AURTTM004 - Assemble engine blocks and sub-assemblies Competency Mapping Template

Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

AURTTM004 Mapping and Delivery Guide
Assemble engine blocks and sub-assemblies

Version 1.0
Issue Date: May 2024

Qualification	-	Unit of Competency	AURTTM004 - Assemble engine blocks and sub-assemblies
Description
Employability Skills
Learning Outcomes and Application	This unit describes the performance outcomes required to assemble a short engine block and sub-assemblies, and check clearances and tolerances in an engine reconditioning process. It involves preparing for the task, selecting the correct assembly procedure, carrying out the assembly and performing post-assembly testing, and completing workplace processes and documentation.It applies to those working in the automotive service and repair industry. The engine blocks and sub-assemblies include those in vehicles from all sectors of the industry. This unit does not cover fitting semi-finished sleeves, or boring and honing cylinders.No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.
Duration and Setting	X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting. Assessors must satisfy NVR/AQTF assessor requirements. Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting. Assessment must include direct observation of tasks. Where assessment of competency includes third-party evidence, individuals must provide evidence that links them to the engine block and sub-assemblies that they have assembled, e.g. repair orders. Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application. The following resources must be made available: automotive repair workplace or simulated workplace workplace instructions engine specifications AS 4182 Automotive repairs â€“ Code of practice for reconditioning reciprocating spark ignition engines AS 4427 Automotive repairs â€“ Code of practice for reconditioning reciprocating compression ignition engines two different multi-cylinder engine blocks, including: in-line engine blocks V configuration engine blocks full gasket and seal set for the engine block fixed and portable hand, air and power tools, lifting equipment, torque wrench and material suitable for assembling engine block precision measuring equipment, including: dial bore gauges dial indicators inside and outside metric and imperial micrometers.
Prerequisites/co-requisites
Competency Field	Mechanical Miscellaneous

Development and validation strategy and guide for assessors and learners		Student Learning Resources	Handouts Activities	Slides PPT	Assessment 1	Assessment 2	Assessment 3	Assessment 4
Elements of Competency	Performance Criteria
Element: Prepare to assemble engine block and sub-assembly	Job requirements are determined from workplace instructions Information is sourced, procedures and methods are analysed, and appropriate tools are selected for assembling engine block and sub-assemblies Tools and measuring equipment are prepared and checked for serviceability Hazards associated with the work are identified and risks are managed Pre-assembly cleaning of engine components is carried out according to safety and environmental requirements, and components are laid out in logical order Replacement component parts are checked for size and suitability according to manufacturer specifications and job requirements
Element: Check engine block and sub-assembly clearances and tolerances	Clearances and tolerances are measured to the tolerance required by manufacturer specifications Clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications
Element: Assemble engine block and engine sub-assembly	Engine sub-assemblies are assembled in correct order and without damage, against manufacturer specifications and tolerances and according to workplace procedures and relevant Australian standards and safety requirements Engine blocks are assembledin correct order against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards, and safety requirements, and without causing damage to components or systems Assembled components are measured according to manufacturer specifications and workplace procedures Assembled component clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications
Element: Complete assembly process	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-assemblies 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
Element: Prepare to assemble engine block and sub-assembly	Job requirements are determined from workplace instructions Information is sourced, procedures and methods are analysed, and appropriate tools are selected for assembling engine block and sub-assemblies Tools and measuring equipment are prepared and checked for serviceability Hazards associated with the work are identified and risks are managed Pre-assembly cleaning of engine components is carried out according to safety and environmental requirements, and components are laid out in logical order Replacement component parts are checked for size and suitability according to manufacturer specifications and job requirements
Element: Check engine block and sub-assembly clearances and tolerances	Clearances and tolerances are measured to the tolerance required by manufacturer specifications Clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications
Element: Assemble engine block and engine sub-assembly	Engine sub-assemblies are assembled in correct order and without damage, against manufacturer specifications and tolerances and according to workplace procedures and relevant Australian standards and safety requirements Engine blocks are assembledin correct order against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards, and safety requirements, and without causing damage to components or systems Assembled components are measured according to manufacturer specifications and workplace procedures Assembled component clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications
Element: Complete assembly process	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-assemblies 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

Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

Elements

Elements describe the essential outcomes.

Performance Criteria

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold and italicised text is used, further information is detailed in the range of conditions section.

1. Prepare to assemble engine block and sub-assembly

1.1 Job requirements are determined from workplace instructions

1.2 Information is sourced, procedures and methods are analysed, and appropriate tools are selected for assembling engine block and sub-assemblies

1.3 Tools and measuring equipment are prepared and checked for serviceability

1.4 Hazards associated with the work are identified and risks are managed

1.5 Pre-assembly cleaning of engine components is carried out according to safety and environmental requirements, and components are laid out in logical order

1.6 Replacement component parts are checked for size and suitability according to manufacturer specifications and job requirements

2. Check engine block and sub-assembly clearances and tolerances

2.1 Clearances and tolerances are measured to the tolerance required by manufacturer specifications

2.2 Clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications

3. Assemble engine block and engine sub-assembly

3.1 Engine sub-assemblies are assembled in correct order and without damage, against manufacturer specifications and tolerances and according to workplace procedures and relevant Australian standards and safety requirements

3.2 Engine blocks are assembledin correct order against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards, and safety requirements, and without causing damage to components or systems

3.3 Assembled components are measured according to manufacturer specifications and workplace procedures

3.4 Assembled component clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications

4. Complete assembly process

4.1 Final inspection is made to ensure finished work complies with workplace requirements

4.2 Bright surfaces are treated with rust prevention solution and engine block and sub-assemblies are prepared for further process or storage according to workplace procedures

4.3 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

4.4 Workplace documentation is processed according to workplace procedures

Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unitâ€™s elements, performance criteria, range of conditions and foundation skills:

assemble two different engine blocks, one of which must be a V configuration engine block, and the sub-assemblies of those engine blocks, in which the work must involve:

a multi-cylinder diesel engine

a multi-cylinder petrol engine.

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to assembling engine blocks and sub-assemblies, including procedures for:

selecting and using personal protective equipment (PPE) for handling engine blocks and sub-assemblies and using chemical cleaning agents

correctly operating specialised equipment, including heating torches, ovens and presses

handling freezing substances, including liquid nitrogen

manual handling techniques, including:

using machinery for lifting engine blocks and engine components

using slings, chains and other lifting equipment according to safe work practices

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

procedures for clearance testing and adjusting or machining components, including:

piston to connecting rod big end alignment

big end and main bearing crush with bearing blue

piston ring end gap, back clearance and side clearance

bearing to crankshaft clearances with plastigage and measuring and calculating clearances

semi-flanged thrust bearings

finished camshaft bearings and measuring clearances

camshafts and cam followers

camshaft end float

crankshaft end float

gear backlash

oil pump sealing and pick-up oil piping

component assembly procedures and processes, including:

pre-assembly wash procedures for components

welsh plugs and oil gallery plugs

piston and connecting rod assemblies

big end bearings

piston rings to pistons, including procedures for using ring compressors

main bearings and thrust washers

semi-flanged thrust bearings

crankshafts, including protection measures for crankshaft journals, bearings, rings and bores

finished camshaft bearings

camshafts and cam followers

timing gears

chains and tensioners

oil pumps, oil squirters and oil pump pick-ups

balance shafts

fitting ancillary components, including:

covers and seals

housings

diesel fuel injection pumps

oil coolers

crankshaft pulleys

flywheels

bell housings

requirements of Australian standards relevant to engine reconditioning, including:

AS 4182 Automotive repairs â€“ Code of practice for reconditioning reciprocating spark ignition engines

AS 4427 Automotive repairs â€“ Code of practice for reconditioning reciprocating compression ignition engines.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title] Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.