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Evidence Guide: AURTTM004 - Assemble engine blocks and sub-assemblies

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

 

AURTTM004 - Assemble engine blocks and sub-assemblies

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

Prepare to assemble engine block and sub-assembly

  1. Job requirements are determined from workplace instructions
  2. Information is sourced, procedures and methods are analysed, and appropriate tools are selected for assembling engine block and sub-assemblies
  3. Tools and measuring equipment are prepared and checked for serviceability
  4. Hazards associated with the work are identified and risks are managed
  5. Pre-assembly cleaning of engine components is carried out according to safety and environmental requirements, and components are laid out in logical order
  6. Replacement component parts are checked for size and suitability according to manufacturer specifications and job requirements
Job requirements are determined from workplace instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Information is sourced, procedures and methods are analysed, and appropriate tools are selected for assembling engine block and sub-assemblies

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Tools and measuring equipment are prepared and checked for serviceability

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Hazards associated with the work are identified and risks are managed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Pre-assembly cleaning of engine components is carried out according to safety and environmental requirements, and components are laid out in logical order

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Replacement component parts are checked for size and suitability according to manufacturer specifications and job requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check engine block and sub-assembly clearances and tolerances

  1. Clearances and tolerances are measured to the tolerance required by manufacturer specifications
  2. Clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications
Clearances and tolerances are measured to the tolerance required by manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assemble engine block and engine sub-assembly

  1. Engine sub-assemblies are assembled in correct order and without damage, against manufacturer specifications and tolerances and according to workplace procedures and relevant Australian standards and safety requirements
  2. Engine blocks are assembledin correct order against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards, and safety requirements, and without causing damage to components or systems
  3. Assembled components are measured according to manufacturer specifications and workplace procedures
  4. Assembled component clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications
Engine sub-assemblies are assembled in correct order and without damage, against manufacturer specifications and tolerances and according to workplace procedures and relevant Australian standards and safety requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine blocks are assembledin correct order against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards, and safety requirements, and without causing damage to components or systems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assembled components are measured according to manufacturer specifications and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assembled component clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete assembly process

  1. Final inspection is made to ensure finished work complies with workplace requirements
  2. Bright surfaces are treated with rust prevention solution and engine block and sub-assemblies are prepared for further process or storage according to workplace procedures
  3. Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
  4. Workplace documentation is processed according to workplace procedures
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 and sub-assemblies are prepared for further process or storage according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Workplace documentation is processed according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare to assemble engine block and sub-assembly

  1. Job requirements are determined from workplace instructions
  2. Information is sourced, procedures and methods are analysed, and appropriate tools are selected for assembling engine block and sub-assemblies
  3. Tools and measuring equipment are prepared and checked for serviceability
  4. Hazards associated with the work are identified and risks are managed
  5. Pre-assembly cleaning of engine components is carried out according to safety and environmental requirements, and components are laid out in logical order
  6. Replacement component parts are checked for size and suitability according to manufacturer specifications and job requirements
Job requirements are determined from workplace instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Information is sourced, procedures and methods are analysed, and appropriate tools are selected for assembling engine block and sub-assemblies

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Tools and measuring equipment are prepared and checked for serviceability

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Hazards associated with the work are identified and risks are managed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Pre-assembly cleaning of engine components is carried out according to safety and environmental requirements, and components are laid out in logical order

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Replacement component parts are checked for size and suitability according to manufacturer specifications and job requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check engine block and sub-assembly clearances and tolerances

  1. Clearances and tolerances are measured to the tolerance required by manufacturer specifications
  2. Clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications
Clearances and tolerances are measured to the tolerance required by manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assemble engine block and engine sub-assembly

  1. Engine sub-assemblies are assembled in correct order and without damage, against manufacturer specifications and tolerances and according to workplace procedures and relevant Australian standards and safety requirements
  2. Engine blocks are assembledin correct order against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards, and safety requirements, and without causing damage to components or systems
  3. Assembled components are measured according to manufacturer specifications and workplace procedures
  4. Assembled component clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications
Engine sub-assemblies are assembled in correct order and without damage, against manufacturer specifications and tolerances and according to workplace procedures and relevant Australian standards and safety requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine blocks are assembledin correct order against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards, and safety requirements, and without causing damage to components or systems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assembled components are measured according to manufacturer specifications and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assembled component clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete assembly process

  1. Final inspection is made to ensure finished work complies with workplace requirements
  2. Bright surfaces are treated with rust prevention solution and engine block and sub-assemblies are prepared for further process or storage according to workplace procedures
  3. Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
  4. Workplace documentation is processed according to workplace procedures
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 and sub-assemblies are prepared for further process or storage according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

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. Prepare to assemble engine block and sub-assembly

1.1 Job requirements are determined from workplace instructions

1.2 Information is sourced, procedures and methods are analysed, and appropriate tools are selected for assembling engine block and sub-assemblies

1.3 Tools and measuring equipment are prepared and checked for serviceability

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

1.5 Pre-assembly cleaning of engine components is carried out according to safety and environmental requirements, and components are laid out in logical order

1.6 Replacement component parts are checked for size and suitability according to manufacturer specifications and job requirements

2. Check engine block and sub-assembly clearances and tolerances

2.1 Clearances and tolerances are measured to the tolerance required by manufacturer specifications

2.2 Clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications

3. Assemble engine block and engine sub-assembly

3.1 Engine sub-assemblies are assembled in correct order and without damage, against manufacturer specifications and tolerances and according to workplace procedures and relevant Australian standards and safety requirements

3.2 Engine blocks are assembledin correct order against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards, and safety requirements, and without causing damage to components or systems

3.3 Assembled components are measured according to manufacturer specifications and workplace procedures

3.4 Assembled component clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications

4. Complete assembly process

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

4.2 Bright surfaces are treated with rust prevention solution and engine block and sub-assemblies are prepared for further process or storage according to workplace procedures

4.3 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

4.4 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. Prepare to assemble engine block and sub-assembly

1.1 Job requirements are determined from workplace instructions

1.2 Information is sourced, procedures and methods are analysed, and appropriate tools are selected for assembling engine block and sub-assemblies

1.3 Tools and measuring equipment are prepared and checked for serviceability

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

1.5 Pre-assembly cleaning of engine components is carried out according to safety and environmental requirements, and components are laid out in logical order

1.6 Replacement component parts are checked for size and suitability according to manufacturer specifications and job requirements

2. Check engine block and sub-assembly clearances and tolerances

2.1 Clearances and tolerances are measured to the tolerance required by manufacturer specifications

2.2 Clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications

3. Assemble engine block and engine sub-assembly

3.1 Engine sub-assemblies are assembled in correct order and without damage, against manufacturer specifications and tolerances and according to workplace procedures and relevant Australian standards and safety requirements

3.2 Engine blocks are assembledin correct order against manufacturer specifications and tolerances and according to workplace procedures, relevant Australian standards, and safety requirements, and without causing damage to components or systems

3.3 Assembled components are measured according to manufacturer specifications and workplace procedures

3.4 Assembled component clearances and tolerances are adjusted according to workplace procedures and to the tolerance required by manufacturer specifications

4. Complete assembly process

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

4.2 Bright surfaces are treated with rust prevention solution and engine block and sub-assemblies are prepared for further process or storage according to workplace procedures

4.3 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

4.4 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:

assemble two different engine blocks, one of which must be a V configuration engine block, and the sub-assemblies of those engine blocks, in which the work must involve:

a multi-cylinder diesel engine

a multi-cylinder petrol engine.

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to assembling engine blocks and sub-assemblies, including procedures for:

selecting and using personal protective equipment (PPE) for handling engine blocks and sub-assemblies and using chemical cleaning agents

correctly operating specialised equipment, including heating torches, ovens and presses

handling freezing substances, including liquid nitrogen

manual handling techniques, including:

using machinery for lifting engine blocks and engine components

using slings, chains and other lifting equipment according to safe work practices

environmental requirements, including procedures for trapping, storing and disposing of cleaning fluids released during the assembly process

procedures for clearance testing and adjusting or machining components, including:

piston to connecting rod big end alignment

big end and main bearing crush with bearing blue

piston ring end gap, back clearance and side clearance

bearing to crankshaft clearances with plastigage and measuring and calculating clearances

semi-flanged thrust bearings

finished camshaft bearings and measuring clearances

camshafts and cam followers

camshaft end float

crankshaft end float

gear backlash

oil pump sealing and pick-up oil piping

component assembly procedures and processes, including:

pre-assembly wash procedures for components

welsh plugs and oil gallery plugs

piston and connecting rod assemblies

big end bearings

piston rings to pistons, including procedures for using ring compressors

main bearings and thrust washers

semi-flanged thrust bearings

crankshafts, including protection measures for crankshaft journals, bearings, rings and bores

finished camshaft bearings

camshafts and cam followers

timing gears

chains and tensioners

oil pumps, oil squirters and oil pump pick-ups

balance shafts

fitting ancillary components, including:

covers and seals

housings

diesel fuel injection pumps

oil coolers

crankshaft pulleys

flywheels

bell housings

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.

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.

Tools must include:

fixed and portable hand, air and power tools

lifting equipment

torque wrench

material suitable for assembling engine block.

Pre-assembly cleaning must include:

removing machining residue

ensuring gasket faces are clean, and oil and water passageways are clear using appropriate tools, such as a rifle brush.

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:

power tool electrical safety

manual and mechanical lifting and shifting equipment

toxic cleaning substances

environmental requirements, including procedures for trapping, storing and disposing of cleaning fluids released during the assembly process.

Measuring clearances and tolerances must include:

back clearance and side clearance

bearing to journal clearance

end floats

piston ring end gap

piston to bore clearance.

Adjusting clearances and tolerances must include:

adjusting gear backlash

machining semi-finished thrust bearings

machining piston protrusion and valve pockets

pin-boring connecting rod little ends.

Assembled must include:

gaskets

seals.

Australian standards must include:

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.