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2024-2025 College Catalog

AVM 232 - Reciprocating Engine Overhaul

3.5 Credits, 7 Contact Hours
1.75 lecture periods 5.25 lab periods
Basic aircraft reciprocating engine overhaul. Includes engine components, wrist pins, connection rods, crankshafts, case, cam shafts, lifters, valves, push rods and tubes, rocker assemblies, accessories, lubrication, overhaul options overhaul credentials, overhaul procedures, reassembly after overhaul, engine installations, engine break-in, and test cell procedures.

Button linking to AZ Transfer course equivalency guide    button image Prior Learning and link to PLA webpage

Course Learning Outcomes
  1. Recall proficient knowledge of common reciprocating engine nomenclature
  2. Recall proficient knowledge of reciprocating engine inspection procedures
  3. Demonstrate common processes/procedures associated with reciprocating engine overhaul processes
Outline:
  1. General Requirements
    1. Power and Weight
    2. Fuel Economy
    3. Durability and Reliability
    4. Operating Flexibility
    5. Compactness
    6. Powerplant Selection
  2. Types of Engines
    1. Inline Engines
    2. Opposed or O-Type Engines
    3. V-Type Engines
    4. Radial Engines
  3. Reciprocating Engines 
    1. Design and Construction
    2. Crankcase Sections
    3. Accessory Section
    4. Accessory Gear Trains
  4. Crankshafts
    1. Crankshaft Balance 
    2. Dynamic Dampers 
  5. Connecting Rods
    1. Master-and-Articulated Rod Assembly
    2. Knuckle Pins
    3. Plain-Type Connecting Rods
    4. Fork-and-Blade Rod Assembly
  6. Pistons
    1. Piston Construction 
    2. Piston Pin
  7. Piston Rings
    1. Piston Ring Construction 
    2. Compression Ring
    3. Oil Control Rings
    4. Oil Scraper Ring
  8. Cylinders
    1. Cylinder Heads
    2. Cylinder Barrels
    3. Cylinder Numbering
  9. Firing Order
    1. Single-Row Radial Engines
    2. Double-Row Radial Engines
  10. Valves
    1. Valve Construction
  11. Valve Operating Mechanism
    1. Cam Rings
    2. Camshaft
    3. Tappet Assembly
    4. Solid Lifters/Tappets
    5. Hydraulic Valve Tappets/Lifters
    6. Push Rod
    7. Rocker Arms
    8. Valve Springs
  12. Bearings
    1. Plain Bearings
    2. Ball Bearings
    3. Roller Bearings
  13. Propeller Reduction Gearing
  14. Propeller Shafts
  15. Reciprocating Engine Operating Principles
  16. Operating Cycles
    1. Four-Stroke Cycle
    2. Two-Stroke Cycle
    3. Rotary Cycle
    4. Diesel Cycle
  17. Reciprocating Engine Power and Efficiencies
    1. Work
    2. Horsepower
    3. Piston Displacement
    4. Area of a Circle
    5. Compression Ratio
    6. Indicated Horsepower
    7. Brake Horsepower 
    8. Friction Horsepower
    9. Friction and Brake Mean Effective Pressures
    10. Thrust Horsepower
  18. Efficiencies
    1. Thermal Efficiency
    2. Mechanical Efficiency
    3. Volumetric Efficiency
    4. Propulsive Efficiency
  19. Principles of Engine Lubrication
    1. Types of Friction
    2. Functions of Engine Oil
  20. Requirements and Characteristics of Reciprocating Engine Lubricants
    1. Viscosity
    2. Viscosity Index
    3. Flash Point and Fire Point
    4. Cloud Point and Pour Point
    5. Specific Gravity
  21. Reciprocating Engine Lubrication Systems
    1. Combination Splash and Pressure Lubrication
    2. Lubrication System Requirements
    3. Dry Sump Oil Systems
    4. Oil Tanks
    5. Oil Pump
    6. Oil Filters
    7. Oil Pressure Regulating Valve
    8. Oil Pressure Gauge
    9. Oil Temperature Indicator
    10. Oil Cooler
    11. Oil Cooler Flow Control Valve
    12. Surge Protection Valves
    13. Airflow Controls
    14. Dry Sump Lubrication System Operation
    15. Wet-Sump Lubrication System Operation
  22. Lubrication System Maintenance Practices  
    1. Oil Tank
    2. Oil Cooler
    3. Oil Temperature Bulbs
    4. Pressure and Scavenge Oil Screens
    5. Oil Pressure Relief Valve
  23. Recommendations for Changing Oil
    1. Draining Oil
    2. Oil and Filter Change and Screen Cleaning 
    3. Oil Filter Removal Canister Type Housing
    4. Oil Filter/Screen Content Inspection
    5. Assembly of and Installation of Oil Filters
    6. Troubleshooting Oil Systems
  24. Engine Cooling Systems
    1. Reciprocating Engine Cooling Systems
    2. Reciprocating Engine Cooling System Maintenance
    3. Maintenance of Engine Cowling
    4. Engine Cylinder Cooling Fin Inspection
    5. Cylinder Baffle and Deflector System Inspection
    6. Cylinder Temperature Indicating Systems
    7. Exhaust Gas Temperature Indicating Systems
  25. Reciprocating Engine Overhaul
    1. Top Overhaul
    2. Major Overhaul and Major Repairs
  26. General Overhaul Procedures
  27. Receiving Inspection
  28. Disassembly
  29. Inspection Process
    1. Visual Inspection
    2. Cylinder Head
    3. Piston, Valve Train, and Piston Pin
    4. Crankshaft and Connecting Rods
  30. Cleaning
    1. Degreasing
    2. Removing Hard Carbon
  31. Structural Inspection
    1. Dye Penetrant Inspection
    2. Eddy Current Inspection
    3. Ultrasonic Inspection
    4. Magnetic Particle Inspection
    5. X-ray
  32. Dimensional Inspection
    1. Cylinder Barrel
    2. Valves and Valve Springs
    3. Crankshaft
    4. Checking Alignment
    5. Repair and Replacement
    6. Cylinder Assembly Reconditioning
    7. Piston and Piston Pins
    8. Valves and Valve Springs
    9. Refacing Valve Seats
    10. Valve Reconditioning
    11. Valve Lapping and Leak Testing
    12. Piston Repairs
    13. Cylinder Grinding and Honing
  33. Reassembly
  34. Installation and Testing
    1. Engine Testing of Reciprocating Engines
    2. Test Cell Requirements
    3. Engine Instruments
    4. Carburetor Air Temperature (CAT) Indicator
    5. Fuel Pressure Indicator
    6. Oil Pressure Indicator
    7. Oil Temperature Indicator
    8. Fuel Flow Meter
    9. Manifold Pressure Indicator
    10. Tachometer Indicator
    11. Cylinder Head Temperature Indicator
    12. Torquemeter
    13. Warning Systems
  35. Reciprocating Engine Operation
    1. Engine Instruments
    2. Engine Starting
    3. Pre-Oiling
    4. Hydraulic Lock
    5. Engine Warm-Up
    6. Ground Check
    7. Fuel Pressure and Oil Pressure Check
    8. Propeller Pitch Check
    9. Power Check
    10. Idle Speed and Idle Mixture Checks
    11. Engine Stopping
  36. Basic Engine Operating Principles 
    1. Combustion Process
    2. Detonation
    3. Pre-Ignition
    4. Backfiring
    5. Afterfiring
  37. Factors Affecting Engine Operation
    1. Compression
    2. Fuel Metering
    3. Idle Mixture
    4. Induction Manifold
    5. Operational Effect of Valve Clearance
  38. Engine Troubleshooting
    1. Valve Blow-By
  39. Cylinder Compression Tests
    1. Differential Pressure Tester
    2. Cylinder Replacement
  40. Cylinder Removal
  41. Cylinder Installation
  42. Cold Cylinder Check

Effective Term:
Fall 2024