Work applies to diesel fuelled vehicles and equipment in light and heavy vehicle, mining, construction, agricultural, motorcycle, outdoor power equipment and marine environments.

Engine management systems are systems where the electronic control unit (ECU) incorporates control over fuel injection, ignition timing control and all other systems relating to engine performance and emissions.

Work requires individuals to demonstrate some judgement and problem-solving skills in managing own work activities and contributing to a productive team environment.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare to diagnose and repair electronic compression ignition engine management systems

1.1. Workplace instructions are used to determine job requirements

1.2. Workplace health and safety (WHS) requirements are observed throughout the work

1.3. Procedures and information are sourced and interpreted

1.4. Options for diagnosing faults are identified and used, using appropriate tools and diagnostic techniques

1.5. Tools and equipment are identified for effective repair methods

2. Diagnose electronic compression ignition engine management systems

2.1. Electronic compression ignition engine management systems are tested to isolate faults according to workplace procedures and without causing damage to components or systems as a result of inappropriate testing procedures

2.2. Faults are identified from test results and causes of faults are determined

2.3. Diagnosis findings are reported according to workplace procedures, including recommendations for necessary repairs or adjustments

3. Repair electronic compression ignition engine management systems

3.1. Repair options are analysed and those most appropriate to the circumstances are selected

3.2. Appropriate tools, techniques and materials are selected and prepared

3.3. Repairs and component replacements and adjustments are carried out without causing damage, according to workplace procedures and manufacturer and component supplier specifications

3.4. Post-repair testing is carried out according to workplace procedures and relevant legislation

4. Prepare vehicle and equipment for delivery to customer after repair is completed

4.1. Final inspection is made to ensure work is to workplace expectations

4.2. Vehicle is cleaned to workplace expectations and presented ready for use

4.3. Workplace documentation is processed according to workplace procedures

5. Clean up work area and finalise work processes

5.1. Material that can be reused is collected and stored according to workplace sustainability practices

5.2. Waste and scrap are removed according to workplace practices

5.3. Tools, equipment and work area are cleaned and inspected according to workplace procedures

5.4. Tools and equipment are maintained according to workplace procedures

5.5. Faulty equipment is identified, tagged and isolated according to workplace procedures

Required skills

communication skills to:

follow verbal and written instructions

clarify workplace instructions and determine job requirements

gain information from appropriate persons and assistance as required

initiative and enterprise skills to:

apply learning when diagnosing and repairing various electronic compression ignition engine management systems

recognise a workplace problem or potential problem and take action

learning skills to identify sources of information, assistance and expert knowledge to expand skills, knowledge and understanding

literacy skills to:

read and follow information in written 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:

test, measure and analyse test equipment results compared to desired system performance

assess tolerances and apply accurate measurements and adjustments

planning and organising skills to:

plan own work requirements and prioritise actions to achieve required outcomes and ensure tasks are completed on time

identify risk factors and take action to minimise them

problem-solving skills to:

determine the underlying causes of faults

refer problems outside area of responsibility to appropriate person and suggest possible causes

seek information and assistance as required to solve problems

self-management skills to:

select and use appropriate equipment, materials, processes and procedures

recognise limitations and seek timely advice

follow workplace documentation, such as codes of practice and operating procedures

teamwork skills to apply knowledge of own role to complete activities efficiently to support team activities and tasks

technical skills to use hand, power, measuring and specialised tools relating to the repair of electronic compression ignition engine management systems

technology skills to:

operate diagnostic and test equipment

use technology to collect, analyse and provide information

Required knowledge

WHS regulations, requirements, equipment, material and personal safety requirements relating to diagnosing and repairing electronic compression ignition engine management systems, including:

individual state and territory legislation

codes of practice

personal protection needs

dangers of working with high-pressure diesel fuel systems

principal types of vehicle electronic compression ignition engine management systems, including:

direct injection, including:

electronic unit injectors (EUI)

hydraulic electronic unit injectors (HEUI)

indirect injection

common rail systems, including:

common rail solenoid

piezo design

amplified systems

application, purpose and operation of electronic compression ignition engine management systems, including:

common rail fuel control system

fuel injectors, types and designs

glow plugs

exhaust gas recirculation (EGR) and positive crankcase ventilation (PCV) system

diesel particulate diffuser (DPD) exhaust after-treatment system

turbo and super charger and intercooler systems

fuel filter, coolers and water trap

techniques for reading and interpreting technical information, graphic symbols and diagrams

diagnostic and testing procedures, including:

diagnostic procedures for electronic compression ignition engine management systems, including:

accessing and interpreting diagnostic trouble codes

diagnostic flow charts

analysis of system operation using electrical test equipment, scan tools, oscilloscopes and other industry-relevant test equipment

visual, aural and functional assessments, including:

component damage and wear

component corrosion

repair procedures, including:

component removal and replacement procedures

component and associated system adjustment and recalibration procedures

The evidence guide provides advice on assessment and must be read in conjunction with the Performance Criteria, required Skills and Knowledge, the 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

demonstrate safe work procedures relating to working with high fuel pressure and high injector voltages on diesel engines

select methods and techniques appropriate to the circumstances

complete preparatory activity in a systematic manner

diagnose and repair a range of electronic compression ignition engine management systems

conduct diagnosis and repair procedures according to workplace, manufacturer and component supplier requirements

present vehicle and equipment in a condition that complies with workplace requirements.

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.

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:

workplace location or simulated workplace

vehicles with electronic compression ignition engine management faults relevant to the qualification being sought

equipment appropriate for the testing of vehicle electronic compression ignition engine management systems

specifications and workplace instructions

tools appropriate for repairing, replacing and adjusting vehicle electronic compression ignition engine management systems.

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 the 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 correct interpretation and application.

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 the needs of diverse clients.

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

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:

electronic or hard copy instructions

verbal instructions

written instructions.

Job requirements may include:

diagnosis and repair methods, processes and equipment.

Workplace health and safety requirements may include:

personal protective clothing and equipment

hazards associated with high pressure fuel systems

hazards associated with high injector voltage circuits

safe use of tools and equipment

safe handling of material

use of fire-fighting equipment

workplace safety policies and procedures

workplace first aid equipment

hazard control, including control of hazardous materials and toxic substances.

Procedures and information may include:

verbal, written and graphical instructions

signage

work schedules, plans and specifications

work bulletins and memos

material safety data sheets

diagrams and sketches

safe work procedures relating to the repair and replacement of electronic compression ignition engine management systems

regulatory and legislative requirements relating to automotive industry

Australian Design Rules

engineer's design specifications and instructions

workplace work specifications and requirements

instructions issued by authorised workplace or external persons

Australian standards

vehicle service requirements and repair manuals.

Options for diagnosing faultsmay include:

isolation of faults

component inspection and evaluation.

Tools and equipment may include:

hand tools

testing equipment, including multimeters, ohmmeters, voltmeters and tachometers

insulation testers

power tools and air tools

fuel pressure and fuel flow gauges

engine analysers

dynamometers

oscilloscopes

diagnostic scan tools.

Electronic compression ignition engine management systems may include:

direct injection:

electronic unit injectors

hydraulic electronic unit injectors

indirect injection

common rail systems, including:

solenoid

piezo electric

amplified systems.

Inappropriate testing procedures may include:

intrusive testing (which must not be performed as it is not a recommended test and repair method), which includes:

back probing terminals and connectors and fuse holders with inappropriate test probes

probing terminal and connectors with inappropriate test probes

pushing sharp probes and objects into wiring insulation.

Faults may include:

engine difficult to start or will not start

engine misfiring

poor engine performance

engine knock

overheating

black or white smoke from exhaust

PCV defective

diesel fuel contamination

blocked or restricted fuel injectors

DPD exhaust after treatment system defective or not serviced

diagnosis trouble codes (DTC) being set.

Repair options may include:

pre- and post-repair testing

identifying and testing components

diagnosing and determining faults

component repair procedures, including:

removal, replacement and adjustment procedures

dismantle, repair, re-assembly and adjustment procedures

electrical measurements

fuel pressure testing involving visual and functional assessments, including for damage and wear.

Post-repair testing may include:

validating effectiveness of the repair action

confirming that reported fault has been rectified

confirming that no other faults are present as a result of the repair action.

Electrical

Unit sector

Technical – Electrical and Electronic

This unit contains employability skills.