Product Overview

This Engine and Driveline Repair SWMS is a comprehensive Safe Work Method Statement designed to identify, control, and minimise risks associated with engine, gearbox, and driveline work in automotive and mechanical environments. It provides detailed, practical controls across multiple aspects of engine and driveline repair to support robust WHS compliance and safer workshop operations.

Activities & Specific Tasks Covered

This document includes specific risk controls for:

• Adjusting gear linkages, including safe access, isolation, and post-adjustment testing procedures
• Adjusting throttle bodies with controls for hot surfaces, moving parts, and fuel system exposure
• Attaching coupling devices and driveline components with correct lifting, alignment, and torque procedures
• Bench testing transmissions, including securing units, guarding rotating parts, and managing noise and vibration
• Safe handling, removal, and installation of catalytic converters, including controls for heat, fumes, and manual handling
• Changing motor belts and pulleys, including lockout/tagout, tensioning, guarding, and verification of direction of rotation
• Checking and cleaning fuel injectors with controls for fuel spray, ignition sources, and hazardous substances
• Conducting repairs on equipment with internal combustion engines, including isolation, ventilation, and fire prevention
• Cutting driveline tubes with appropriate cutting equipment, guarding, eye and face protection, and hot work controls
• Cylinder honing tasks, including secure work holding, controlling airborne contaminants, and safe use of power tools
• Disassembling drive shafts with procedures for supporting components, marking alignment, and managing stored energy
• Disconnection and removal of drive shafts, including safe lifting, correct use of stands, and prevention of crush injuries
• Dismantling gearboxes with step-by-step controls for draining fluids, handling heavy components, and preventing pinch points
• Driveline inspection and repair, including fault diagnosis, test procedures, and safe road testing requirements
• Engine and motor operation tasks, including controlled start-up, warm-up, emissions management, and emergency shutdown
• Use of vehicle hoists, stands, and jacks to safely support vehicles during engine and driveline work
• Housekeeping, spill management, and waste disposal for oils, fuels, coolants, and other automotive fluids
• Performing engine overhauls and major rebuilds, including cylinder head removal, block cleaning, and component replacement
• Engine tune-ups and system optimisation, including spark plug replacement, ignition timing checks, and emissions verification
• Setting and adjusting engine timing (camshaft, crankshaft, injection), including lockout procedures and alignment tool use
• Valve grinding and cylinder head servicing, with controls for silica dust, rotating tools, and chemical cleaning agents
• Undertaking clutch repairs and replacements, including flywheel resurfacing, alignment tool use, and transmission support
• Installing and removing flywheels, drive plates, and clutch assemblies with torque sequence compliance and crush hazard controls
• Fitting synchro rings, selector forks, and internal gearbox components during manual transmission rebuilding
• Rebuilding and repairing transfer cases and differentials, including gear alignment, preload adjustment, and seal replacement
• Swapping differential gears and adjusting gear mesh patterns with precision tools and lift assistance
• Installation and removal of complete transmissions and gearboxes, including hoist use, alignment, and bellhousing bolting
• Pressure testing transmissions and driveline components for leaks, including fluid containment and pressure relief
• Installing and servicing power take-offs (PTOs), including driveline alignment and guarding of rotating shafts
• Working on or near running engines for diagnostics or adjustments, including exclusion zones, PPE, and entanglement prevention
• Inspecting and replacing drive belts, fan belts, and tensioners with isolation and rotation hazard controls
• Replacing spark plugs and high-tension ignition components with electrical isolation and hot surface precautions
• Repairing exhaust systems beyond catalytic converters, including manifolds, mufflers, and brackets, with heat and fume controls
• Fitting new gaskets and seals with correct surface preparation, torque sequences, and chemical exposure management
• Replacing and bleeding power steering systems, including high-pressure fluid hazards and lockout procedures
• Removing, installing, and pressure testing radiators and cooling system components with coolant handling and burn prevention
• Tightening bolts on high-pressure fuel or hydraulic lines with calibrated tools and splash/eye protection
• Operating diesel and petrol engines during diagnostics, including ventilation, fire watch, and runaway engine protocols
• Using tailshaft balancers and dynamic balancing equipment with guarding, rotation controls, and hearing protection
• Hook-up and inspection of fifth wheel coupling systems on heavy vehicles, including load security and fall prevention
• Working inside engine compartments with confined space awareness, pinch points, and electrical isolation
• Speed governor and engine control module (ECM) adjustments with electronic safety and diagnostic tool protocols

Who is this for?

This SWMS is designed for automotive mechanics, heavy vehicle and diesel fitters, mobile plant technicians, driveline specialists, and workshop supervisors responsible for engine, gearbox, and driveline repair activities.

Specific Job Steps & Hazards Covered

Legislation & References

This document was researched and developed to align with:

• Work Health and Safety Act 2011
• Work Health and Safety Regulations 2017
• Managing Risks of Plant in the Workplace Code of Practice: Guidance on controlling risks associated with machinery, tools, and equipment
• Managing Risks of Hazardous Chemicals in the Workplace Code of Practice: Requirements for safe handling of fuels, solvents, cleaners, and other automotive chemicals
• How to Manage Work Health and Safety Risks Code of Practice: Risk management framework applied to engine and driveline repair tasks
• Managing Noise and Preventing Hearing Loss at Work Code of Practice: Controls for noise from engines, cutting, and bench testing
• Safe Work Australia – Guide for Managing the Risks of Machinery and Equipment: Practical guidance for guarding, isolation, and maintenance activities
• AS/NZS 4024 Safety of Machinery (relevant parts): Principles for machinery guarding and safe access around rotating and moving parts