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

AURTTM008 Mapping and Delivery Guide
Dismantle and evaluate engine blocks and sub-assemblies

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency AURTTM008 - Dismantle and evaluate engine blocks and sub-assemblies
Description
Employability Skills
Learning Outcomes and Application This unit describes the performance outcomes required to dismantle and evaluate an engine block and its sub-assemblies as part of an engine repair or reconditioning process. It involves preparing for the task, dismantling and evaluating the engine blocks and sub-assemblies, determining required repair action, 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.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 blocks and sub-assemblies that they have dismantled and evaluated, 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

manufacturer engine specifications

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

three different multi-cylinder engine blocks specified in the performance evidence

precision measuring equipment, including:

dial bore gauges

dial indicators

inside and outside metric and imperial micrometers

fixed and portable hand, air and power tools and lifting equipment suitable for dismantling and evaluating engine blocks and sub-assemblies.
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 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       


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 dismantle engine block and sub-assembly

1.1 Job requirements are determined from workplace instructions

1.2 Engine block and sub assembly dismantling information is sourced and interpreted

1.3 Tools and measuring equipment are selected and checked for serviceability

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

1.5 Engine is set up for dismantling using appropriate lifting equipment and avoiding fluid spillage according to safety and environmental requirements

1.6 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

2.1 Covers and ancillary components are removed, cleaned and stored according to workshop procedures

2.2 Engine block and sub-assembly are dismantled according to safety requirements and laid out in a logical order using approved methods, tools and equipment

2.3 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

3.1 Engine block and sub-assembly are inspected, measured and tested against manufacturer specifications and tolerances and according to workplace procedures and safety requirements

3.2 Engine block and sub-assembly are evaluated and repair requirements are determined and reported according to workplace procedures

4. Complete dismantle and evaluation processes

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-assembly 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 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.

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.

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.

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 dismantle engine block and sub-assembly

1.1 Job requirements are determined from workplace instructions

1.2 Engine block and sub assembly dismantling information is sourced and interpreted

1.3 Tools and measuring equipment are selected and checked for serviceability

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

1.5 Engine is set up for dismantling using appropriate lifting equipment and avoiding fluid spillage according to safety and environmental requirements

1.6 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

2.1 Covers and ancillary components are removed, cleaned and stored according to workshop procedures

2.2 Engine block and sub-assembly are dismantled according to safety requirements and laid out in a logical order using approved methods, tools and equipment

2.3 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

3.1 Engine block and sub-assembly are inspected, measured and tested against manufacturer specifications and tolerances and according to workplace procedures and safety requirements

3.2 Engine block and sub-assembly are evaluated and repair requirements are determined and reported according to workplace procedures

4. Complete dismantle and evaluation processes

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-assembly 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

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.

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
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 
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 
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 
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 
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 
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 
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 
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 

Forms

Assessment Cover Sheet

AURTTM008 - Dismantle and evaluate engine blocks and sub-assemblies
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

AURTTM008 - Dismantle and evaluate engine blocks and sub-assemblies

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: