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

AURTTM011 Mapping and Delivery Guide
Recondition engine cylinder heads

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency AURTTM011 - Recondition engine cylinder heads
Description
Employability Skills
Learning Outcomes and Application This unit describes the performance outcomes required to recondition engine cylinder heads as part of an engine reconditioning process. It involves preparing for the task, determining engine cylinder head damage and required repair action, preparing reconditioning machines, performing machining to specifications and workplace requirements, reassembling and testing the cylinder head, and completing workplace processes and documentation.It applies to those working in the automotive service and repair industry. The engine cylinder heads include overhead valve or overhead camshaft design cylinder heads 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 cylinder heads that they have reconditioned, 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

precision measuring equipment relevant to the engine component and work process

three different multi-cylinder engine cylinder heads as specified in the performance evidence

fixed and portable hand, air and power tools, lifting equipment and material suitable for reconditioning cylinder heads.
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 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       
Element: 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
       


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 undertake engine cylinder head reconditioning

1.1 Job requirements are determined from workplace instructions

1.2 Cylinder head dismantling procedures are 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 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

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

2.2 Cylinder head is 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 Cylinder head is hardness tested as required according to manufacturer specifications, workplace procedures and safety requirements

3.2 Cylinder head is pressure and/or crack tested according to manufacturer specifications, workplace procedures, and safety and environmental requirements

3.3 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

4.1 Components are adjusted and/or machined against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards, and safety and environmental requirements

4.2 Adjustments and/or machining of components are achieved without causing damage to components or system

4.3 Cylinder head is thoroughly cleaned and oil and waterways are cleared using appropriate tools

5. Assemble engine cylinder head

5.1 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

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

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

5.4 Assembled engine cylinder head is tested and adjusted against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards and safety requirements

5.5 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

6.1 Final inspection is made to ensure finished work complies with workplace requirements and engine cylinder heads are presented ready for use or storage

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

6.3 Tools and equipment are checked and stored according to workplace procedures

6.4 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:

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.

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.

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 undertake engine cylinder head reconditioning

1.1 Job requirements are determined from workplace instructions

1.2 Cylinder head dismantling procedures are 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 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

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

2.2 Cylinder head is 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 Cylinder head is hardness tested as required according to manufacturer specifications, workplace procedures and safety requirements

3.2 Cylinder head is pressure and/or crack tested according to manufacturer specifications, workplace procedures, and safety and environmental requirements

3.3 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

4.1 Components are adjusted and/or machined against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards, and safety and environmental requirements

4.2 Adjustments and/or machining of components are achieved without causing damage to components or system

4.3 Cylinder head is thoroughly cleaned and oil and waterways are cleared using appropriate tools

5. Assemble engine cylinder head

5.1 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

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

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

5.4 Assembled engine cylinder head is tested and adjusted against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards and safety requirements

5.5 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

6.1 Final inspection is made to ensure finished work complies with workplace requirements and engine cylinder heads are presented ready for use or storage

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

6.3 Tools and equipment are checked and stored according to workplace procedures

6.4 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 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.

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 
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 
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 
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 
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 
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 
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 
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 
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 
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 
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 
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 
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 

Forms

Assessment Cover Sheet

AURTTM011 - Recondition engine cylinder heads
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

AURTTM011 - Recondition engine cylinder heads

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: