Removing and refitting motorsport engines and ancillary components
Overview
This standard identifies the competences you need to carry out the removal and refitting of motorsport engines and ancillary components such as pumps, oil coolers, heat exchangers, radiators, engine mountings, exhaust primaries, flexible and rigid pipework, water header tanks, gear and belt drives, control cables and `lifed' components, in accordance with approved procedures.
It covers a range of motorsport vehicles such as single seater, rallying, sports cars, karts, historic and other specific approved competition vehicles. The removal and refitting methods and techniques will include, dismantling the equipment to an appropriate level, protecting exposed components, checking components for serviceability, making mechanical and electrical connections, releasing stored pressure, setting, aligning and adjusting refitted components, tightening fasteners to the required torque, and replenishing oils, greases and fluids.
On completion of the removal and re-fitting activities, you will be required to carry out a range of final checks, tests and adjustments, such as checking for coolant, fuel, oil and hydraulic fluid leaks, starting and running the engine to ensure that it meets the required specification, ignition timing checks, carburettor vacuum testing, electrical charging tests.
Your responsibilities will require you to comply with organisational policy and procedures for the removal and refitting activities undertaken, and to report any problems with these activities that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You must ensure that all tools, equipment and materials used are correctly accounted for on completion of the activities, and that all necessary job/task documentation is completed accurately and legibly.
You will be expected to work as a member of a team, with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Where team working is involved, you must demonstrate a significant personal contribution during the team activities in order to satisfy the requirements of the standard, and competence in all the areas required by the standard must be demonstrated.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the appropriate removal and refitting techniques and procedures to motorsport engines and ancillary components. You will understand the removal and refitting methods and procedures, and their application. You will know how the equipment functions, the common problems that can occur, the purpose of the individual components and associated defects, in adequate depth to provide a sound basis for carrying out the removal and refitting activities, correcting faults and ensuring that the equipment is replaced to the required standard. You will also have sufficient knowledge of these components to ensure that they are fit for purpose and meet the specifications, thus providing a sound basis for carrying out the refitting activities.
You will understand the safety precautions required when working on motorsport vehicles, especially those for isolating the equipment. You will be required to demonstrate safe working practices throughout, and will understand your responsibility for taking the necessary safeguards to protect yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, vehicle manuals and publications to carry out the required work
- remove and refit the components in their correct positions using appropriate methods and techniques
- take suitable precautions to prevent damage to components and surrounding structure
- ensure that the removed components are clean and free from dirt, oil and debris, and that they are in a usable condition, prior to being refitted and tested
- replace and secure the components, using the specified connectors and securing devices
- check that all operations have been completed and that the finished assembly meets the required specification
- label and store components that require repair or overhaul
- deal promptly and effectively with problems within your control and report those that cannot be solved
ensure that work records are completed, stored securely and available to others as per organisational requirements
leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- the procedures for obtaining the various types of manuals/drawings, job instructions and specifications used during the removal and refitting of motorsport engines, and how to interpret them to correctly
- how to identify different types of motorsport engines and ancillary components to be used
- the removal and refitting methods and techniques to be used, and the importance of adhering to these procedures
- how the ancillaries are to be aligned and positioned, prior to securing, and the tools and equipment that are used (including jigs and fixtures)
- the various mechanical fasteners that will be used and their method of installation (threaded fasteners, quick release fasteners, circlips)
- the application of sealants and adhesives within the refitting activities, and the precautions to be taken when working with them
- the company `lifing' procedure for components, to meet the team's requirements
- the operational function of the various motorsport engine ancillary components
- the use of torque wrenches and the importance of ensuring that fasteners are adjusted to the required settings
- preparations to be undertaken on the components and mounting points, prior to fitting the ancillaries to the motorsport engine
- how to apply correct lubricant/fluids to motorsport engines and the importance of ensuring that the lubricant/fluid is to the correct specification
- the tools and equipment to be used for the removal and refitting of motorsport engines and ancillary components
- the importance of using the specified fasteners for the refitting and why you must not use substitutes
- how to deal with components or fastening devices that are incorrectly installed, damaged or have other faults
- the quality control procedures to be followed during the removal and refitting activities
- the various tests, checks and adjustments to be carried out on completion of the engine removal and refitting activities
- how to recognise assembly defects (incorrect refitting, ineffective fasteners, component damage)
- the importance of ensuring that the completed assembly is free from foreign objects, dirt or other contamination
- the methods and equipment used to transport, handle and lift motorsport engines into position, and how to check that the lifting equipment is within its current certification dates
- how to check that the tools and equipment to be used are correctly calibrated, and are in a safe and serviceable condition
- the importance of ensuring that all tools are used correctly, checked and stored after use
- problems with the removal and refitting operations, and the importance of informing appropriate people of non- conformances
- the recording documentation to be completed for the activities undertaken
- the procedure for the safe disposal of waste materials, scrap components, oils and fluids
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the removal and refitting of the motorsport engine or ancillary equipment:
- plan the removal and refitting activities prior to beginning the work
- obtain and use the appropriate documentation (such as job instructions, assembly drawings, manuals, quality control documentation)
- adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide safe access and working arrangements for the working area, and ensure that any appropriate environmental conditions can be met
- ensure that the work area is suitably prepared for the removal and refitting activities to take place
- obtain approval to carry out the removal and refitting activities
- position and secure the vehicle using the correct equipment
- ensure that any required consumables are available
- leave the vehicle and work area in a safe and appropriate condition, free from spillages and foreign object debris
- return all tools and equipment to the correct location on completion of the activities
Remove and refit motorsport engines to one of the following types of motorsport vehicle:
- single seater
- sports car
- historic vehicle
- rallying
- kart
- other specific approved competition vehicle
Use appropriate methods and techniques to remove and refit motorsport engines, using sixteen of the following:
- removing covers, cowlings and bodywork
- checking components for serviceability
making an initial judgment of the condition of vehicle (such as damage, missing components)
replacing all damaged/defective components replacing all 'lifed' items (such as seals, gaskets)
- isolating the engine from ancillary equipment and fluids
- draining/removing oils, greases or fluids
- releasing stored energy (where appropriate)
- dismantling equipment to an appropriate level
- disconnecting/removing hoses and pipes
- supporting items of equipment to be removed
- disconnecting electrical connections
- protecting exposed components, vents, looms and pipework
- setting, aligning and adjusting replaced components
- marking and labelling components to aid reassembly
- re-assembling components to the appropriate level (such as sub-assembly)
- tightening fastenings to the required torque
- making mechanical connections
- replenishing oils, greases or fluids
- making electrical connections
- bleeding fluid systems
- returning the engine and ancillary components to working order on completion of activities
Use six of the following during the removal and refitting activities:
- jigs/fixtures
- torque wrenches
- fluid filling devices
- hand tools
- lifting equipment
- bleeding devices
- specific diagnostic aids
- coolant pressure pumps
- vacuum gauges
- volt/ammeter
- strobe light
- special tools and equipment
- pneumatic wrenches
- alignment devices
Remove and refit eight of the following motorsport engine ancillary components:
- engine mountings
- pumps (such as pressure, scavenge)
- sensors
- oil cooler
- gear and belt drives
- heat exchanger
- wiring looms
- lubricant/fluid tanks
- electronic control units (ECUs)
- radiators
- mounting studs
- pipe fittings/connectors
- mechanical fasteners
- exhaust primary systems
- clutch components (such as pressure plates, drive discs and actuators)
- rigid and flexible pipework (such as water, fuel, hydraulic and pneumatic)
- air intake systems (such as filters, plenums, ducting)
- control cables (such as throttle and clutch)
Carry out final checks and adjustments on the refitted engine, to include eight of the following:
- checking that all engine and ancillary components are free from foreign objects, dirt or other contamination
- checking that the engine assembly is complete and complies to specification
- checking that all mechanical fixings are secure and have been `torqued' to specification and where appropriate, bolt locking devices are fitted
- ensuring that pipes and cables are correctly secured and free from potential chafing
- checking for system leaks under pressure (such as oil, hydraulic, fuel, coolant)
- cranking the engine to obtain initial oil pressure
- carrying out start-up procedures, and confirming that the engine meets the required standard
- checking for 100% throttle opening
- monitoring temperatures and pressures (such as oil, coolant and hydraulic, pneumatic)
- carrying out carburettor vacuum testing
- carrying out ignition timing
- carrying out electrical charging tests
- carrying out other specific tests
Check that completed removal and refit complies with one of the following:
- race associations
- vehicle manufacturer's specification
- team/company standards and procedures
- specific vehicle requirements