Work applies to sleeving, reboring and honing in an engine reconditioning process. Engine cylinders to be sleeved, bored and honed may include those of light vehicles, heavy vehicles, agricultural and plant equipment, recreational vehicles and motorcycles.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare to bore cylinders

1.1. Workplace instructions are used to determine job requirements, including method, process and equipment

1.2. Information is accessed, procedures and methods are analysed, and appropriate tooling options are selected for fitting sleeves and boring and honing engine blocks

1.3. Tools and measuring equipment are checked and prepared for operation

1.4. Safe operating procedures and workplace health and safety (WHS) and environmental requirements are observed throughout the work

1.5. Measuring and/or calibration for boring is performed

1.6. Engine cylinder block is prepared for boring

1.7. Reboring machine is prepared to accept cylinder block or barrel

1.8. Cylinder block is positioned, securely clamped and limit stop is set

2. Bore cylinders

2.1. Boring operations are performed without causing damage to components or system

2.2. Cylinders are checked/measured with instruments to ensure compliance with specifications

2.3. Boring operations are completed to required specifications and honing allowances

3. Prepare to sleeve cylinder block

3.1. Tools and equipment for sleeving are selected, checked and prepared for operation

3.2. Measuring and/or calibration requirements for sleeving are determined and required sleeve is selected

3.3. Engine cylinder block is prepared for sleeving

4. Sleeve engine cylinder blocks

4.1. Sleeving operations are performed without causing damage to components or system

4.2. Measuring operations are performed to ensure compliance with specifications

4.3. Boring operations are completed to required specifications and honing allowances

5. Prepare cylinders for honing operations

5.1. Tools and equipment for honing are selected, checked and prepared for operation

5.2. Measuring and/or calibration requirements for honing are determined

5.3. Bored cylinder is cleaned of residue and swarf, using appropriate cleaning materials for the component

5.4. Honing machine is prepared to accept cylinder block or barrel

5.5. Cylinder is positioned and securely clamped, and required hone stroke is set

5.6. Hone stones are selected and speed is set to achieve required finish and cross hatch

6. Hone cylinders

6.1. Cylinder is honed at correct speed and rate to required finish without causing damage to components or system

6.2. Components are checked/measured with instruments to ensure compliance with specifications

6.3. Honing operations are completed to specifications, ensuring required piston to bore clearance is achieved

7. Finalise sleeving, boring and honing processes

7.1. Cylinder is thoroughly cleaned of residue honing oil

7.2. Final inspection is made to ensure finished work complies with workplace requirements

7.3. Machined surfaces are treated with a protective coating to prevent rust if cylinder engine block is to be stored

7.4. Engine cylinder block is prepared for storage according to workplace requirements

7.5. Workplace documentation is processed according to workplace procedures

Required skills

technical skills to:

select correct replacement tip or sharpen tool for material to be bored

identify worn and damaged cutting tools

mount and position cutting tools

set machining parameters to achieve job requirements and maximise tool life

use appropriate and sufficient clamping and mounting of the work piece

use coolant and lubricant correctly

check for conformance to specifications

measure 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

Required knowledge

WHS regulations and requirements, equipment, material and personal safety requirements, including:

personal protective equipment (PPE) for handling engine cylinder blocks, using boring and honing machines, and using chemical cleaning and lubricating agents

hazards associated with rotating boring and honing tools

types and application of sleeves, including:

dry sleeves, including:

interference fit parallel sleeve

interference fit flanged sleeves

chrome-type finished-to-size dry flanged sleeves

wet sleeves, including:

flanged

stepped

sleeve fitting procedures, including:

fitting interference sleeves, including fitting parallel sleeves to step in parent bore

fitting wet sleeves

types, characteristics and limitations of honing and boring machines, including:

types and grades of boring tools

types and grades of honing stones

hand-held and machine-operated hones

tool sharpening methods, including:

maintaining sharpness of tool throughout boring operations

compensation methods for tool wear throughout boring operations

boring methods and procedures, including:

determining required size of bore, including honing allowance

preparing the engine cylinder block for boring and setting engine cylinder block into boring machine, including jigs, rails and clamps

setting the boring tool to the correct diameter, locking the boring tool and setting the limit stop

reasons for taking a test cut

speed and feed rates of the boring tool for differing materials, such as alloysil or nicolsil, and for bore diameters

methods for setting the speed and feed rate of the boring tool

honing methods and procedures, including:

cleaning the engine cylinder block before and after honing

preparing portable and stationary honing machines, setting engine cylinder block into honing machine and setting hone stroke

setting honing speeds and feed rates to achieve required finish

methods of measuring bores for taper, ovality and barrelling

types and application of cleaning, lubricating and protective agents, including:

material suitability

application of lubricating agents for different speeds and feed rates of boring machines and honing machines

hazards associated with chemical cleaning and lubricating agents

Australian standards relating to engine reconditioning

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 boring and honing methods and techniques appropriate to the circumstances

complete preparatory activity in a systematic manner

fit a range of sleeves to engines according to workplace, manufacturer and component supplier requirements

bore and hone a range of multi-cylinder engines according to workplace, manufacturer and component supplier requirements

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

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. 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

multi-cylinder engine blocks appropriate to the workplace, including in-line multi-cylinder engine blocks and vee-configuration multi-cylinder engine blocks

fixed and portable hand, air and power tools and equipment appropriate to reboring and honing cylinders and barrels

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.

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 fitting sleeves to engine cylinder blocks and boring and honing engine cylinders

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

Tools and measuring equipment may include:

arbors

clamps

dial bore gauges

dial indicators

inside and outside micrometers

press

pullers.

WHS requirements may include:

individual state or territory regulatory requirements

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.

Measuring and/or calibrating may include:

determining piston to bore clearance

determining sizes of cut

determining required honing allowance.

Preparing for boring may include:

removing main bearings from engine block

fitting a torque plate to engine block.

Preparing reboring machine must include:

clamps

jigs

rails.

Mechanical Miscellaneous

Sector

Technical - Manufacture

This unit contains employability skills.