AURTTM002 — Repair bearing tunnels and connecting rods in engines

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What an assessment for AURTTM002 must cover

52 assessable components: 8 elements (34 performance criteria), 5 performance evidence and 8 knowledge evidence requirements, plus 5 foundation skills. An audit-defensible tool maps every question and task back to these — that mapping is the coverage matrix Auditori generates alongside the assessment.

Elements & performance criteria

1 Determine line boring requirements

1.1Job requirements are determined from workplace instructions
1.2Engine block is cleaned and main bearing bolt holes are crack tested according to workplace procedures and safety requirements
1.3Information is sourced and repair options are analysed and those most appropriate to the circumstances are selected
1.4Required tools and measuring equipment are checked and prepared for operation according to manufacturer specifications and workplace procedures
1.5Hazards associated with the work are identified and risks are managed

2 Prepare engine and line boring machine

2.1Engine is measured and calibration requirements for line boring are determined
2.2Engine block or cylinder head is prepared for line boring according to workplace procedures and safety and environmental requirements
2.3Line boring machine is prepared to accept cylinder engine block or cylinder head according to manufacturer specifications and workplace procedures
2.4Engine block or cylinder head is positioned and clamped according to manufacturer specifications and workplace procedures

3 Line bore engine bearing tunnels

3.1Tool is set and locked and a test cut is taken according to workplace procedures and safety requirements, and following machinery safe operating procedures
3.2Engine tunnels are line bored at correct speeds and feed rates according to workplace procedures and safety requirements, and following machinery safe operating procedures
3.3Line boring tool sharpness is checked and maintained throughout boring operation according to manufacturer specifications and workplace procedures
3.4Engine block thrust faces and seal diameter are machined to original size
3.5Tunnels are measured to ensure compliance with manufacturer specifications
3.6Line 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

4.1Line-bored engine block or cylinder head is cleaned of residue and swarf according to workplace procedures and safety requirements
4.2Tools and equipment for honing are selected and checked for serviceability
4.3Measuring and calibration requirements for honing are determined
4.4Honing machine is prepared to accept engine block or cylinder head according to manufacturer specifications and workplace procedures
4.5Engine block or cylinder head is positioned and securely clamped, and required hone stroke is set according to manufacturer specifications and workplace procedures
4.6Hone stones are selected and speed is set to achieve required finish

5 Hone engine bearing tunnels

5.1Tunnels are honed at correct speed and rate to required finish according to workplace procedures and safety requirements, and following machinery safe operating procedures
5.2Components are measured to ensure compliance with manufacturer specifications
5.3Honing 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

6.1Connecting rods are cleaned and checked for serviceability according to workplace procedures and safety requirements
6.2Connecting rods are checked for straightness and straightened as required according to workplace procedures and safety requirements, and following machinery safe operating procedures
6.3Connecting rod boring machine is prepared to accept connecting rod
6.4Connecting rod is positioned ready for honing, and securely clamped if machining

7 Repair connecting rod

7.1Connecting rod little ends and big ends are resized according to workplace procedures and safety requirements, and following machinery safe operating procedures
7.2Components are measured to ensure compliance with manufacturer specifications

8 Complete repair process

8.1Engine block or cylinder head is thoroughly cleaned of residual honing oil according to workplace procedures
8.2Final inspection is made to ensure finished work complies with workplace requirements
8.3Bright surfaces are treated with rust prevention solution and engine block or cylinder head is prepared for further process or storage according to workplace procedures
8.4Workplace documentation is processed according to workplace procedures

Performance evidence

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

Knowledge evidence

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

Foundation skills

Learning skills to:: locate appropriate sources of information efficiently.
Reading skills to:: interpret engine component specifications from manufacturer and workshop literature interpret machinery safe operating procedures from operating manuals and signs.
Writing skills to:: legibly and accurately fill out workplace documentation to record measurements.
Numeracy skills to:: interpret numerical information in manufacturer specifications, workshop literature, and machinery dials and gauges use basic mathematical operations, including addition and subtraction, to: convert metric dimensions to imperial, and imperial dimensions to metric calculate tolerances and clearances interpret numerical measurements on metric and precision measuring equipment.
Planning and organising skills to:: select best tooling option for the work and sequence procedure to reduce time and material wastage.

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.

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Questions about assessing AURTTM002

What does an assessment tool for AURTTM002 need to cover?

To satisfy the Principles of Assessment and Rules of Evidence, an assessment for AURTTM002 needs to address all 52 unit components: 8 elements with 34 performance criteria, 5 performance evidence requirements, 8 knowledge evidence requirements, and the foundation skills. A coverage matrix mapping each question and task to these components is what an auditor looks for.

How does Auditori generate an assessment tool for AURTTM002?

Auditori pulls the current release of AURTTM002 from training.gov.au and generates a complete package: candidate assessment, assessor guide with model answers and observation criteria, and a coverage matrix mapping every component. A suitably qualified person then reviews and approves the draft in a built-in workflow — consistent with ASQA's guidance on AI use in VET — before export as branded PDF and editable Word.

Is the first assessment tool really free?

Yes. Every new account includes one free credit — enough to generate the complete assessment tool for AURTTM002 — with no card and no subscription required. After that it's pay-as-you-go per unit.

Can I check my existing AURTTM002 assessment instead of generating a new one?

Yes — upload your existing assessment or learner guide and Auditori maps it against every element, performance criterion, PE and KE of AURTTM002, showing exactly what's covered and what's missing. Mapping costs a quarter of a credit.

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