AERO ENGINE MAINTENANCE AND

REPAIR

HINDUSTAN INSTITUTE
OF TECHNOLOGY AND
SCIENCE
 MODULE - 03

OVERHAUL OF PISTON ENGINE

Symptoms of failure
Fault diagnostics
Case studies of different engine systems
l:Tools and equipment requirements for various checks and
alignment during overhauling
Tools for inspection
Tools for safety and for visual inspection
Methods and instruments for non destructive testing techniques
Equipment for replacement of part and their repair. Engine
testing: Engine testing procedures and schedule preparation
Online maintenance.
 What is Overhaul ?

Overhaul is a procedure where the engine is disassembled,

cleaned and re-assembled with the same components.

This is done with the guidelines and rules stated in the standard
DGCA and FAA manual
 Overhaul Vs Repair

Overhaul Repair

An overhauled engine is A repair engine undergoes same

disassembly cleaning and re- procedure as that of overhaul but
assembly of engine with same use components of a new engine.
components.

It is tested according to the It is tested according to the

performance of used engine performance of a newly built
components. engine.
 Need for Overhaul

Critical dimensions of components might have changed

which may
• Lead to excess fuel consumption
• Increase in vibrations etc.
Foreign materials, sludge, carbon residue deposit in
engine leading to corrosion.
Metals in certain parts may have been crystallized due to
repeated thermal stress.
 Basic Overhaul Procedure

➢ Receiving inspection
➢ Disassembly
➢ Visual Inspection
➢ Cleaning
➢ Structural inspection
➢ Dimensional inspection
➢ Replacement and repair
➢ Reassembly
➢ Engine testing
 Tools and Equipment
Engine Shop equipment
• Arbor press
• Crank shaft wrench
• Magneto test stand
• Drill press
• Parts tray
• Engine lathe
• Heating equipment's
• Lifting sling
• Test stand and propellers, timing disk, vises
• Crank shaft tread cap
• Chain hoist
• Magneto timing tools
• Overhaul stand
 Tools and Equipment
➢ Hand tools
▪ Socket wrenches, box wrenches, bushing wrenches
▪ Torque wrenches, diagonal cutters, drill motors, end
wrenches, stud pullers
▪ Pliers
➢ Measuring tools
• Depth gauges, small hole gauges, surface gauges, dial
gauges, Surface plates, height gauges, telescope
gauges.
• Vernier calliper
 Engine Overhaul Tools
➢ Connecting rod alignment tools, piston ring
compressors, gear pullers value guide tools, tap and
die tools, valve seat, grinding equipment’s
➢ Ignition hardness tools
➢ Piston ring compressor.
 Receiving Inspection
INVENTORY
The receiving inspection report should be made on a
standardized form and a copy of this form should be given to
the owner.

ORGANIZATION OF THE ENGINE RECORDS

• FAA type certificate data sheet must be reviewed to ensure
that the engine conforms to its type certification.
• From time to time, engine manufactures issue special
service bulletins that require alteration.
• FAA issues Airworthiness directive pertaining to aircraft
and engine should made to correct discrepancies or to
improve the reliability of the unit.
DISSASSEMBLY
• The tags are stamped with the work order number.
• Added additional tags to show the locations.
Abrasion – Erosion
Runout – Wobble of the rotation parts
Brinelling – Ball bearing (force press)
Scoring - Deep scratches caused by hard particles
Burning - Excess temperature
Scratches - Shallow thin lines, varying in degree of depth and width
Burr - Sharp edge of metal
Scuffing or Pickup- Transfer of metal from one surface to a mating surface
under heavy force without adequate lubrication
Chafing - wear due to rubbing of 2 parts without lubrication
Peening - Striking of surface by blunt object
Chipping - Breaking of small pieces carless handling
Pitting or Spalling - Deep cavities with sharp edges
Corrosion - Electrolytic chemical decomposition
Growth – Elongation due to excessive heat and centrifugal force
Crack A - Separation of metal (fatigue stress)
Oxidation - Aluminium oxide protects but iron oxide destructs
Dent - Sheet metal (Impact of hard surfaces)
Nick - Sharp sided depression with a V-shaped bottom
Elongation - Increases in length
Flaking - Breaking away of surface coating
Fretting - Surface erosion caused by very slight movement
Galling - Severe erosion of metal pressed tight together
Gouging - Tearing away between hard material over soft material
Grooving - Formation of channel worn into metal due to poor alignment
Indentation - Dent or depression severe bows
Cleaning
• To clean the engine before disassembly
• To clean the partes after disassembly

Two types of cleaning required

1. Degreasing - removal of oil, soft types of dirt and soft
carbon
2. Decarbonizing - Removal of hard carbon deposits

Vapour Degreasing

Decarbonizing
• Stripping
• Grit blasting
• Vapour blasting
Structural Inspection – NDT Equipment’s
To determine the structural integrity
Engine parts are structurally inspected by NDE

1. Liquid Penetrant method

2. Eddy current method
3. Magnetic inspection method
4. Ultrasonic testing
5. X-Ray method
 Eddy current testing

Eddy current testing is particularly well suited for detecting

surface cracks but can also be used to male electrical
conductivity and coating thickness measurement. Here a
small surface probe is scanned over the part surface in all
attempt to detect crack.
DIMENSIONAL INSPECTION
To determine the degree of wear for parts of the engine where moving surface
are in contact with other surfaces.
Equipment for replacement of parts and their
repair
Unrepairable parts components should have been discarded, repairable parts
labelled and parts requiring no further action organized for reassembly on a
parts rack.
• Cylinder - Checks for the wear and damage, do the cleaning, reseating
• Cylinder heads – Check for cracks develop in the cylinder heads
• Studs – Exhaust pipes attached to the cylinder subject to severe corrosion
• Valve guides, Fins
• Valve seats
• Valves
• Rocker arm, Cylinder barrels, Crack case

Reassembly
Piston, Piston rings, Piston pins, Exhaust valves, Valve keepers, Main and
rod bearing, Bushing, Connecting rods, Bolts nuts, All hoses, Gaskets, Seals,
Cotter pins, Circlips, Lock plates, all parts has to be properly assembled.
TORQUE VALUES
INSTALLATION
The assembled engine is ready for installation in a test cell where it will be
tested, run in and finally preserved for storage.
The engine test stand should be mounted in a test cell and tested for
• Fuel consumption
• Power output
• Oil consumption
• Conduction of heat to the oil
• Standard engine performance

1. Test club should be used use the test stand for all testing make the
model of engine to be installed.
2. Hoist the engine into place align mounting brackets
3. Installing mounting bolts washer ,lock washers and nuts. tighten nuts to
proper torque
4. Install short exhaust stacks with gaskets to cylinder exhaust ports.
5. Connect the fuel supply line to the engine driven pump inlet.
6.Connect the oil supply and return lines if the engine is dry sump
type
7.Attach CHT sensing units
8.Connect the magneto switch wires to the magneto
9.Connect the pressure line for the oil pressure guage
10.Connect the pressure line for the fuel pressure guage
11.Connect the oil temp gage
12.Connect manifold pressure line
13.Connect throttle control
14.Connect electric cable to starter
15.Connect ground cable to the crankcase
16.Connect tachometer cable
17 .install suitable cooling system
18.Install test propellar
19.Service the engine with proper grade of lubricating oil.
20.Perform complete inspection of the installation .
Piston Engine Testing Procedure After Overhaul
1. Pre-oiling: Before the engine is started for the first time, it should be pre-
oiled to remove air trapped in oil passages and lines and to ensure that all
bearing surfaces are lubricated

One method:
• One spark plug is removed from each cylinder.
• The crank case or external oil tank to be filled with oil for run-in and
• The engine is cranked with the starter until an oil pressure indication is read
on the oil pressure gauge.

Another method:
Oil is forced by means of a pressure oiler at a prescribed pressure, through the oil
galleries until it comes out an oil outlet or the opposite end of an oil gallery.
Power check
• Manufacturer’s overhaul manual provides instruction and run in
schedule for a newly overhauled engines.
• The purpose of run in is to permit newly installed parts to burnish or
wear in, piston rings to seat against cylinder wall, and valves to
become seated.
• And also makes it possible to observe the engine operation under
controlled conditions.
• To ensure proper operation from idle to 100 percent power.
• The time during which an engine is operated at full power is referred
to as power check.
• The run in should be accomplished with the engine installed in a test
cell equipped as specified in the manufacturer’s overhaul manual
Oil consumption run
1. An oil consumption run is made at the end of the test.
2. Record the oil temperature.
3. Stop the engine
4. Place a previously weighed container under the oil tank or oil sump.
5. Remove the drain plug.
6. Allow the oil to drain for 15 mints.
7. Replace the drain plug.
8. Weigh the oil and the container.
9. Record the weight of the oil (total weight less the weight of the container).
10. Replace the oil in the tank or sump.
11. Start the engine, warmup the engine to the specified rpm and operate at
this speed for 1 hour.
12. At the end of one hour of operation with the same oil temperature drain the
oil as before.
13. The difference in oil weights at the start and end of the run will give the
amount of oil used in 1 hour.
Overhaul Manual
➢ Every engine has its own overhaul manual given by the
manufacturer.

➢ This manual provides with the proper procedure and technique to

be followed while overhauling that engine.

➢ The overhaul manual prepared by the manufacturer is the most

valuable source of information for that particular model engine.

➢ The technician must be careful enough to follow the manual

properly.
Certification of Overhaul Station

➢ The certified repair or overhaul station as defined by FAA states

“a Facility for the maintenance, repair and alteration of
airframe, powerplant, propellers or appliances holding a valid
aircraft manual and tools issued by the administrator or the
aircraft manufacturer”.

➢ All agencies currently approved by the FAA are listed in the

consolidated listing of “FAA certified repair stations”.
Safety Precautions
➢ The Arrangement of the shop should be in such a way that crowding should
not exist.

➢ Materials and tools must be stored in proper racks and containers.

➢ Electric equipment and power outlets must be correctly identified for

voltage and power handling capability.

➢ Properly designed engine hoisting equipment must be available for lifting

engines.

➢ Operators of lathes, Machine tools, drills and grinders must wear safety
goggles.

➢ The floor of the shop should have a surface which does not become
slippery.
Safety Precautions
➢ Personnel should take care to stay clear of an engine which is being hoisted
except as necessary to prevent it from swaying or turning.

➢ Flammable liquids must be stored in an approved fireproof area. The

approval is normally granted by the local fire department.

➢ The area where engines are run should be paved and kept free of all debris
which could be picked up air currents caused by a propeller.

➢ Adequate lighting must be provided for all areas.

➢ Suitable engine overhaul stands must be provided for each types of engines
to be overhauled. The design of engine stands varies with the type of
engine.