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.
Elements and Performance Criteria
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 are |
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 |
Evidence of Performance
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.
Evidence of Knowledge
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.
Assessment Conditions
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.
Foundation Skills
This section describes those language, literacy, numeracy and employment skills that are essential to performance and are not explicit in the performance criteria.
Skills | Description |
Learning skills to: | locate appropriate sources of information efficiently. |
Reading skills to: | identify and interpret engine cylinder head specifications from workshop literature interpret engine cylinder head rebuild machinery safe operating procedures from operating manuals and signs. |
Writing skills to: | legibly and accurately fill out workplace documentation to record measurements. |
Numeracy skills to: | interpret numerical information in manufacturer specifications, workshop literature, and machinery dials, gauges and computer readouts use basic mathematical operations, including addition and subtraction, to: convert metric dimensions to imperial, and imperial dimensions to metric calculate tolerances and clearances. |
Planning and organising skills to: | select best tooling option for the work and sequence procedure to reduce time and material wastage. |
Technology skills to: | use precision metric and imperial measuring equipment. |
Range Statement
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 standards | 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. |
Sectors
Technical - Manufacture
Competency Field
Mechanical Miscellaneous