RECIPROCATING ENGINE (POWERPLANT1L)
Module
Overview of Reciprocating Engine Page 1 of 4
Title:
Week 1 – Prelim
Faculty: Engr. Richard E. Olipas, MEAM
Period
PRELIM - WEEK 1 – OVERVIEW
Aircraft Reciprocating Engine Overhaul
Top Overhaul
Reciprocating piston aircraft engines can be repaired by a top overhaul. This means an
overhaul of those parts on top of the crankcase, without completely dismantling the
engine. It includes removal of the units (i.e., exhaust collectors, ignition harness, intake
pipes) necessary to remove the cylinders. The actual top overhaul consists of
reconditioning the engine’s cylinders by replacing or reconditioning the piston and piston
rings, and reconditioning or plating the cylinder wall and valve-operating mechanism,
including valve guides if needed. A top overhaul is a little misleading, because it is really
an engine repair procedure and not a real overhaul as described earlier. Usually at this
time, the accessories require no attention other than that normally required during
ordinary maintenance functions. This repair is generally due to valves or piston rings
wearing prematurely. Many stress that if an engine requires this much dismantling, it
should be completely disassembled and receive a major overhaul.
Major Overhaul and Major Repairs
Major overhaul consists of the complete reconditioning of the powerplant. A
reciprocating engine would require that the crankcase be disassembled per the FAA; a
major overhaul is not generally a major repair. A certified powerplant-rated technician
can perform or supervise a major overhaul of an engine if it is not equipped with an
internal supercharger, or has a propeller reduction system other than spur-type gears.
At regular intervals, an engine should be completely dismantled, thoroughly cleaned,
and inspected. Each part should be overhauled in accordance with the manufacturer’s
instructions and tolerances for the engine involved. At this time all accessories are
removed, overhauled, and tested. Again, instructions from the manufacturer of the
accessory concerned should be followed.
General Overhaul Procedures
Because of the continued changes and the many different types of engines in use, it is
not possible to treat the specific overhaul of each engine in this text. However, there are
various overhaul practices and instructions of a nonspecific nature that apply to all
makes and models of engines. Any engine to be overhauled completely should receive
a runout check of its crankshaft or propeller shaft as a first step. Any question
concerning crankshaft or propeller shaft replacement is resolved at this time, since a
shaft whose runout is beyond limits must be replaced.
RECIPROCATING ENGINE (POWERPLANT1L)
Module
Overview of Reciprocating Engine Page 2 of 4
Title:
Week 1 – Prelim
Faculty: Engr. Richard E. Olipas, MEAM
Period
Receiving Inspection
The receiving inspection consists of determining the general condition of the total
engine as received, along with an inventory of the engine’s components. The accessory
information should be recorded, such as model and serial numbers, and the
accessories should be sent to overhaul if needed. The overhaul records should be
organized and the appropriate manuals obtained and reviewed along with a review of
the engine’s history (log books). The engine’s service bulletins, airworthiness directives,
and type certificate compliance should be checked. The exterior of the engine should be
cleaned after mounting it on an overhaul stand. [Figure]
Engine mounted on an overhaul stand
Disassembly
As visual inspection immediately follows disassembly, all individual parts should be laid
out in an orderly manner on a workbench as they are removed. To guard against
damage and to prevent loss, suitable containers should be available in which to place
small parts (nuts, bolts, etc.) during the disassembly operation.
RECIPROCATING ENGINE (POWERPLANT1L)
Module
Overview of Reciprocating Engine Page 3 of 4
Title:
Week 1 – Prelim
Faculty: Engr. Richard E. Olipas, MEAM
Period
Other practices to observe during disassembly include:
1. Drain the engine oil sumps and remove the oil filter. Drain the oil into a suitable
container; strain it through a clean cloth. Check the oil and the cloth for metal particles.
2. Dispose of all safety devices (safety wire, cotter pins, etc.) as they are removed.
Never use them a second time. Always replace with new safety devices.
3. All loose studs, and loose or damaged fittings, should be carefully tagged to
prevent being overlooked during inspection.
4. Always use the proper tool for the job. Use sockets and box end wrenches
wherever possible. If special tools are required, use them rather than improvising.
Aircraft Engine Removal and Replacement
Procedures for removing or installing an aircraft engine usually vary widely with the type
of aircraft and the type of engine. Thus, no single list of instructions can be provided as
a guideline for all engines. Because of the many types of engine and aircraft
installations and the large number of design variations within each type or category,
representative examples have been selected to illustrate the most typical installation
procedures for reciprocating, turboprop, and turbofan engines. There are some common
tasks that must be accomplished when replacing an aircraft engine. Most engines
require disconnecting and reconnecting electrical, hydraulic, fuel supply, intake and
exhaust air path components, engine controls, and engine mounting connections to the
airframe.
Reciprocating engines and gas turbine engines are used in this site to describe and
represent general and typical procedures for engine buildup, removal, preservation,
storage, and installation. Although these two types of engines have some common
areas, each procedure has been included to ensure adequate coverage of the engines
used in both heavy and light aircraft. It should be emphasized that while procedures for
specific engines and aircraft are included in this post, many pertinent or mandatory
references have been omitted because of their irrelevance to a general discussion. For
RECIPROCATING ENGINE (POWERPLANT1L)
Module
Overview of Reciprocating Engine Page 4 of 4
Title:
Week 1 – Prelim
Faculty: Engr. Richard E. Olipas, MEAM
Period
this reason, always reference the applicable manufacturer’s instructions before
performing any phase of engine removal or installation.
Reasons for Removal of Aircraft Reciprocating and Turbine Engines
The following paragraphs outline the most common reasons for removing and replacing
an engine. Information to aid in determining engine conditions that require removal is
included; however, in every case, consult applicable manufacturer’s instructions as the
final authority in establishing the basis for engine replacement.
Engine or Component Lifespan Exceeded
Engine life is dependent upon such factors as operational use, the quality of
manufacture or overhaul, the type of aircraft in which the engine is installed, the kind of
operation being carried out, and the degree to which maintenance is accomplished.
Thus, the manufacturer sets engine removal times. Based on service experience, it is
possible to establish a maximum expected time before overhaul (TBO) or span of time
within which an engine needs to be overhauled. Regardless of condition, an engine
should be removed when it has accumulated the recommended maximum allowable
time since the last overhaul.
Engine Sudden Stoppage
Sudden stoppage is a very rapid and complete stoppage of the engine. It can be caused
by engine seizure or by one or more of the propeller blades striking an object in such a
way that revolutions per minute (rpm) goes to zero in less than one complete revolution
of the propeller. Sudden stoppage may occur under such conditions as complete and
rapid collapse of the landing gear, nosing over of the aircraft, or crash landing. Sudden
stoppage can cause internal damage, such as cracked propeller gear teeth, gear train
damage, crankshaft counterweights becoming detuned or misalignment, or damaged
propeller bearings. When sudden stoppage occurs, the engine usually requires
replacement or disassembly and inspection as per manufacturer’s instructions.