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Evidence Guide: AURTTM002 - Repair bearing tunnels and connecting rods in engines

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

AURTTM002 - Repair bearing tunnels and connecting rods in engines

What evidence can you provide to prove your understanding of each of the following citeria?

Determine line boring requirements

  1. Job requirements are determined from workplace instructions
  2. Engine block is cleaned and main bearing bolt holes are crack tested according to workplace procedures and safety requirements
  3. Information is sourced and repair options are analysed and those most appropriate to the circumstances are selected
  4. Required tools and measuring equipment are checked and prepared for operation according to manufacturer specifications and workplace procedures
  5. Hazards associated with the work are identified and risks are managed
Job requirements are determined from workplace instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine block is cleaned and main bearing bolt holes are crack tested according to workplace procedures and safety requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Information is sourced and repair options are analysed and those most appropriate to the circumstances are selected

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Required tools and measuring equipment are checked and prepared for operation according to manufacturer specifications and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Hazards associated with the work are identified and risks are managed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare engine and line boring machine

  1. Engine is measured and calibration requirements for line boring are determined
  2. Engine block or cylinder head is prepared for line boring according to workplace procedures and safety and environmental requirements
  3. Line boring machine is prepared to accept cylinder engine block or cylinder head according to manufacturer specifications and workplace procedures
  4. Engine block or cylinder head is positioned and clamped according to manufacturer specifications and workplace procedures
Engine is measured and calibration requirements for line boring are determined

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine block or cylinder head is prepared for line boring according to workplace procedures and safety and environmental requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Line boring machine is prepared to accept cylinder engine block or cylinder head according to manufacturer specifications and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine block or cylinder head is positioned and clamped according to manufacturer specifications and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Line bore engine bearing tunnels

  1. Tool is set and locked and a test cut is taken according to workplace procedures and safety requirements, and following machinery safe operating procedures
  2. Engine tunnels are line bored at correct speeds and feed rates according to workplace procedures and safety requirements, and following machinery safe operating procedures
  3. Line boring tool sharpness is checked and maintained throughout boring operation according to manufacturer specifications and workplace procedures
  4. Engine block thrust faces and seal diameter are machined to original size
  5. Tunnels are measured to ensure compliance with manufacturer specifications
  6. Line boring operations are completed according to required specifications and honing allowances, workplace procedures and safety requirements, and following machinery safe operating procedures
Tool is set and locked and a test cut is taken according to workplace procedures and safety requirements, and following machinery safe operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine tunnels are line bored at correct speeds and feed rates according to workplace procedures and safety requirements, and following machinery safe operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Line boring tool sharpness is checked and maintained throughout boring operation according to manufacturer specifications and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine block thrust faces and seal diameter are machined to original size

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Tunnels are measured to ensure compliance with manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Line boring operations are completed according to required specifications and honing allowances, workplace procedures and safety requirements, and following machinery safe operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare to hone engine bearing tunnels

  1. Line-bored engine block or cylinder head is cleaned of residue and swarf according to workplace procedures and safety requirements
  2. Tools and equipment for honing are selected and checked for serviceability
  3. Measuring and calibration requirements for honing are determined
  4. Honing machine is prepared to accept engine block or cylinder head according to manufacturer specifications and workplace procedures
  5. Engine block or cylinder head is positioned and securely clamped, and required hone stroke is set according to manufacturer specifications and workplace procedures
  6. Hone stones are selected and speed is set to achieve required finish
Line-bored engine block or cylinder head is cleaned of residue and swarf according to workplace procedures and safety requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Tools and equipment for honing are selected and checked for serviceability

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Measuring and calibration requirements for honing are determined

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Honing machine is prepared to accept engine block or cylinder head according to manufacturer specifications and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine block or cylinder head is positioned and securely clamped, and required hone stroke is set according to manufacturer specifications and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Hone stones are selected and speed is set to achieve required finish

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Hone engine bearing tunnels

  1. Tunnels are honed at correct speed and rate to required finish according to workplace procedures and safety requirements, and following machinery safe operating procedures
  2. Components are measured to ensure compliance with manufacturer specifications
  3. Honing operations are completed to required tunnel to journal clearance according to workplace procedures and safety requirements, and following machinery safe operating procedures
Tunnels are honed at correct speed and rate to required finish according to workplace procedures and safety requirements, and following machinery safe operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Components are measured to ensure compliance with manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Honing operations are completed to required tunnel to journal clearance according to workplace procedures and safety requirements, and following machinery safe operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare to repair connecting rods

  1. Connecting rods are cleaned and checked for serviceability according to workplace procedures and safety requirements
  2. Connecting rods are checked for straightness and straightened as required according to workplace procedures and safety requirements, and following machinery safe operating procedures
  3. Connecting rod boring machine is prepared to accept connecting rod
  4. Connecting rod is positioned ready for honing, and securely clamped if machining
Connecting rods are cleaned and checked for serviceability according to workplace procedures and safety requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Connecting rods are checked for straightness and straightened as required according to workplace procedures and safety requirements, and following machinery safe operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Connecting rod boring machine is prepared to accept connecting rod

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Connecting rod is positioned ready for honing, and securely clamped if machining

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair connecting rod

  1. Connecting rod little ends and big ends are resized according to workplace procedures and safety requirements, and following machinery safe operating procedures
  2. Components are measured to ensure compliance with manufacturer specifications
Connecting rod little ends and big ends are resized according to workplace procedures and safety requirements, and following machinery safe operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Components are measured to ensure compliance with manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete repair process

  1. Engine block or cylinder head is thoroughly cleaned of residual honing oil according to workplace procedures
  2. Final inspection is made to ensure finished work complies with workplace requirements
  3. Bright surfaces are treated with rust prevention solution and engine block or cylinder head is prepared for further process or storage according to workplace procedures
  4. Workplace documentation is processed according to workplace procedures
Engine block or cylinder head is thoroughly cleaned of residual honing oil according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Bright surfaces are treated with rust prevention solution and engine block or cylinder head is prepared for further process or storage according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Workplace documentation is processed according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine line boring requirements

  1. Job requirements are determined from workplace instructions
  2. Engine block is cleaned and main bearing bolt holes are crack tested according to workplace procedures and safety requirements
  3. Information is sourced and repair options are analysed and those most appropriate to the circumstances are selected
  4. Required tools and measuring equipment are checked and prepared for operation according to manufacturer specifications and workplace procedures
  5. Hazards associated with the work are identified and risks are managed
Job requirements are determined from workplace instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine block is cleaned and main bearing bolt holes are crack tested according to workplace procedures and safety requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Information is sourced and repair options are analysed and those most appropriate to the circumstances are selected

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Required tools and measuring equipment are checked and prepared for operation according to manufacturer specifications and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Hazards associated with the work are identified and risks are managed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare engine and line boring machine

  1. Engine is measured and calibration requirements for line boring are determined
  2. Engine block or cylinder head is prepared for line boring according to workplace procedures and safety and environmental requirements
  3. Line boring machine is prepared to accept cylinder engine block or cylinder head according to manufacturer specifications and workplace procedures
  4. Engine block or cylinder head is positioned and clamped according to manufacturer specifications and workplace procedures
Engine is measured and calibration requirements for line boring are determined

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine block or cylinder head is prepared for line boring according to workplace procedures and safety and environmental requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Line boring machine is prepared to accept cylinder engine block or cylinder head according to manufacturer specifications and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine block or cylinder head is positioned and clamped according to manufacturer specifications and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Line bore engine bearing tunnels

  1. Tool is set and locked and a test cut is taken according to workplace procedures and safety requirements, and following machinery safe operating procedures
  2. Engine tunnels are line bored at correct speeds and feed rates according to workplace procedures and safety requirements, and following machinery safe operating procedures
  3. Line boring tool sharpness is checked and maintained throughout boring operation according to manufacturer specifications and workplace procedures
  4. Engine block thrust faces and seal diameter are machined to original size
  5. Tunnels are measured to ensure compliance with manufacturer specifications
  6. Line boring operations are completed according to required specifications and honing allowances, workplace procedures and safety requirements, and following machinery safe operating procedures
Tool is set and locked and a test cut is taken according to workplace procedures and safety requirements, and following machinery safe operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine tunnels are line bored at correct speeds and feed rates according to workplace procedures and safety requirements, and following machinery safe operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Line boring tool sharpness is checked and maintained throughout boring operation according to manufacturer specifications and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine block thrust faces and seal diameter are machined to original size

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Tunnels are measured to ensure compliance with manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Line boring operations are completed according to required specifications and honing allowances, workplace procedures and safety requirements, and following machinery safe operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare to hone engine bearing tunnels

  1. Line-bored engine block or cylinder head is cleaned of residue and swarf according to workplace procedures and safety requirements
  2. Tools and equipment for honing are selected and checked for serviceability
  3. Measuring and calibration requirements for honing are determined
  4. Honing machine is prepared to accept engine block or cylinder head according to manufacturer specifications and workplace procedures
  5. Engine block or cylinder head is positioned and securely clamped, and required hone stroke is set according to manufacturer specifications and workplace procedures
  6. Hone stones are selected and speed is set to achieve required finish
Line-bored engine block or cylinder head is cleaned of residue and swarf according to workplace procedures and safety requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Tools and equipment for honing are selected and checked for serviceability

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Measuring and calibration requirements for honing are determined

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Honing machine is prepared to accept engine block or cylinder head according to manufacturer specifications and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine block or cylinder head is positioned and securely clamped, and required hone stroke is set according to manufacturer specifications and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Hone stones are selected and speed is set to achieve required finish

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Hone engine bearing tunnels

  1. Tunnels are honed at correct speed and rate to required finish according to workplace procedures and safety requirements, and following machinery safe operating procedures
  2. Components are measured to ensure compliance with manufacturer specifications
  3. Honing operations are completed to required tunnel to journal clearance according to workplace procedures and safety requirements, and following machinery safe operating procedures
Tunnels are honed at correct speed and rate to required finish according to workplace procedures and safety requirements, and following machinery safe operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Components are measured to ensure compliance with manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Honing operations are completed to required tunnel to journal clearance according to workplace procedures and safety requirements, and following machinery safe operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare to repair connecting rods

  1. Connecting rods are cleaned and checked for serviceability according to workplace procedures and safety requirements
  2. Connecting rods are checked for straightness and straightened as required according to workplace procedures and safety requirements, and following machinery safe operating procedures
  3. Connecting rod boring machine is prepared to accept connecting rod
  4. Connecting rod is positioned ready for honing, and securely clamped if machining
Connecting rods are cleaned and checked for serviceability according to workplace procedures and safety requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Connecting rods are checked for straightness and straightened as required according to workplace procedures and safety requirements, and following machinery safe operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Connecting rod boring machine is prepared to accept connecting rod

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Connecting rod is positioned ready for honing, and securely clamped if machining

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair connecting rod

  1. Connecting rod little ends and big ends are resized according to workplace procedures and safety requirements, and following machinery safe operating procedures
  2. Components are measured to ensure compliance with manufacturer specifications
Connecting rod little ends and big ends are resized according to workplace procedures and safety requirements, and following machinery safe operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Components are measured to ensure compliance with manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete repair process

  1. Engine block or cylinder head is thoroughly cleaned of residual honing oil according to workplace procedures
  2. Final inspection is made to ensure finished work complies with workplace requirements
  3. Bright surfaces are treated with rust prevention solution and engine block or cylinder head is prepared for further process or storage according to workplace procedures
  4. Workplace documentation is processed according to workplace procedures
Engine block or cylinder head is thoroughly cleaned of residual honing oil according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Bright surfaces are treated with rust prevention solution and engine block or cylinder head is prepared for further process or storage according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Workplace documentation is processed according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

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. Determine line boring requirements

1.1 Job requirements are determined from workplace instructions

1.2 Engine block is cleaned and main bearing bolt holes are crack tested according to workplace procedures and safety requirements

1.3 Information is sourced and repair options are analysed and those most appropriate to the circumstances are selected

1.4 Required tools and measuring equipment are checked and prepared for operation according to manufacturer specifications and workplace procedures

1.5 Hazards associated with the work are identified and risks are managed

2. Prepare engine and line boring machine

2.1 Engine is measured and calibration requirements for line boring are determined

2.2 Engine block or cylinder head is prepared for line boring according to workplace procedures and safety and environmental requirements

2.3 Line boring machine is prepared to accept cylinder engine block or cylinder head according to manufacturer specifications and workplace procedures

2.4 Engine block or cylinder head is positioned and clamped according to manufacturer specifications and workplace procedures

3. Line bore engine bearing tunnels

3.1 Tool is set and locked and a test cut is taken according to workplace procedures and safety requirements, and following machinery safe operating procedures

3.2 Engine tunnels are line bored at correct speeds and feed rates according to workplace procedures and safety requirements, and following machinery safe operating procedures

3.3 Line boring tool sharpness is checked and maintained throughout boring operation according to manufacturer specifications and workplace procedures

3.4 Engine block thrust faces and seal diameter are machined to original size

3.5 Tunnels are measured to ensure compliance with manufacturer specifications

3.6 Line boring operations are completed according to required specifications and honing allowances, workplace procedures and safety requirements, and following machinery safe operating procedures

4. Prepare to hone engine bearing tunnels

4.1 Line-bored engine block or cylinder head is cleaned of residue and swarf according to workplace procedures and safety requirements

4.2 Tools and equipment for honing are selected and checked for serviceability

4.3 Measuring and calibration requirements for honing are determined

4.4 Honing machine is prepared to accept engine block or cylinder head according to manufacturer specifications and workplace procedures

4.5 Engine block or cylinder head is positioned and securely clamped, and required hone stroke is set according to manufacturer specifications and workplace procedures

4.6 Hone stones are selected and speed is set to achieve required finish

5. Hone engine bearing tunnels

5.1 Tunnels are honed at correct speed and rate to required finish according to workplace procedures and safety requirements, and following machinery safe operating procedures

5.2 Components are measured to ensure compliance with manufacturer specifications

5.3 Honing operations are completed to required tunnel to journal clearance according to workplace procedures and safety requirements, and following machinery safe operating procedures

6. Prepare to repair connecting rods

6.1 Connecting rods are cleaned and checked for serviceability according to workplace procedures and safety requirements

6.2 Connecting rods are checked for straightness and straightened as required according to workplace procedures and safety requirements, and following machinery safe operating procedures

6.3 Connecting rod boring machine is prepared to accept connecting rod

6.4 Connecting rod is positioned ready for honing, and securely clamped if machining

7. Repair connecting rod

7.1 Connecting rod little ends and big ends are resized according to workplace procedures and safety requirements, and following machinery safe operating procedures

7.2 Components are measured to ensure compliance with manufacturer specifications

8. Complete repair process

8.1 Engine block or cylinder head is thoroughly cleaned of residual honing oil according to workplace procedures

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

8.3 Bright surfaces are treated with rust prevention solution and engine block or cylinder head is prepared for further process or storage according to workplace procedures

8.4 Workplace documentation is processed according to workplace procedures

Required Skills and Knowledge

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. Determine line boring requirements

1.1 Job requirements are determined from workplace instructions

1.2 Engine block is cleaned and main bearing bolt holes are crack tested according to workplace procedures and safety requirements

1.3 Information is sourced and repair options are analysed and those most appropriate to the circumstances are selected

1.4 Required tools and measuring equipment are checked and prepared for operation according to manufacturer specifications and workplace procedures

1.5 Hazards associated with the work are identified and risks are managed

2. Prepare engine and line boring machine

2.1 Engine is measured and calibration requirements for line boring are determined

2.2 Engine block or cylinder head is prepared for line boring according to workplace procedures and safety and environmental requirements

2.3 Line boring machine is prepared to accept cylinder engine block or cylinder head according to manufacturer specifications and workplace procedures

2.4 Engine block or cylinder head is positioned and clamped according to manufacturer specifications and workplace procedures

3. Line bore engine bearing tunnels

3.1 Tool is set and locked and a test cut is taken according to workplace procedures and safety requirements, and following machinery safe operating procedures

3.2 Engine tunnels are line bored at correct speeds and feed rates according to workplace procedures and safety requirements, and following machinery safe operating procedures

3.3 Line boring tool sharpness is checked and maintained throughout boring operation according to manufacturer specifications and workplace procedures

3.4 Engine block thrust faces and seal diameter are machined to original size

3.5 Tunnels are measured to ensure compliance with manufacturer specifications

3.6 Line boring operations are completed according to required specifications and honing allowances, workplace procedures and safety requirements, and following machinery safe operating procedures

4. Prepare to hone engine bearing tunnels

4.1 Line-bored engine block or cylinder head is cleaned of residue and swarf according to workplace procedures and safety requirements

4.2 Tools and equipment for honing are selected and checked for serviceability

4.3 Measuring and calibration requirements for honing are determined

4.4 Honing machine is prepared to accept engine block or cylinder head according to manufacturer specifications and workplace procedures

4.5 Engine block or cylinder head is positioned and securely clamped, and required hone stroke is set according to manufacturer specifications and workplace procedures

4.6 Hone stones are selected and speed is set to achieve required finish

5. Hone engine bearing tunnels

5.1 Tunnels are honed at correct speed and rate to required finish according to workplace procedures and safety requirements, and following machinery safe operating procedures

5.2 Components are measured to ensure compliance with manufacturer specifications

5.3 Honing operations are completed to required tunnel to journal clearance according to workplace procedures and safety requirements, and following machinery safe operating procedures

6. Prepare to repair connecting rods

6.1 Connecting rods are cleaned and checked for serviceability according to workplace procedures and safety requirements

6.2 Connecting rods are checked for straightness and straightened as required according to workplace procedures and safety requirements, and following machinery safe operating procedures

6.3 Connecting rod boring machine is prepared to accept connecting rod

6.4 Connecting rod is positioned ready for honing, and securely clamped if machining

7. Repair connecting rod

7.1 Connecting rod little ends and big ends are resized according to workplace procedures and safety requirements, and following machinery safe operating procedures

7.2 Components are measured to ensure compliance with manufacturer specifications

8. Complete repair process

8.1 Engine block or cylinder head is thoroughly cleaned of residual honing oil according to workplace procedures

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

8.3 Bright surfaces are treated with rust prevention solution and engine block or cylinder head is prepared for further process or storage according to workplace procedures

8.4 Workplace documentation is processed according to workplace procedures

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:

set up the following multi-cylinder engine configurations on a line boring machine:

a V configured engine

an in-line configured engine

line bore the main bearing tunnels of a cylinder block, including each of the following:

relocating a main bearing cap

fitting a semi-finished main bearing cap

sleeving a main bearing tunnel

repair camshaft bearing tunnels of an overhead camshaft cylinder head

repair full set of connecting rods

repair one connecting rod with a stepped parting face.

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS), and occupational health and safety (OHS) requirements relating to repairing bearing tunnels and connecting rods in engines, including:

procedures for:

selecting and using personal protective equipment (PPE), including safety glasses, ear protection and safety footwear

using hand tools and lifting equipment

operational risk assessment and treatments associated with:

electrical safety of line boring and honing machinery

line boring and honing machinery movement and operation

environmental requirements, including procedures for trapping, storing and disposing of cooling and lubricating fluids released during machining process

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

types and grades of boring tools

types and grades of honing stones

tool sharpening and dressing methods, including:

maintaining sharpness of tools throughout boring operations

dressing procedures for stones

line boring methods and procedures, including:

preparing line borer to accept engine block or cylinder head

setting engine block or cylinder head into line boring machine and aligning to centre line of boring bar

setting line boring tool to correct diameter and locking boring tool

welding and relocating main bearing caps

machining top and bottom of bearing caps

machining parting faces of cylinder head camshaft bearing

line boring cylinder head camshaft tunnels

line boring damaged tunnels to oversize to accept sleeving operation

machining parting faces of cylinder block

line boring cylinder block tunnels to accept oversized back bearings

line boring tunnels to leave a honing allowance

line boring rear main bearing areas and thrust bearing diameters to original size

machining and squaring thrust faces in engine blocks

line boring semi-finished camshaft bearings

line honing methods and procedures, including:

procedures for setting diameter of honing stone

rotational and oscillating speeds of honing bar

connecting rod repair methods and procedures, including:

removing rod eye bush and measuring rod eye bore

checking alignment of connecting rod and straightening connecting rod

boring rod eye for oversized bush

removing cap bolts and nuts and machining parting faces on connecting rod and big end cap, including cracked rods

resizing big end for standard and oversize back bearings

fitting new little end bushes and pin boring little ends

types and application of cleaning and lubricating agents

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 operations, including rust protection of machined surfaces.

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.

Calibration requirements must include:

determining depths of cuts and required honing allowances

determining tunnel to journal clearance.

Preparing engine block or cylinder head must include:

removing main bearing caps from engine block

machining bearing cap and engine block parting faces

fitting bearing caps to required tensions.

Safety and environmental requirements must include:

work health and safety (WHS), and occupational health and safety (OHS) requirements, including:

procedures for:

selecting and using personal protective equipment (PPE), including safety glasses, ear protection and safety footwear

using hand tools and lifting equipment

operational risk assessment and treatments associated with:

electrical safety of line boring and honing machinery

line boring and honing machinery movement and operation

environmental requirements, including procedures for trapping, storing and disposing of cooling and lubricating fluids released during machining process.

Preparing line boring machine must include:

sharpening and shaping cutting tools

identifying worn and damaged cutting tools

mounting and positioning cutting tools

correctly using clamps, jigs and rails.

Positioning and clamping must include:

setting work piece into line boring machine and aligning work piece to centre line of boring bar

using appropriate and sufficient clamping of work piece.

Setting and locking tool must include:

setting tool to required diameter

locking tool according to manufacturer specifications.

Line boring at correct speeds and feed ratesmust include:

using coolant and lubricant correctly

setting machining parameters to achieve job requirements and maximise tool life

setting speed and feed rates for tunnel material and diameter.

Specifications and honing allowancesmust include:

consideration of speed and feed and nose radius of boring tool.

Cleaning and checking for serviceability must include:

crack testing connecting rod

measuring little end and big end size

checking big end fitment in connecting rod.