaning, lubricating and protective agents, including:

material suitability

application of lubricating agents for different speeds and feed rates of boring machines and honing machines

hazards associated with chemical cleaning and lubricating agents

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 procedures, including rust protection.

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