DATE..

4/7/76

‘ADVISORY
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CIRCULAR
DEPARTMENT
OFTRANSPORTATION
FEDERAL
AVIATION
ADMINISTRATION
RECIPROCATING ENGINE OVERHAUL TERMINOLOGY AND
SUBJECT: STANDARDS

1. PURPOSE. or operators and engine overhaul facilities will

This advisory circular discusses engine over- have a better understanding of the terms and
haul terminology and standards that are being standards relating to those terms.
used in the aviation industry :
4. DISCUSSION.
a. To inform the owner or operator of the
variety of terms used to describe types of a. The selection of an overhaul facility by the
reciprocating engine overhaul. average aircraft owner is usually deter-
mined by the cost quoted by the engine
b. To clarify the standards used by the in- overhauler. Engine overhauls can lx ac-
dustry during reciprocating engine over- complished to a variety of standards. They
haul. can also be accomplished by many different
c. To review the Federal Aviation Regulations facilities, ranging from engine manufactur-
(FAR) regarding engine records and stand- ers, large repair stations, or individual
ards. powerplant mechanics. The selection of an
overhaul facility can and does, in most
2. REFERENCES. cases, determine the standards that, are used
FAR 43, Sections 43.9, 43.13 (a), and 43.13 (b) ; during overhaul. The FAR requirement in
FAR 91, Sections 91.173 and 91.175. Section 43.13(a) is that the person perform-
ing the overhaul shall use methods, tech-
3. BACKGROUND. niques, and practices that are acceptable to
the Administrator. In most cases, the
In the maintenance of aircraft engines, terms standards that are outlined in the Engine,
such as top overhaul, major overhaul, etc., are Manufacturer Overhaul hfanuals are stand-
used throughout the aviation industry. ThC ards acceptable to the Administrator.
standard to which an engine is overhauled
usually depends on the terms used by the person b. These manuals clearly st,ipulate the work
who is performing the engine overhaul. These that must bc accomplished during engine
terms are familiar to the aviation community, overhauls and out,linc limits and tolerances
but their specific meanings are not fully under- used during t,hc inspections. There is no
stood. This could result in similar engines being dictionary that provides a commonly ac-
overhauled to different tolerances. We belicvc cepted standard definition ‘of all the terms
that through the discussion that follows, owners used in the aviation industry. The terms

Initiated by: AFS-830

AC 42-11 417176

discussed in this advisory circular are of- facturer’s overhaul data, service bulletin,
fered for information purposes only and are. or an airworthiness directive.
not to be considered as definitions set forth (2) Top Overhaul consists of the repair of
in the Federal Aviation Regulations. parts outside of the crankcase and can
c. The only definition regarding engine over- be accomplished without completely dis-
haul is the word “rebuilt.” This is defined assembling the entire engine. It can
in FAR 91.175 and refers to rebuilt engine include the removal of cylinders, inspec-
maintenance records. tion and repair to cylinders, inspection
and repair to cylinder walls, pis-
5. ENGINE OVERHAUL TERMINOLOGY tons, valve-operating mechanisms, valve
a. “Rebuilt.” guides, valve seats, and the replacement
of pistons and piston rings. A top
(1) The term “rebuilt” is defined in FAR
91.175. The definition allows an owner overhaul is not recommended by all
or operator to use a new maintenance manufacturers. Some manufacturers in-
record without previous operating his- dicate that if a powerplant requires
tory for an aircraft engine rebuilt by work to this extent, it should be given
the manufacturer or an agency approved a complete overhaul.
by the manufacturer.
6. FITS AND LIMITS.
(2) A rebuilt engine as defined in FAR
91.175, “is a used engine that has been As discussed above, two kinds of dimensional
completely disassembled, inspected, re- limits are observed during engine overhaul.
paired as necessary, reassembled, tested, These limits are outlined in the engine overhaul
and approved in the same manner and manual as a “Table of Limits” or a “Table of
to the same tolerances and limits as a Dimensional Limits.” These tables, listing the
new engine with either new or used parts of the engine that are subject to wear,
parts.” All parts used must conform contain minimum and maximum figures for the
to the production drawing tolerances dimensions of those parts and the clearances be-
and limits for new parts or be of ap- tween mating surfaces. The lists specify two
proved oversized dimensions for a new limits as follows:
engine. a. Manufacturer’s Minimum and Maximum.
b. Overhaul. In the general aviation industry, These arc also referred to by some manu-
the term engine overhaul has two identifi- facturers as new parts or new dimensions.
cations that make a distinction between the These are the dimensions that all new parts
degrees of work done on an engine: meet during manufacture and are held to
(1) A major overhaul consists of the com- specific quality control standards as required
plete disassembly of an engine, in- by the FAR in the issuance of an Engine
spected, repaired as necessary, reassem- Type Certificate to a manufacturer. It is
bled, tested, and approved for return to important to note that new dimensions do
service within the fits and limits speci- not mean new parts are installed in an en-
fied by the manufacturer’s overhaul gine when a manufacturer or his authorized
data. This could be to new fits or 1imit.s representative present.s zero time records in
or serviceable limits. The determination accordance with FAR Section 91.175. It
as to what fits and limits are used dur- does mean that used parts in the engine
ing an engine overhaul should be clearly have been inspected and found to meet the
understood by the engine owner at the manufacturer’s new specifications.
time the engine is presented for over- b. Service limits. These are the dimensions
haul. The owner should also be aware that represent limits that must not be ex-
of any parts that are replaced, regard- ceeded and arc dimension limits for per-
less of condition, as a result of a manu- missible wear.

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4/7/76 AC 43-11

(1) The comparative measurements of parts b. However, not all engine overhaul facilities
will determine their serviceability ; how- which advertise “Remanufactured Engines”
ever, it is not always easy to determine overhaul engines to new dimensions. Some
which part has the most wear. The of these facilities do overhaul to new dimen-
manufkturer’s new dimensions or limits sions, but may not be authorized to zero
are used as a guide for determining the time the engine records. As outlined in
amount of wear that has occurred dur-
FAR 91.175, only the manufacturer or an
ing service. In an engine overhaul cer-
tain parts must be replaced regardless agency approved by the manufacturer cab
of condition. If an engine is overhauled grant zero time to an engine.
to “serviceable” limits, the parts must
conform to the’ fits and limits specifica- 8. ENGINE OVERHAUL FACILITIES.
tions as listed in the manufacturer’s a. Engine overhaul facilities can include the
overhaul manuals and service bulletins. manufacturer, or a manufacturer’s ap-
(2) If a major overhaul is performed to proved agency, large and small FAA cer-
serviceable limits or an engine is top
tificated repair stations, and engine shops
overhauled, the total time on the engine
continues in the engine records. that perform custom overhauls or individual
certificated powerplant mechanics. The
7. REMANUFACTURE. services offered by these facilities vary.
a. The general term remanufacture has no However, regardless of the type or size of
specific meaning in the FARs. A new en- the facility, all are required to comply with
gine is a product that is manufactured from. FAR 43.13(a) and 43.13(b). In this re-
raw materials. These raw materials are gard, it is the responsibility of the owner
made into parts and accessories that con- to assure that proper entries are made in
form to specifications for the issuance of an the engine records (Refer to FAR 91.165
engine type certificate. The term “remanu- and 91.173).
factured” infers that it would be necessary
b. Engine overhaul facilities are required by
to return the part to its basic raw material
and manufacture it again. “Remanufac- FAR 43.9 to make appropriate entries in
tured,” as used by most engine manufactur- the engine records of maintenance that was
ers and overhaul facilities, means that an performed on the engine. The owner should
engine has been overhauled to the standards insure that the engine overhaul facility ref-
required to zero time it in accordance with erences the tolerances used (new or service-
FAR 91.175. able) to accomplish the engine overhaul.

R. P. SKULLY, Dire&o{
Flight Standards Service

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