Required skills

technical skills to

dismantle engine blocks without causing damage to components

clean parts using appropriate solutions and procedures

identify components for reuse or replacement

check for abnormal wear and defects

check for conformance to specifications

measure to specified tolerances and dimensions

identify repair procedures

communication skills to

follow oral instructions

work as part of a team

literacy skills to

understand quality procedures

read interpret and follow job instructions specifications standard operating procedures charts lists drawings and other applicable reference documents

obtain and record measurements

document required repairs and parts

numeracy skills to use mathematical ideas and techniques to

assess tolerances and clearances

apply accurate measurements

calculate component dimensions

problemsolving skills to

prevent time and material wastage

plan and sequence operations

selfmanagement skills to

select and use appropriate equipment materials processes and procedures

follow workplace documentation such as codes of practice and operating procedures

technology skills to use communication devices and computerised equipment to

search and gather supporting material

take locate download and view digital images

Required knowledge

WHS regulations and requirements equipment material and personal safety requirements including

personal protective equipment PPE for handling engine blocks and subassemblies and using chemical cleaning agents

correct operation of specialised equipment such as pullers

manualhandling techniques including

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 the chosen tools techniques and equipment

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

preevaluation checks to determine suitability of component to be reused

reasons for checking endfloats before disassembly

cleaning solutions and cleaning procedures of components

use of pullers presses and specialised tools and the application of heat to dismantle components such as gears pulleys and dowels

procedures for recording the facing directions of pistons connecting rods main and bigend caps and positions of removable counterweights and counterweight shafts assemblies

precautions to be aware of when removing the connecting rod cap in relation to snapbroken rods

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 balanceidler 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

measuring testing and evaluating procedures including

characteristics of surface finishes and wear patterns as applied to cylinder bores crankshafts pistons gears cam followers camshafts bearings and bushes block facings parting faces of connecting rod and 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 the parent bores of engine blocks with dry sleeves

camshaft lobe lift

main bearing tunnels for alignment

connecting rod alignment and littleend 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

Australian standards relating to engine reconditioning

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria required skills and knowledge range statement and the Assessment Guidelines for the Training Package

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

The evidence required to demonstrate competency in this unit must be relevant to workplace operations and satisfy all of the requirements of the performance criteria and required skills and knowledge

A person who demonstrates competency in this unit must be able to

observe safety procedures and requirements

select dismantling and evaluation methods and techniques appropriate to the circumstances

complete preparatory activity in a systematic manner

complete the dismantling and evaluation of a range of engine blocks and subassemblies

measure and check work against manufacturer and component supplier specifications

evaluate components according to workplace requirements and specifications

determine required repair procedures

complete the dismantling and evaluation of engine blocks and subassembly components within workplace timeframes

complete work without damage to tools and equipment or injury to persons

Context of and specific resources for assessment

Competency is to be assessed in the workplace or a simulated workplace environment that accurately reflects performance in a real workplace setting Performance is demonstrated consistently over a period of time and in a suitable range of contexts

Assessment is to occur

using standard workplace practices and procedures

following safety requirements

applying environmental constraints

Assessment is to comply with relevant

regulatory requirements

Australian standards

industry codes of practice

The following resources must be made available for the assessment of this unit

appropriate worksite

multicylinder engine blocks appropriate to the workplace including those with and without cylinder sleeves

equipment and hand air and power tools appropriate to dismantling and evaluating engine blocks and subassembly components

specifications and work instructions

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of this Training Package

Assessment methods must confirm consistency and accuracy of performance over time and in a range of workplace relevant contexts together with application of required skills and knowledge

Assessment methods must be by direct observation of tasks and include questioning on required skills and knowledge to ensure its correct interpretation and application

Assessment must confirm that competency is able not only to be satisfied under the particular circumstance but is able to be transferred to other circumstances

Competence in this unit may be assessed in conjunction with other units which together form part of a holistic work role

Where applicable reasonable adjustment must be made to work environments and training situations to accommodate ethnicity age gender demographics and disability

Assessment processes and techniques must be culturally sensitive and appropriate to the language and literacy capacity of the candidate and the work being performed

Workplace instructions may include:

Information may include:

Tools and measuring equipment may include:

WHS requirements may include:

Environmental requirements are to include:

Sub-assemblies include:

Positions of auxiliary equipment may include: