This unit refers to work typically undertaken in a bottom-end engine overhaul.

It includes cylinder honing using hand held power tools, and replacement of bearings, piston rings and similar activities but not major machining such as crankshaft grinding, cylinder boring and tunnel boring.

Band: A

Unit Weight: 4

Path 1

MEM09002B

Interpret technical drawing

MEM12023A

Perform engineering measurements

MEM18001C

Use hand tools

MEM18002B

Use power tools/hand held operations

MEM18055B

Dismantle, replace and assemble engineering components

ELEMENT

PERFORMANCE CRITERIA

1. Dismantle, clean and assess parts

1.1. Characteristics of surface finishes and wear patterns associated with crankshaft and piston assemblies are understood and parts are correctly assessed for reuse or replacement.

1.2. Engine is removed from plant, top-end components are removed and block assembly is dismantled according to manufacturers' recommendations.

1.3. Parts are assessed for abnormal wear or defects.

1.4. Appropriate cleaning solution and procedure is selected.

1.5. Parts are racked or set out according to their original location in the engine.

1.6. Characteristics of surface finishes and wear patterns associated with crankshaft and piston assemblies are understood and parts are correctly assessed for reuse or replacement.

2. Record and interpret measurements

2.1. Measurements are accurately obtained and recorded.

2.2. Readings are correctly interpreted regarding replacement or reuse and appropriate under/oversize of replacement parts is determined.

3. Recondition components

3.1. Ridges, gaps, tapers, ovality and protrusions are identified and necessary corrective action is taken.

3.2. Tools and equipment are correctly used.

3.3. Components are assembled according to manufacturers' specifications.

3.4. Bearing clearances are correctly determined by calculation or direct measurement.

Required skills

Look for evidence that confirms skills in:

reading, interpreting and following information on written job instructions, specifications, standard operating procedures, charts, lists, drawings and other applicable reference documents

planning and sequencing operations

checking task-related information

checking for conformance to specification

removing the engine and top-end components

removing ridges, gaps, tapers, protrusions and ovality

dismantling block assembly

calculating bearing clearances

checking parts for abnormal wear or defects

identifying components for reuse or replacement

cleaning parts using appropriate solutions and procedures

racking and setting out engine parts according to their original position in readiness for reassembly

obtaining and recording measurements

identifying replacement parts required as being under or over size

using tools and equipment

assembling engine bottom-end components

undertaking calculations and numerical operations within the scope of this unit

Required knowledge

Look for evidence that confirms knowledge of:

the characteristics of surface finishes and wear patterns as applied to crankshaft and piston assemblies

the specifications of crankshaft and piston assemblies

the reasons for identifying the components for reuse or replacement

the procedures for dismantling the block assembly and removing the engine from the plant

the procedures for removing the top end from the engine

the tools, techniques and equipment to be used

the reasons for selecting the chosen tools, techniques and equipment

the hazards and control measures associated with the removal of engines/engine components, including housekeeping

the action to be taken when abnormal wear or defects are observed in the engine components

the procedures and solution for cleaning engine parts

the procedures for racking and/or setting out of parts in readiness for reassembly

the measuring instruments to be used to measure engine components

the procedures for recording engine measurements

the concept of under/over size of replacement parts and the reasons for identifying replacement parts as under or over size

the procedures for removing ridges, gaps, tapers, ovality and protrusions

the tools, techniques and equipment required to correct the above faults

the procedures for assembling engine bottom ends

the precautions to be taken when assembling engine bottom ends

the methods and procedures for determining bearing clearances

safe work practices and procedures

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

A person who demonstrates competency in this unit must be able to perform engine bottom-end overhaul. Competency in this unit cannot be claimed until all prerequisites have been satisfied.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Assessors must be satisfied that the candidate can competently and consistently perform all elements of the unit as specified by the criteria, including required knowledge, and be capable of applying the competency in new and different situations and contexts.

Context of and specific resources for assessment

This unit may be assessed on the job, off the job or a combination of both on and off the job. Where assessment occurs off the job, that is the candidate is not in productive work, then an appropriate simulation must be used where the range of conditions reflects realistic workplace situations. The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team. The assessment environment should not disadvantage the candidate.

This unit could be assessed in conjunction with any other units addressing the safety, quality, communication, materials handling, recording and reporting associated with performing engine bottom-end overhaul or other units requiring the exercise of the skills and knowledge covered by this unit.

Method of assessment

Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisor's reports, project work, samples and questioning. Questioning techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency. The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.

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.

Unit sector

Maintenance and diagnostics

This unit contains employability skills.