Reciprocating Engine Systems
and Overhaul

Introduction:  This course will provide the powerplant maintenance technician with the theory, repair, inspection of the following powerplant systems: Induction, Cooling, Exhaust, and Lubrication.  The above will be intergrated into the overhaul and repair of reciprocating engines and the final testing and installation of the engine back into an airframe.

Objectives:

    Induction Systems:

Level 2 - Inspect, check, troubleshoot, service, and repair engine ice and rain control systems.   Inspect, check, service, and repair heat exchangers and superchargers.

Level 3 - Inspect, check, service and repair carburetor air intake and induction manifolds.

    Engine Cooling Systems

Level 2 - Repair engine cooling system components

Level 3 - Inspect, check, troubleshoot, service, and repair engine cooling systems.

    Engine Exhaust Systems

Level 2 - Repair engine exhaust system components

Level 3 - Inspect, check, troubleshoot, service, and repair engine exhaust systems.

    Engine Lubrication Systems

Level 2 - Identify and select lubricants.  Repair engine lubrication system components.

Level 3 - Inspect, check, service, troubleshoot, and repair engine lubrication systems.

    Reciprocating Engines

Level 1 - Inspect and repair 14 cylinder or larger radial engines.

Level 2 - Overhaul reciprocating engines

Level 3 - Inspect, check, service, and repair opposed and radial engines and reciprocating engine installations.  Install, troubleshoot, and remove reciprocating engines.

Required Texts

1. Aircraft Powerplants (AP)
2. AC 43.13-1B (AC43.13)
3. FAR's
4. Lycoming Overhaul Manual - Direct Drive Engines

Reading Assignments

Required Tools

Your tool set

Speciality tools are provided by the department

Evaluation and Performance

This course will be evaluated in two sections; one being the theory portion and the other being the Practical/Shop portion.

The theory portion will be weighted so that it represents 30 percent of your grade and will include the following, Quizzes, Unit Tests, and Final Test.

The practical/shop portion will be weighted so that 50 percent is your projects and 20 percent is your shop grade.  NOTE:  There will be no tolerance for horseplay, or practical jokes in the laboratory or shop.  There are to be no automobile parts brought into the shop during this semester and that includes the cleaning room.  Carelessness, a disregard of safe practices, etc. will lower both your project and shop grades and if serious enough could lead to dismissal from the course.

Class Schedule

January  9, - Induction Systems, Ice and Rain Control
January 10, - Turbochargers, Normalizers, Superchargers
January 11, - Repair, Service, Troubleshooting - Unit Test
January 12, - Engine Exhaust Systems

January 15, - Holiday (Martin Luther King Jr.)
January 16, - Exhaust Systems continued - Unit test
January 17, - Engine Development, Theory and Nomenclature
January 18, - Volumetric Efficiency and Firing Orders
January 19, - Reasons for overhaul and the overhaul work station.  (Engine inventory and Removal )

January 22, - Engine disassembly, cleaning procedures and pre-inspection
January 23, - Airworthiness Directives, Service bulletins - Letters - Instructions, and Part ordering
January 24, - Engine Cooling Systems
January 25, - Cooling systems continued and Unit Test
January 26, - Cylinder Inspection

January 29, - Stud removal and installation
January 30, - Crankcase and accessory case.
January 31, - Pistons, piston pins and rings
February 1, - Crankshaft and connecting rods
Fecruary 2, - The Valve train

February  5, - Valves, Valve guides and seats
February  6, - Engine bearings - Cleaning and inspection
February  7, - Part acceptance and verification
February  8, - Engine Mounts
february  9, - Engine nose cases, loads and propeller speed reduction

February 12, - Engine Lubrication Systems
February 13, -
February 14, -
February 15, -
February 16, -

February 19, - Holiday (President's day)
February 20, -
February 21, -
February 22, -
February 23, -

February 26, -
February 27, -
February 28, -
March  1, -
March  2, -

March  5, -
March  6, -
March  7, -
March  8 - 18 (SPRING BREAK)

March 19, - Assembly Procedures and Mandatory Phase checks
March 20, -
March 21, - Crankshaft and rod assemblies
March 22, -
March 23, - Crankcase and accessory case assemblies

March 26, -
March 27, - Cylinder assemblies
March 28, -
March 29, - Installation and timing of magnetos
March 30, -

April  2, - Fuel control unit installation and rigging
April  3, -
April  4, - Engine control installation and rigging
April  5, -
April  6, - Propeller installation, vibration, and balance

April  9, -
April 10, - Engine Break-in and system checks
April 11, -
April 12, - Engine Troubleshooting
April 13, -

April 16, -
April 17, -
April 18, -
April 19, -
April 20, -

April 23, -
April 24, -
April 25, -
April 26, -
April 27, -

April 30, -
May  1, -
May  2, -
May  3, -
May  4, -