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Unit of competency details

AURTTM008 - Dismantle and evaluate engine blocks and sub-assemblies (Release 1)

Summary

Usage recommendation:
Current
Mapping:
MappingNotesDate
Supersedes and is equivalent to AURTTM3008 - Dismantle and evaluate engine blocks and sub-assemblies 13/Apr/2016

Release Status:
Current
Releases:
ReleaseRelease date
1 1 (this release) 14/Apr/2016


Training packages that include this unit

Classifications

SchemeCodeClassification value
ASCED Module/Unit of Competency Field of Education Identifier 030503 Vehicle Mechanics  

Classification history

SchemeCodeClassification valueStart dateEnd date
ASCED Module/Unit of Competency Field of Education Identifier 030503 Vehicle Mechanics  09/Aug/2016 
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Unit Of competency

Modification History

Release 

Comment 

Release 1 

New unit of competency.

Application

This unit describes the performance outcomes required to dismantle and evaluate an engine block and its sub-assemblies as part of an engine repair or reconditioning process. It involves preparing for the task, dismantling and evaluating the engine blocks and sub-assemblies, determining required repair action, and completing workplace processes and documentation.

It applies to those working in the automotive service and repair industry. The engine blocks and sub-assemblies include those in vehicles from all sectors of the industry.

No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.

Competency Field

Mechanical Miscellaneous

Unit Sector

Technical - Manufacture

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 dismantle engine block and sub-assembly

1.1 Job requirements are determined from workplace instructions

1.2 Engine block and sub assembly dismantling information is 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 Engine is set up for dismantling using appropriate lifting equipment and avoiding fluid spillage according to safety and environmental requirements 

1.6 Engine block and sub-assembly are cleaned according to safety and environmental procedures and relevant Australian standards, and positions of auxiliary equipment are recorded, including  photographic evidence

2. Dismantle engine block and sub-assembly

2.1 Covers and ancillary components are removed, cleaned and stored according to workshop procedures

2.2 Engine block and sub-assembly are 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 Engine block and sub-assembly are inspected, measured and tested  against manufacturer specifications and tolerances and according to workplace procedures and safety requirements

3.2 Engine block and sub-assembly are evaluated and repair requirements are determined and reported according to workplace procedures

4. Complete dismantle and evaluation processes

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-assembly 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

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 component specifications from workshop literature
  • interpret safe operating procedures for engine component rebuild machinery from operating manuals and signs.

Writing skills to:

  • legibly and accurately fill out workplace documentation when making recommendations.

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 components to reduce time and material wastage.

Technology skills to:

  • use metric and imperial precision measuring equipment.

Range of Conditions

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 equipment used in dismantling and evaluating engine blocks and sub-assemblies
  • 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 process.

Inspecting, measuring and testing  must include:

  • applying surface finishes and wear patterns to:
  • cylinder bores, crankshafts, pistons, gears, cam followers, and camshafts
  • bearings and bushes
  • block facings
  • parting faces of connecting rod
  • main bearing caps
  • crack testing:
  • connecting rods
  • crankshaft
  • camshaft
  • cylinder block surface
  • camshaft and main bearing tunnels
  • main bearing caps
  • hardness testing:
  • alloy cylinder blocks, pistons, crankshaft journals and camshaft followers
  • checking taper, ovality and wear of:
  • crankshaft and camshaft journals
  • main bearing and connecting rod tunnels
  • cylinder bores in conventional engine blocks and parent bores of engine blocks with dry sleeves
  • checking:
  • camshaft lobe lift
  • straightness of shafts
  • main bearing tunnels for alignment
  • connecting rod alignment and little end bore size
  • cylinder block flatness and deck height
  • piston ring land clearance, piston skirt wear, and gudgeon pin to piston clearance
  • cylinder liner register in both upper and lower parts of cylinder block
  • oil pump for serviceability
  • idler gear hub to bearing clearance.

Unit Mapping Information

Equivalent to AURTTM3008 Dismantle and evaluate engine blocks and sub-assemblies

Links

Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=b4278d82-d487-4070-a8c4-78045ec695b1

 

Assessment requirements

Modification History

Release 

Comment 

Release 1 

New unit of competency.

Performance Evidence

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:

  • dismantle and evaluate the following three different engine blocks and their sub-assemblies:
  • in-line engine block
  • V configuration engine block
  • diesel engine block with sleeves.

Knowledge Evidence

Individuals must be able to demonstrate knowledge of:

  • work health and safety (WHS) and occupational health and safety (OHS) requirements relating to dismantling and evaluating engine blocks and sub-assemblies, including operational risk assessment and treatments associated with:
  • electrical equipment used in dismantling and evaluating engine blocks and sub-assemblies
  • 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 process
  • manual handling techniques, including those relating to:
  • using machinery for lifting engine blocks and engine components
  • using slings, chains and other lifting equipment according to safe work practices
  • dismantling methods and procedures, including:
  • reasons for selecting chosen tools, techniques and equipment
  • hazards and fluid control measures associated with removal of engines and engine components, including housekeeping
  • procedures for recording positions of components, including photographic evidence
  • pre-evaluation checks to determine suitability of component to be re-used
  • reasons for checking end float before disassembly
  • cleaning solutions and cleaning procedures for components
  • use of pullers, presses and specialised tools, and application of heat to dismantle components, including gears, pulleys and dowels
  • procedures for recording facing directions of pistons, connecting rods, main and big end caps, and positions of removable counterweights and counterweight shaft assemblies
  • precautions to be used when removing connecting rod cap
  • removing crankshaft and identifying main bearing caps that have lost register
  • removing dry and wet sleeves
  • dismantling pistons from connecting rods
  • removing camshaft bearings and balance/idler shaft bearings
  • removing welsh plugs and oil gallery plugs
  • removing diesel injection pumps
  • dismantling components that have seized, bent or broken, including seized stud and bolt removal
  • inspection, measurement and testing procedures, including:
  • characteristics of surface finishes and wear patterns as applied to:
  • cylinder bores, crankshafts, pistons, gears, cam followers, and camshafts
  • bearings and bushes
  • block facings
  • parting faces of connecting rod
  • main bearing caps
  • crack testing components
  • testing hardness of alloy cylinder blocks, pistons, crankshaft journals and camshaft followers
  • straightness of shafts
  • taper, ovality and wear of:
  • crankshaft and camshaft journals
  • main bearing and connecting rod tunnels
  • cylinder bores in conventional engine blocks and parent bores of engine blocks with dry sleeves
  • camshaft lobe lift
  • straightness of shafts
  • main bearing tunnels for alignment
  • connecting rod alignment and little end bore size
  • cylinder block flatness and deck height
  • piston ring land clearance, piston skirt wear and gudgeon pin to piston clearance
  • cylinder liner register in both the upper and lower parts of the cylinder block
  • oil pump for serviceability
  • idler gear hub to bearing clearance
  • 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.

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 blocks and sub-assemblies that they have dismantled and evaluated, 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
  • three different multi-cylinder engine blocks specified in the performance evidence
  • precision measuring equipment, including:
  • dial bore gauges
  • dial indicators
  • inside and outside metric and imperial micrometers
  • fixed and portable hand, air and power tools and lifting equipment suitable for dismantling and evaluating engine blocks and sub-assemblies.

Links

Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=b4278d82-d487-4070-a8c4-78045ec695b1

Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=b4278d82-d487-4070-a8c4-78045ec695b1