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Elements and Performance Criteria

1. Prepare to undertake engine cylinder head reconditioning
   • Job requirements are determined from workplace instructions
   • Cylinder head dismantling procedures are sourced and interpreted
   • Tools and measuring equipment are selected and checked for serviceability
   • Hazards associated with the work are identified and risks are managed
   • Cylinder head is cleaned according to safety and environmental requirements and relevant Australian standards, and positions of auxiliary equipment arerecorded, including photographic evidence
2. Dismantle engine cylinder head
   • Covers and ancillary components are removed, cleaned and stored according to workshop procedures
   • Cylinder head is 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
   • Cylinder head is hardness tested as required according to manufacturer specifications, workplace procedures and safety requirements
   • Cylinder head is pressure and/or crack tested according to manufacturer specifications, workplace procedures, and safety and environmental requirements
   • Cylinder head and component parts are inspected, measured and tested against manufacturer specifications and tolerances and according to workplace procedures and safety and environmental requirements
4. Recondition engine cylinder head and component parts
   • Components are adjusted and/or machined against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards, and safety and environmental requirements
   • Adjustments and/or machining of components are achieved without causing damage to components or system
   • Cylinder head is thoroughly cleaned and oil and waterways are cleared using appropriate tools
5. Assemble engine cylinder head
   • Cylinder head is assembled in correct order and without damage, against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards and safety requirements
   • Assembled components are measured according to manufacturer specifications and workplace procedures
   • Assembled component clearances and tolerances are adjusted to the tolerance required by manufacturer specifications according to workplace procedures
   • Assembled engine cylinder head is tested and adjusted against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards and safety requirements
   • Bright surfaces are treated with rust prevention solution and cylinder head is prepared for further process or storage according to workplace procedures
6. Complete work processes
   • Final inspection is made to ensure finished work complies with workplace requirements and engine cylinder heads are presented ready for use or storage
   • 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
7. Prepare to undertake engine cylinder head reconditioning
   • Job requirements are determined from workplace instructions
   • Cylinder head dismantling procedures are sourced and interpreted
   • Tools and measuring equipment are selected and checked for serviceability
   • Hazards associated with the work are identified and risks are managed
   • Cylinder head is cleaned according to safety and environmental requirements and relevant Australian standards, and positions of auxiliary equipment arerecorded, including photographic evidence
8. Dismantle engine cylinder head
   • Covers and ancillary components are removed, cleaned and stored according to workshop procedures
   • Cylinder head is 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
9. Determine repair procedures
   • Cylinder head is hardness tested as required according to manufacturer specifications, workplace procedures and safety requirements
   • Cylinder head is pressure and/or crack tested according to manufacturer specifications, workplace procedures, and safety and environmental requirements
   • Cylinder head and component parts are inspected, measured and tested against manufacturer specifications and tolerances and according to workplace procedures and safety and environmental requirements
10. Recondition engine cylinder head and component parts
    • Components are adjusted and/or machined against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards, and safety and environmental requirements
    • Adjustments and/or machining of components are achieved without causing damage to components or system
    • Cylinder head is thoroughly cleaned and oil and waterways are cleared using appropriate tools
11. Assemble engine cylinder head
    • Cylinder head is assembled in correct order and without damage, against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards and safety requirements
    • Assembled components are measured according to manufacturer specifications and workplace procedures
    • Assembled component clearances and tolerances are adjusted to the tolerance required by manufacturer specifications according to workplace procedures
    • Assembled engine cylinder head is tested and adjusted against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards and safety requirements
    • Bright surfaces are treated with rust prevention solution and cylinder head is prepared for further process or storage according to workplace procedures
12. Complete work processes
    • Final inspection is made to ensure finished work complies with workplace requirements and engine cylinder heads are presented ready for use or storage
    • 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.

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 safety of power tools manual and mechanical lifting and shifting equipment toxic cleaning substances selecting and using personal protective equipment (PPE) for handling engine cylinder heads and using specialised equipment environmental requirements, including procedures for trapping, storing and disposing of cleaning fluids and machining waste released during reconditioning process.
Australian standardsmust 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.
Inspecting, measuring and testing must include:	checking for straightness of both sides of cylinder head and all manifold faces checking camshaft tunnels for wear and pick-up checking water jackets for corrosion checking valve suitability for refacing, including stem condition checking valve guide condition and material resurfacing valves sizing and fitting K lines machining and fitting valve seats establishing valve stem protrusion.

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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:

recondition two of the following engine cylinder heads:

overhead valve (OHV) petrol cylinder head

overhead camshaft (OHC) petrol cylinder head

diesel cylinder head

resurface a cylinder head.

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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 reconditioning engine cylinder heads, including:

operational risk assessment and treatments associated with:

electrical safety of power tools

manual and mechanical lifting and shifting equipment

toxic cleaning substances

selecting and using personal protective equipment (PPE) for handling engine cylinder heads and using specialised equipment

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

procedures for removing cylinder head from engine block

dismantling methods and procedures relating to cylinder heads

cleaning methods and procedures relating to cylinder heads

procedures for measuring, testing and evaluating cylinder heads, including:

hardness of aluminium alloy cylinder heads and re-hardening aluminium alloy cylinder heads

visual inspections

cylinder head testing, including:

dye penetrant for alloy cylinder heads

wet and dry magnetic particle for cast iron cylinder heads

vacuum for valve leakage

pressure for porosity

inspecting valve guides and valve seats

procedures for measuring, testing and evaluating associated parts, including inspecting camshafts, valves, valve springs, valve spring seats, valve spring retainers, collets and lash caps, rocker arms, rocker shafts and pushrods

procedures for repairing cylinder heads and associated components, including:

heat treating aluminium alloy cylinder heads

straightening cylinder heads

repairing cracks in cylinder heads

welding aluminium alloy and cast iron cylinder heads

types of surface finishes for different cylinder head gaskets

surfacing cylinder heads, including manifold faces

repairing valve guides, valve seats, rocker arms and rocker shafts

replacing valve guides

cutting valve seats to required angles

re-facing valves in valve re-facer

setting valve stem protrusion

setting valve masking heights in diesel cylinder heads

fitting injector tubes and setting injector protrusion

cleaning cylinder heads of residue and swarf, including removing residue from bead cleaning

procedures for assembling cylinder heads, including:

refitting welsh plugs and oil gallery plugs, valves, springs, spring seats, retainers, collets lash caps, camshafts, rocker gear, cam followers and associated components

reasons for setting valve timing before fitting cylinder head to block

evaluating and setting rocker arm geometry

preparing cylinder block to accept cylinder head

fitting head gaskets and cylinder heads to engine blocks

tightening procedures for cylinder head bolts

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 test procedures, including machined surface protection.

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