Removal and fitting fuel systems to prototype engines for test
Overview
This standard identifies the competences you need to carry out the removal and fitting of fuel systems and other components to prototype engines being prepared for test in a vehicle or on a dynamometer. Fitment and set-up of diesel and petrol units will be covered, and will include components such as fuel pumps, wiring looms, non-return valves, flexible hoses, thermocouples and transducers, in accordance with approved procedures.
It covers a range of prototype engines including petrol, diesel and hybrid. The removal and fitting methods and techniques will include assembling the equipment from sub-assembly and component level, protecting exposed components, checking components for suitability, making mechanical and electrical connections, releasing stored pressure, setting, aligning and adjusting components, tightening fasteners to the required torque, and replenishing oils, greases and fluids.
On completion of the removal and fitting activities, you will be required to carry out a range of final checks, tests and adjustments, such as pressure checking the system for potential fuel leaks, checking electrical looms for correct routeing and security for prevention of wear and chafing, checking hoses and pipework for correct routeing and security for prevention of wear and chafing, to ensure that the system meets the required specification.
Your responsibilities will require you to comply with organisational policy and procedures for the removal and fitting 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 fitting techniques and procedures to motorsport fuel systems and components. You will understand the removal and fitting 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 fitting 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 fitting activities.
You will understand the safety precautions required when working on prototype engines, 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 requirement
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 manual/drawing, job instructions and specifications that are used during the removal and fitting of fuel systems to prototype engines, and how to interpret them correctly
- how to identify different types of fuel systems used on prototype engines
- the removal and fitting methods and procedures used, and the importance of adhering to these
- how the components are to be aligned and positioned, prior to securing, and the tools and equipment that are used (jigs and fixtures)
- the various mechanical fasteners and other components that are used (the use of threaded fasteners and studs, hose fittings, gaskets, seals and specialised fasteners)
- the application of greases, sealants and fluids within the removal and fitting activities, and the precautions that must be taken when working with them
- the company `lifing' procedure for components, to meet the team's requirements
- the operational function of the various fuel systems that are used
- the use of torque wrenches, and the importance of ensuring that they are adjusted to the required settings
- preparation to be undertaken on the components, prior to fitting them onto the prototype engine
- how to apply correct lubricant/fluids to fuel system components, and the correct waste disposal of surplus fluids
- the consumables, tools and equipment used for removal and fitting of the fuel systems to the vehicle
- the importance of using the specified fasteners for the installation, and why you must not use substitutes
- how to deal with components or fastening devices that are incorrectly fitted, damaged or have other faults
- the quality control procedures to be followed during the removal and fitting operations
- the various tests, checks and adjustments to be made on completion of the removal and fitting activities
- how to recognise assembly defects (incorrect installation, ineffective fasteners, component damage, fuel leaks)
- the importance of ensuring that the completed assembly is free from foreign objects, dirt or other contamination
- the importance of ensuring that all sealants and lubricants used are of the correct specification for the fuel system being re-built
- how to check that the tools and equipment to be used are correctly calibrated, and are in a safe, tested and serviceable condition
- the importance of ensuring that all tools are used correctly, checked and stored after use
- problems with the removal and fitting operations, and the importance of informing appropriate people of non-conformances
- the procedure for the safe disposal of waste materials, scrap components, oils and fuel
- 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 fitting of the prototype engine fuel systems:
- plan the removal and fitting activities prior to beginning the work
- obtain and use the appropriate documentation (such as job instructions, drawings, specifications, planning and 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 and maintain safe access and working arrangements for the work area, and ensure that any appropriate environmental conditions can be met
- ensure that the work area is suitably prepared for the removal and fitting activities to take place
- obtain approval to carry out the fuel system removal and fitting activities
- position and secure the vehicle, using the correct equipment
- ensure that any required consumables are available
- return all tools and equipment to the correct location on completion of the fitting activities
- leave the work area and vehicle in a safe and appropriate condition on completion of the activities
Remove and fit fuel system components on two of the following types of engine:
- petrol inline
- diesel inline
- hybrid (such as electric, LPG)
- petrol vee
- diesel vee
- rotary
Use appropriate methods and techniques to remove and fit fuel systems, to include all of the following:
- removing covers
- isolate hybrid high voltage systems (where appropriate)
- making an initial judgment of the condition of the fuel system (such as damage, missing components)
- draining and removing fuel
- dismantling the fuel system to an appropriate level
- replacing all 'lifed' items (such as filters, seals, gaskets)
- marking and labelling components to aid reassembly
- setting, aligning and adjusting replaced components
- disconnecting hoses and hard lines
- disconnecting electrical plugs and wiring looms (where appropriate)
- checking components for serviceability
- replacing/changing components
- re-assembling fuel system components
- fitting and connecting hoses and hardlines following the correct routeing
- making mechanical connections and tightening fastenings to the required torque
- protecting exposed components, looms and pipework
- reconnecting wiring looms following the correct routeing (where appropriate)
- refilling the fuel system
- priming/bleeding the fuel system
Use five of the following during the removal and fitting activities:
- jigs
- specialist tools
- alignment devices
- fixtures
- torque wrenches
- fuel filling devices
- hand tools
- measuring equipment
- priming devices
Remove and fit eight of the following prototype engine fuel system components:
- fuel supply lines
- mechanical fuel pumps
- throttle bodies
- fuel temperature sensors
- wiring looms
- electronic sensors
- auxiliary tanks
- non-return valves
- fuel rails
- collector pots
- injectors
- fuel return system
- electric fuel pumps
- flexible hoses
- fuel pressure sensors
- other specific fuel system components
Carry out final checks and adjustments on the fuel system, to include six of the following:
- ensuring that all fuel system components are free from foreign objects, dirt or other contamination
- ensuring that the fuel system assembly is complete and complies to specification
- checking that all mechanical fixings are secure and have been `torqued' to specification and, where appropriate, that bolt securing devices are fitted
- pressure checking the system for potential fuel leaks
- checking electrical looms for correct routeing and security for prevention of wear and chafing
- checking hoses and pipework for correct routeing and security for prevention of wear and chafing
- checking that low pressure pumps are fitted in correct position
- making adjustments, using prototype engine control module
- adjusting fuel delivery is set to specification, using prototype engine control module
- checking and adjusting fuel delivery with standard and multi-injection injectors
- carrying out other specific checks/tests
Check refitted fuel systems, in comply with one of the following:
- current industry standards, codes of practice and procedures
- customer standards and requirements
- engineer developed procedures
- specific engine requirements
- company-specific requirements