AURTTM006 — Perform advanced machining and blueprinting of engine components

Elements & performance criteria

Performance evidence

• machine and blueprint two of the following different engine components:
• engine with multiple overhead camshafts
• V configuration engine with at least six cylinders
• multi-cylinder diesel engine.

Knowledge evidence

• work health and safety (WHS) and occupational health and safety (OHS) requirements relating to performing advanced machining and blueprinting of engine components, including: procedures for selecting and using personal protective equipment (PPE) for: handling engine blocks and sub-assemblies; using chemical cleaning agents; operational risk assessment and treatments associated with: electrical safety of machinery; machinery movement and operation; environmental requirements, including procedures for trapping, storing and disposing of cleaning and lubricating fluids released during process
• procedures for preparing cylinder blocks and cylinder heads for blueprinting, including: chemically cleaning engine components, including methods for avoiding damage or loss of components; chasing threads to remove debris with correct grade tap; hardness testing components; pressure testing cylinder heads; checking cylinder heads for bend on both sides; checking cylinder heads for minimum thickness; checking valve guides, valve stems, collets and valve springs for wear; testing engine block, including sonic testing and crack testing; dummy assembling engines, including reasons for dummy assembling engines
• procedures for blueprinting cylinder blocks, including: line boring main tunnels to produce datum; fitting bearings and checking crush; measuring main bearing tunnel with bearings fitted; grinding crankshaft to suit bearings and to achieve desired clearance and phasing consistency; sleeving lifter bores to centre line of camshaft and checking lifter to bore clearance and alignment to camshaft; fitting camshaft bearings and checking running clearances; squaring up deck to crankshaft tunnel to ensure crankshaft is parallel to block; fitting torque plate to bore and hone; honing cylinders to desired surface finish, matching individual pistons to respective bores; setting ring end gap; achieving consistent piston height for desired compression ratio and checking rotational clearance
• procedures for blueprinting connecting rods, including: shot peening connecting rods; preparing rod for re-sizing, including removing and locating dowels as required; selecting bolts; tensioning and re-sizing tunnel, maintaining centre-to-centre height; checking little end running clearance; removing bushes and checking parent bore of rod and bush fitment; pin fitting rod, maintaining centre-to-centre height and running clearance; checking alignment of rod; fitting up bearings, checking crush and running clearance; resizing connecting rods and fitting new bolts to ensure centre-to-centre length and alignment is correct
• procedures to blueprint cylinder heads, including: methods for achieving optimum airflow, including limitations of cylinder head modifications; machining for larger valves, including identifying machining shifts in castings; operating flow bench; porting for improved air flow and to balance combustion chambers; calculating capacity of individual combustion chambers and machining combustion chambers to achieve consistency; calculating compression ratio; selecting camshaft; setting valve heights; calculating installed height of valve springs and seat pressure; calculating valve spring open height and pressure; calculating valve spring solid height and coil bind clearance; calculating spring retainer to stem seal clearance; dialling camshaft; machining pistons to achieve desired compression ratio; setting rocker geometry, including length and sweep
• 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-grinding operations, including rust protection of machined surfaces.

Foundation skills

• Learning skills to: locate appropriate sources of information efficiently.
• Reading skills to: interpret engine component specifications from workshop literature; interpret machinery safe operating procedures from operating manuals.
• Writing skills to: legibly and accurately fill out workplace documentation when making recommendations and recording measurements and material used.
• Numeracy skills to: interpret numerical information in manufacturer specifications, workshop literature, and machinery dials and gauges; use basic mathematical operations, including addition and subtraction, multiplication and division 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 procedure to reduce time and material wastage.
• Technology skills to: operate machinery when adjusting or machining engine components; use metric and imperial precision measuring equipment.

Unit content sourced from training.gov.au — © Commonwealth of Australia, licensed under CC BY 4.0. Auditori is not affiliated with the Department of Employment and Workplace Relations.

Questions about assessing AURTTM006