AUTOMOTIVE INDUSTRY RETAIL, SERVICE & REPAIR - part 21

Automotive Industry RS&R  

AURM4413A Analyse and repair complex performance fuel systems 

©Australian National Training Authority 

 AUR99 Version 4.00 Review by 30 June 2004 

125 

 

AURM4413A Analyse 

and 

repair complex performance 

fuel systems 

Unit descriptor 

This unit covers the competency to inspect, analyse and repair 
complex fuel systems, associated components and refuelling 
equipment. This includes testing, determining repair and/or 
performance improvement strategies, conducting repairs, 
adjustments and post-repair checks. 

Prerequisites 

AUR03170A   Service petrol fuel systems 

AUR03166A   Repair petrol fuel systems 

AUR21171A   Service and repair electronic engine 

management systems 

 

ELEMENT PERFORMANCE 

CRITERIA 

1.  Identify and confirm 

the fault 

1.1 

Controlling body rules, category rules, supplementary 
regulations and team requirements are used to determine 
task specifications including configuration, equipment, 
quality and quantities 

1.2 

Benchmark specifications for a correctly functioning 
complex fuel system are accessed and interpreted 

1.3 

OH&S requirements including equipment and system 
isolation requirements and personal protection needs are 
observed throughout the work 

1.4 

The details of the fault are examined and available 
preliminary information is documented  

1.5 

The effects of the fault are identified and confirmed from 
direct and/or indirect evidence 

1.6 

Possible safety impacts of the fault are considered and 
responded to in accordance with regulatory and team 
obligations and practices 

2.  Prepare for fault 

analysis 

2.1 

Possible causes of the fault, including intermittent faults 
are identified from an analysis of technical support 
information and available on-board diagnostic systems 

2.2 

The most appropriate analysis process, including 
sequence, tests and testing equipment are developed 
and/or identified and selected from the range of available 
options 

2.3 

Testing equipment is obtained and prepared for the 
application in accordance with regulatory, manufacturer/ 
component supplier and team requirements 

AURM4413A Analyse and repair complex performance fuel systems 

Automotive Industry RS&R 

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AUR99 Version 4.00 Review by 30 June 2004 

©Australian National Training Authority 

 

ELEMENT PERFORMANCE 

CRITERIA 

2.  Prepare for fault 

analysis (continued) 

2.4 

Tools and material required to support the diagnostic 
process are identified, selected and prepared for use 

3.  Analyse the fault and 

determine 
repair/performance 
enhancement strategies 

3.1 

The selected analysis process is followed in accordance 
with specifications and directions and/or the locally 
authorised method 

3.2 

Test and testing equipment are applied in accordance 
with regulatory requirements and the manufacturer/ 
component supplier specifications 

3.3 

Test results and other diagnostic findings are verified, if 
necessary by using reliable alternate or optional 
processes 

3.4 

Authority is obtained to partly dismantle components, to 
permit an accurate inspection of analysed fault/s, if 
required 

3.5 

Valid conclusions are drawn about the cause and the 
direct and indirect consequences of the fault are drawn 
from available evidence and documented to team 
requirements 

3.6 

Options for rectifying the fault/enhancing performance 
are identified from research of technical support 
information 

3.7 

The most appropriate option is selected from an analysis 
of the options, the prevailing circumstance, regulatory 
requirements and team policies 

3.8 

The selected repairs/modifications/adaptation of 
equipment are documented and communicated to 
appropriate persons including the analysis outcome and 
repair requirements 

4. Conduct 

repairs/implement 
performance 
improvement strategies 

4.1 

Repairs and adjustments to components/sub-assemblies 
are carried out in accordance with 
manufacturer/component supplier specifications for 
methods, equipment used and tolerance relative to the 
system 

4.2 

Post-repair checks and vehicle start up are conducted 

5.   Clean up work area and 

maintain records 

 

5.1   Testing equipment and tools are returned to be cleaned, 

maintained and prepared ready for further use or stored in 
accordance with manufacturer/component supplier 
specifications and team requirements 

5.2   Surplus and unserviceable components are removed in 

accordance with team procedures 

Automotive Industry RS&R  

AURM4413A Analyse and repair complex performance fuel systems 

©Australian National Training Authority 

 AUR99 Version 4.00 Review by 30 June 2004 

127 

 

ELEMENT PERFORMANCE 

CRITERIA 

5.   Clean up work area and 

maintain records 
(continued) 

 

5.3   Problems with the work area and/or the operation of the 

equipment are identified and reported to appropriate 
persons 

5.4   Recording of work/vehicle documentation is inspected 

for completeness 

 

RANGE STATEMENT  

The Range Statement provides advice to interpret the scope and context of this unit of 
competency, allowing for differences between enterprises and workplaces. It relates to the unit 
as a whole and facilitates holistic assessment. The following variables may be present for this 
particular unit: 

Unit scope 

•  Work includes the maintenance of complex fuel systems 

used within the motorsport/performance enhancement 
environment. It includes the operation and function of 
complex fuel system components and systems, conduct of 
tests and interpretation of test results in order to analyse 
faults within complex fuel systems, determining repair 
and/or performance improvement strategies, conducting 
repairs, adjustments and post-repair checks 

•  A complex fuel system is defined as one that is a 

specialised motorsport/performance system which 
incorporates a configurable management/control system 
and may include a duplicate/backup supply system and 
injection or multiple carburetion configurations 

•  Fuel systems are to cover all sub-systems and components 

including fuel cells, pumps, pressure and/or flow 
regulation, management/control system and injection or 
multiple carburetion components 

•  Diagnosis is to cover that for module and parts 

replacement in related electrical, electronic, pneumatic 
control systems 

•  Fuel system faults covered by this unit include, but are not 

limited to, rough running, under/overfuelling, misfiring, 
poor performance, contamination and leakage 

•  Fuel system faults covered by this unit are to include 

indirect faults caused by the influence of external systems 
which may or may not be faulty in their primary operation 

AURM4413A Analyse and repair complex performance fuel systems 

Automotive Industry RS&R 

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AUR99 Version 4.00 Review by 30 June 2004 

©Australian National Training Authority 

 

RANGE STATEMENT  

Unit context 

•  OH&S requirements include relevant state and 

commonwealth legislation, safety management systems, 
controlling body requirements, manufacturer/component 
supplier specifications and safe operating procedures 

•  Work is carried out in accordance with legislative 

obligations (including environmental requirements), 
relevant health regulations, manual handling procedures 
and insurance requirements  

•  Work requires individuals to demonstrate analytical and 

organisational ability, judgement and problem solving 
skills in the analysis and maintenance of complex fuel 
systems 

•  Competency may be demonstrated in workplaces involved 

in the design, development, manufacture and maintenance 
of performance vehicles and/or performance vehicle 
components and assemblies used in motorsport 

Tools and equipment 

Tools and equipment may include, but are not limited to, 
hand and power tools, vacuum/pressure gauges, flow 
meters, exhaust analysers, multimeters, engine diagnostic 
computer hardware and software  

Components 

•  Components may include, but are not limited to: 

•  rollover valves 

•  fuel cells 

•  fuel lines 

•  breathers 

•  pick up pumps 

•  main pumps 

•  filters 

•  fuel pots / surge tanks / collector tanks 

•  pressure and temperature sensors 

•  injectors 

•  carburetors 

•  hoses and fittings 

•  refuelling equipment including churns/rigs, dry break 

valves, hoses and fittings 

Automotive Industry RS&R  

AURM4413A Analyse and repair complex performance fuel systems 

©Australian National Training Authority 

 AUR99 Version 4.00 Review by 30 June 2004 

129 

 

RANGE STATEMENT  

Personal protective 
equipment 

 

•  Personal protective equipment is to include that prescribed 

under manufacturer/component supplier specifications, 
legislation, regulations and enterprise policies and 
practices 

Information and 
procedures 

•  Controlling body rules, category rules and supplementary 

regulations  

•  Team/enterprise procedures relating to applying 

diagnosing and maintaining complex fuel systems  

•  Task instructions including work sheets, check lists, plans, 

drawings and designs 

•  Team procedures relating to reporting and communication 

•  Team procedures relating to the use of tools and equipment 

•  Manufacturer/component supplier specifications and 

application procedures for testing equipment and material 

•  Australian Design Rules (where applicable) 

 

EVIDENCE GUIDE 

The Evidence Guide identifies the critical aspects, knowledge and skills to be demonstrated 
to confirm competency for this unit. This is an integral part of the assessment of competency 
and should be read in conjunction with the Range Statement. 

Critical aspects of 
evidence 

•  Interpret and apply team requirements, controlling body 

and category rules and supplementary regulations  

•  Apply safety requirements including the isolation of 

equipment and the use of personal protective equipment 

•  Follow task instructions, operating procedures and 

inspection processes to:  

•  minimise the risk of injury to self and others 

•  prevent damage to competition vehicle or equipment 

•  achieve required outcomes within team time and 

quality standards 

•  Correctly analyse, repair and conduct post-repair checks 

on a minimum of three fuel system faults (on more than 
one fuel system type), and involve: 

•  rough running, under/overfuelling, misfiring, poor 

performance, contamination or leaks 

AURM4413A Analyse and repair complex performance fuel systems 

Automotive Industry RS&R 

130 

AUR99 Version 4.00 Review by 30 June 2004 

©Australian National Training Authority 

 

EVIDENCE GUIDE 

Critical aspects of 
evidence (continued) 

•  with at least one fault having possible combination 

causes involved in the sub-systems (fuel cells, pumps, 
pressure and/or flow regulation, management/control 
system and injection or multiple carburetion 
components)  

•  where the scope of the faults necessitates the use of a 

range of testing equipment 

•  Work effectively with others 

•  Modify activities to cater for variations in workplace 

context and environment 

Underpinning knowledge 

•  Workplace safety policies and procedures related to 

complex fuel systems 

•  Types, function, operations and limitations of complex 

fuel system and components 

•  Properties of fuels used within the motorsport industry 

including compatibility with fuel system components 

•  Complex fuel systems layouts 

•  Diagnosis and testing procedures and test instrument 

application 

•  Symptom and cause differentiation 

•  Repair and/or performance improvement strategies 

•  Removal, replacement and repair, adjustment and 

post-repair check procedures 

•  Diagnosis theory including concept, design and planning 

•  Record keeping procedures 

•  Procedures for reporting equipment faults and component 

defects 

•  Team guidelines regarding acceptable quality and 

tolerance levels 

•  Equipment safety requirements 

•  OH&S policies and procedures 

Automotive Industry RS&R  

AURM4413A Analyse and repair complex performance fuel systems 

©Australian National Training Authority 

 AUR99 Version 4.00 Review by 30 June 2004 

131 

 

EVIDENCE GUIDE 

Underpinning skills 

These include a number of processes that are learnt throughout work and life, which are 
required in most jobs. Some of these are covered by the national key competencies, although 
others may be added. The questions below highlight how these processes are applied in this 
competency unit. The number in brackets indicates the level to which the key competency 
needs to be demonstrated where (1) is where work is within set conditions and process, (2) is 
where the management or facilitation of conditions or process is exercised, and (3) is where 
the design and/or development of conditions or process is required. 

How will the candidate 
apply the following key 
competency in this unit? 

The candidate will need to: 

Collect, analyse and 
organise information 

 

Collect, analyse, organise and understand information related to 
complex fuel system analysis and repair 

 (Level 2)

Communicate ideas and 
information 

 

Communicate ideas and information to enable confirmation of 
work requirements, coordination of work with technical 
supervisors, other technicians and workers, and the reporting of 
work outcomes and problems 

(Level 2)

Plan and organise 
activities 

 

Plan and organise activities including the preparation and 
layout of the work area and the obtaining of equipment and 
material to avoid any back tracking, workflow interruptions or 
wastage 

(Level 2)

Work with others and in 
a team 

 

Work with others and in a team by recognising dependencies 
and using cooperative approaches to optimise workflow and 
productivity 

(Level 2)

Use mathematical ideas 
and techniques 

 

Use mathematical ideas and techniques to correctly interpret 
test results in order to determine required action for the 
maintenance of fuel systems 

(Level 2)

Solve problems 

 

Use pre-checking and inspection techniques to anticipate 
maintenance and repair problems, avoid reworking and avoid 
wastage 

(Level 2)

Use technology 

 

Use the workplace technology related to complex fuel systems 
including tools, equipment, calculators and measuring devices 

(Level 2)

AURM4413A Analyse and repair complex performance fuel systems 

Automotive Industry RS&R 

132 

AUR99 Version 4.00 Review by 30 June 2004 

©Australian National Training Authority 

 

EVIDENCE GUIDE 

Resource implications 

•  Access to tools, equipment and fuel systems as identified 

in the Range Statement including relevant technical 
references or information 

Method of assessment 

•  Assessment methods must confirm consistency of 

performance over time and in a range of workplace 
relevant contexts 

•  Assessment should be by direct observation of tasks and 

questioning on underpinning knowledge 

•  Assessment should be conducted over time and may be in 

conjunction with assessment of other units of competency 

Context/s of assessment 

•  Assessment may occur on the job or in a workplace 

simulated facility with relevant process equipment, 
material, work instructions and deadlines