This unit of competence applies to engine reconditioning.

The unit includes identification and confirmation of work requirement, preparation for work, dismantling and checking of cylinder heads, reconditioning, reassembly and testing of cylinder heads and completion of work finalisation processes, including clean-up and documentation.

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

Work is carried out in accordance with award provisions.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare to undertake cylinder head reconditioning

1.1. Nature and scope of work requirements are identified and confirmed

1.2. OH&S requirements, including individual State/Territory regulatory requirements and personal protection needs are observed throughout the work

1.3. Procedures and information such as workshop manuals and specifications, tooling and equipment required, are sourced

1.4. Method options are analysed and those most appropriate to the circumstances are selected and prepared

1.5. Technical and/or calibration requirements for the work to be done are sourced and support equipment is identified and prepared

2. Dismantle cylinder head

2.1. Correct information is accessed and interpreted from manufacturer/component supplier specifications

2.2. Cylinder head is dismantled without causing damage to any component or system

2.3. Cylinder head is dismantled using approved methods and tooling/equipment

2.4. Component parts are cleaned in preparation for evaluation

2.5. Dismantling/cleaning activities are carried out according to industry regulations/guidelines, OH&S legislation, legislation and enterprise procedures/policies

3. Use methods to check/test cylinder head

3.1. Specifications are sourced using manufacturer/component supplier specifications

3.2. Cylinder head is pressure and/or crack tested

3.3. Cylinder head and components are checked against manufacturer/component supplier specifications without causing damage to any component or system

3.4. Components are evaluated and measured according to manufacturer/component supplier specifications

3.5. Checking activities are carried out according to industry regulations/guidelines, OH&S legislation, legislation and enterprise procedures/policies

4. Recondition component parts

4.1. Component parts are reconditioned

4.2. Work is carried out to established industry guidelines

4.3. Reconditioning activities are carried out according to industry regulations/guidelines, OH&S legislation, legislation and enterprise procedures/policies

5. Assemble cylinder head

5.1. Cylinder head is assembled without causing damage to any component or system

5.2. Assembly is carried out to comply with manufacturer/ component supplier specifications and established industry guidelines and Australian Standards

5.3. Assembly activities are carried out according to industry regulations/guidelines, OH&S legislation, legislation and enterprise procedures/policies

6. Carry out testing and adjustment procedures

6.1. Testing and adjustment is carried out to comply with manufacturer/component supplier specifications established industry guidelines and Australian Standards

6.2. Tests and adjustments are completed without causing damage to any component or system

6.3. Tests and adjustments are performed using industry approved procedures and equipment

7. Prepare cylinder head for use or storage

7.1. Work performed is documented

7.2. Final inspection is made to ensure surfaces are protected

7.3. Cylinder head is cleaned for use or storage to workplace expectations

7.4. Job card is processed in accordance with workplace procedures

Required skills

apply research and interpretive skills sufficient to locate, interpret and apply manufacturer/component supplier procedures, workplace policies and procedures

apply analytical skills required for identification and analysis of technical information

apply plain English literacy and communication skills in relation to dealing with customers and team members

apply questioning and active listening skills for example when obtaining information from customers

apply oral communication skills sufficient to convey information and concepts to customers

apply planning and organising skills to own work activities, including making good use of time and resources, sorting out priorities and monitoring own performance

interact effectively with other persons both on a one-to-one basis and in groups, including understanding and responding to the needs of a customer and working effectively as a member of a team to achieve a shared goal

use mathematical ideas and techniques to correctly calculate time, assess tolerances, apply accurate measurements, calculate material requirements and establish quality checks

establish safe and effective work processes which anticipate and/or resolve problems and downtime, to systematically develop solutions to avoid or minimise reworking and avoid wastage

use workplace technology related to reconditioning cylinder heads, including the use of measuring equipment and communication devices, diagnostic and specialist tooling and equipment, computerised technology, and the reporting/ documenting of results

Required knowledge

A working knowledge of:

OH&S regulations/requirements, equipment, material and personal safety requirements

engine operating principles

construction and operation of cylinder heads relevant to application

types and layout of service/repair manuals (hard copy and electronic)

measuring, adjusting and testing procedures

working knowledge of reconditioning procedures

personal safety requirements

assembly/reconditioning procedures

technical information

equipment safety requirements

enterprise quality procedures

work organisation and planning processes

manual handling techniques

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

It is essential that competence is fully observed and there is ability to transfer competence to changing circumstances and to respond to unusual situations in the critical aspects of:

observing safety procedures and requirements

communicating effectively with others involved in or affected by the work

selecting methods and techniques appropriate to the circumstances

completing preparatory activity in a systematic manner

conducting the work in accordance with workplace requirements

interpreting measurements and specifications

carrying out reconditioning to manufacturer/component supplier requirements

measuring and checking against manufacturer/ component supplier specifications

completing a range of cylinder head reconditioning, assembly and testing procedures to manufacturer/ component supplier specifications

cylinder head is presented to customer in compliance with workplace requirements

Context of, and specific resources for assessment

Application of competence is to be assessed in the workplace or simulated worksite

Assessment is to occur using standard and authorised work practices, safety requirements and environmental constraints

Assessment is to comply with regulatory requirements, including Australian Standards

The following resources should be made available:

workplace location or simulated workplace

material relevant to reconditioning cylinder heads

equipment, hand and power tooling appropriate to reconditioning cylinder heads

activities covering mandatory task requirements

specifications and work instructions

Method of assessment

Assessment must satisfy the endorsed assessment guidelines of the automotive industry's RS&R Training Package

Assessment methods must confirm consistency and accuracy of performance together with application of underpinning knowledge

Assessment must be by direct observation of tasks, with questioning on underpinning knowledge and it must also reinforce the integration of key competencies

Assessment may be applied under project related conditions and require evidence of process

Assessment must confirm a reasonable inference that competence is able not only to be satisfied under the particular circumstance, but is able to be transferred to other circumstances

It is preferable that assessment reflects a process rather than an event and occurs over a period of time to cover varying quality circumstances. Evidence of performance may be provided by customers, team leaders/members or other persons subject to agreed authentication arrangements

Competence in this unit may be assessed in conjunction with other functional units which together form part of the holistic work role

Guidance information for assessment

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, if used 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.

Cylinder heads

Cylinder heads may be of various configurations and components will include inserts, valves, valve guides and rocker gear

Reconditioning methods

Reconditioning methods are to include:

pressure checking procedures

crack testing procedures

tolerance checking procedures

surface finishing

seat cutting and replacement

guide replacement

valve grinding

assembly/reconditioning procedure

tensioning procedures

visual checking

use of tooling/equipment

OH&S

OH&S requirements are to be in accordance with legislation/regulations/codes of practice and enterprise safety policies and procedures. This may include protective clothing and equipment, use of tooling and equipment, workplace environment and safety, handling of material, use of fire fighting equipment, enterprise first aid, hazard control and hazardous materials and substances

Personal protective equipment

Personal protective equipment is to include that prescribed under legislation/regulations/codes of practice and workplace policies and practices

Safe operating procedures

Safe operating procedures are to include, but are not limited to the conduct of operational risk assessment and treatments associated with vehicular movement, toxic substances, electrical safety, machinery movement and operation, manual and mechanical lifting and shifting, working in proximity to others and site visitors

Emergency procedures

Emergency procedures related to this unit are to include, but are not limited to emergency shutdown and stopping of equipment, extinguishing fires, enterprise first aid requirements and site evacuation

Environmental requirements

Environmental requirements are to include but are not limited to waste management, noise, dust and clean-up management

Quality requirements

Quality requirements are to include, but are not limited to regulations, including Australian Standards, internal company quality policy and standards and enterprise operations and procedures

Statutory/regulatory authorities

Statutory/regulatory authorities may include Federal, State/Territory and local authorities administering acts, regulations and codes of practice

Tooling and equipment

Tooling and equipment may include hand tooling, power tooling, special equipment (valve facer, head planer/ grinder/miller, seat cutters, insert machine, guide machine) measuring equipment, testing equipment, tolerance checking equipment, personal and protective equipment, measuring equipment, lubricating equipment, gasket seals

Materials

Materials may include spare parts, lubricants and cleaning material

Communications

Communications are to include but are not limited to verbal and visual instructions and fault reporting and may include site specific instructions, written instructions, plans or instructions related to job/task, telephones and pagers

Information/documents

Sources of information/documents may include:

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

safe work procedures related to reconditioning cylinder heads

regulatory/legislative requirements pertaining to the automotive industry, including Australian Design Rules

engineer's design specifications and instructions

organisation work specifications and requirements

instructions issued by authorised enterprise or external persons

Australian Standards

Unit sector

Technical

This unit contains employability skills.