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

AURTTM3011 Mapping and Delivery Guide
Recondition engine cylinder heads

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency AURTTM3011 - Recondition engine cylinder heads
Description This unit describes the performance outcomes required to recondition engine cylinder heads according to workplace requirements. It involves determining engine cylinder head damage and required repair action, and preparing and using reconditioning machines.No licensing, legislative, regulatory or certification requirements apply to this unit at time of endorsement.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application Work applies to reconditioning cylinder heads in an engine reconditioning setting. Engine cylinder heads to be reconditioned are to include overhead valve and overhead camshaft and may include those of light vehicles, heavy vehicles, agricultural and plant equipment, recreational vehicles and motorcycles.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites not applicable.
Competency Field
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 cylinder head reconditioning
  • Workplace instructions are used to determine job requirements, including method, process and equipment
  • Information is accessed, procedures and methods are analysed, and appropriate tooling options are selected for reconditioning engine cylinder heads
  • Tools and measuring equipment are checked and prepared for operation
  • Safe operating procedures and workplace health and safety (WHS) and environmental requirements are observed throughout the work
  • Cylinder head is cleaned
       
Element: Dismantle cylinder head
  • Cylinder head component specifications are accessed and interpreted from manufacturer and component supplier information to determine correct dismantling procedure
  • Cylinder head is dismantled and laid out in a logical order using approved methods, tools and equipment without causing damage to components or systems
  • Component parts are cleaned using cleaning agents appropriate to the type of material and kept in a logical order in preparation for evaluation
       
Element: Use methods to check/test cylinder head
  • Cylinder head is pressure and/or crack tested
  • Cylinder head and components are inspected, measured and tested against manufacturer and component supplier specifications
  • Inspection, measurement and testing are completed without causing damage to component or system
       
Element: Recondition component parts
  • Components are adjusted and/or machined to meet manufacturer and component supplier specifications
  • Adjustments and/or machining of components are achieved without causing damage to components or system
  • Work is carried out according to established industry guidelines
       
Element: Assemble cylinder head
  • Cylinder head is assembled without causing damage to components or system
  • Assembly is carried out to comply with manufacturer and component supplier specifications, established industry guidelines and Australian standards
  • Assembly activities are carried out according to industry regulations and guidelines, OHS legislation, and workplace procedures and policies
       
Element: Carry out testing and adjustment procedures
  • Testing and adjustment are carried out to comply with manufacturer and component supplier specifications, established industry guidelines and Australian standards
  • Tests and adjustments are completed without causing damage to components or system
  • Tests and adjustments are performed using industry-approved procedures and equipment
       
Element: Finalise cylinder head reconditioning
  • Work performed is documented
  • Final inspection is made to ensure surfaces are protected
  • Engine cylinder head is prepared for storage according to workplace requirements
  • 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.

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 reconditioning methods and techniques appropriate to the circumstances

complete preparatory activity in a systematic manner

conduct reconditioning of a range of cylinder heads according to workplace, manufacturer and component supplier requirements

complete reconditioning of cylinder heads within workplace timeframes

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

Context of, and specific resources for assessment

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

cylinder heads appropriate to the workplace, including multi-valve, OHV and OHC cylinder heads

fixed and portable hand, air and power tools and equipment appropriate to reconditioning cylinder heads

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.

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.

Required skills

technical skills to:

select correct replacement tip or sharpening tool for material to be machined

identify worn and damaged cutting tools, pilots and arbors

mount and position cutting tools

set machining parameters to achieve job requirements and maximise tool life

use appropriate and sufficient clamping or mounting of the work piece

check that valve seats conform to specifications and workplace requirements

set and measure adjustments to specified tolerances and dimensions

communication skills to:

follow oral instructions

report deviations from specifications

interact with customers and team members

literacy skills to:

read and interpret routine job instructions, specifications, drawings and standard operating procedures

identify and analyse technical information

understand quality procedures

numeracy skills to use mathematical ideas and techniques to:

calculate time

assess tolerances

apply accurate measurements

calculate material requirements

establish quality checks

problem-solving skills to:

locate, interpret and apply workplace policies and procedures, including manufacturer and component supplier procedures

identify and avoid planning and scheduling problems

prevent time and material wastage

organise work and plan processes

self-management 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 cylinder heads and using specialised equipment, such as:

facing machines

valve refacers

valve spring compressors

ovens and presses

procedures for removing cylinder head from engine block

dismantling methods and procedures

cleaning methods and procedures

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

testing hardness of aluminium alloy cylinder heads and procedures for re-hardening aluminium alloy cylinder heads

visual inspections

cylinder head crack testing, including:

dye-penetrant testing

wet and dry magnetic particle testing

vacuum testing

pressure testing

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

refacing valves in valve refacer

fitting injector tubes and pre-combustion chambers

cleaning cylinder heads of residue and swarf

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 of cylinder head bolts

Australian standards relating to engine reconditioning

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Workplace instructions may include:

computer-generated instructions

verbal instructions

written instructions.

Information may include:

Australian standards

engineer’s design specifications and instructions

instructions issued by authorised workplace or external persons

workplace specifications and requirements

regulatory and legislative requirements relating to the automotive industry, including Australian Design Rules

safe work procedures relating to the operation of machinery associated with reconditioning cylinder heads

verbal, written and graphical instructions, signage, work schedules, plans, specifications, work bulletins, memos, material safety data sheets (MSDS), diagrams or sketches.

Cylinder heads may include:

overhead cam (OHC)

overhead valve (OHV).

Tools and measuring equipment may include:

arbors

clamps

depth micrometer

dial bore gauge

dial indicator

inside and outside micrometer

inside calliper

shim grinder

snap gauge

surfacing machine

vacuum tester

valve refacing machine

valve spring tester.

WHS requirements may include:

operational risk assessment and treatments associated with:

electrical safety

machinery movement and operation

manual and mechanical lifting and shifting

toxic substances

working in proximity to others and site visitors

PPE required by legislation, regulations, codes of practice and workplace policies and procedures.

Environmental requirements are to include:

clean-up management

dust and noise minimisation

waste management.

Inspected, measured and tested may include:

visual checking

pressure checking procedures

crack testing procedures

tolerance checking procedures.

Adjustments/machining may include:

surface finishing

seat cutting and replacement

guide replacement

valve grinding

tensioning procedures.

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
Workplace instructions are used to determine job requirements, including method, process and equipment 
Information is accessed, procedures and methods are analysed, and appropriate tooling options are selected for reconditioning engine cylinder heads 
Tools and measuring equipment are checked and prepared for operation 
Safe operating procedures and workplace health and safety (WHS) and environmental requirements are observed throughout the work 
Cylinder head is cleaned 
Cylinder head component specifications are accessed and interpreted from manufacturer and component supplier information to determine correct dismantling procedure 
Cylinder head is dismantled and laid out in a logical order using approved methods, tools and equipment without causing damage to components or systems 
Component parts are cleaned using cleaning agents appropriate to the type of material and kept in a logical order in preparation for evaluation 
Cylinder head is pressure and/or crack tested 
Cylinder head and components are inspected, measured and tested against manufacturer and component supplier specifications 
Inspection, measurement and testing are completed without causing damage to component or system 
Components are adjusted and/or machined to meet manufacturer and component supplier specifications 
Adjustments and/or machining of components are achieved without causing damage to components or system 
Work is carried out according to established industry guidelines 
Cylinder head is assembled without causing damage to components or system 
Assembly is carried out to comply with manufacturer and component supplier specifications, established industry guidelines and Australian standards 
Assembly activities are carried out according to industry regulations and guidelines, OHS legislation, and workplace procedures and policies 
Testing and adjustment are carried out to comply with manufacturer and component supplier specifications, established industry guidelines and Australian standards 
Tests and adjustments are completed without causing damage to components or system 
Tests and adjustments are performed using industry-approved procedures and equipment 
Work performed is documented 
Final inspection is made to ensure surfaces are protected 
Engine cylinder head is prepared for storage according to workplace requirements 
Workplace documentation is processed according to workplace procedures 

Forms

Assessment Cover Sheet

AURTTM3011 - 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

AURTTM3011 - 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: