Elements and Performance Criteria

Range Statement
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 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 assembling engines
verbal, written and graphical instructions, signage, work schedules, plans, specifications, work bulletins, memos, material safety data sheets (MSDS), diagrams or sketches.
Appropriate tooling options may include:
comparator gauges
ring compressors
hand tooling
plasti-gauge
power tooling
torque wrenches.
Tools and measuring equipment may include:
clamps
dial indicators
inside and outside micrometers
lifting equipment.
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 include:
clean-up management
dust and noise minimisation
waste management.
Technical information may include:
manufacturer or supplier component specifications.
Support equipment includes:
assembly bench
assembly trolleys
engine stands
lifting equipment.
Facilities include:
dedicated engine assembly room
dust and gas exhaust units.
Pre-assembly cleaning includes:
removing machining residue
ensuring gasket faces are clean and oil and water passageways are clear using tools, such as a rifle brush.
Engine components include:
engine blocks, sleeves, crankshafts, camshafts, camshaft followers, piston and connecting rod assemblies, timing chains and gears, oil pumps, oil squirters and coolers
other variables, including ancillary systems and components, such as:
cooling systems
exhaust systems
fuel systems.
Replacement component parts may include:
bearing sets
gasket sets
oil pumps
piston rings
pistons
seals
sleeves
timing chains and gears.
Clearances and tolerances that are measured include:
back clearance and side clearance
bearing to journal clearances
endfloats
gear backlashes
parent bore to dry sleeve fit
piston ring end-gap
piston to bore clearance
sleeve heights.
Clearances and tolerances that are adjusted include:
adjusting gear backlash
machining semi-finished thrust bearings
machining piston protrusion and valve pockets
pin-boring connecting rod little-ends.
Assembling engine sub-assemblies includes:
assembling, aligning and fitting:
air brake compressors
oil coolers
oil pumps
pistons.
Assembling engine blocks includes:
fitting finished dry interference and slip-fit sleeves, chrome sleeves and wet sleeves
fitting crankshafts, piston assemblies, camshafts, camshaft followers, push rods, oil pumps, timing gears and timing chains
fitting balance weights and timing gears to crankshafts
fitting covers, seals, housings, flywheels and forced air induction assemblies.

Evidence Guide
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 methods and techniques for assembling engine blocks and sub-assemblies appropriate to the circumstances
complete the assembly of multi-cylinder blocks, including:
measuring and checking against manufacturer and component supplier specifications
carrying out assembly to manufacturer and component supplier requirements without causing damage to components, tools or systems
complete workplace and equipment records.
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.
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 engines appropriate to the workplace, including in-line multi-cylinder engine and vee-configuration multi-cylinder engine blocks
fixed and portable hand, air and power tools, lifting equipment, torque wrench, measuring equipment and other equipment appropriate to assembling engine blocks and sub-assemblies
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.