Student Exercises – Preparation for Overhaul

Powerplant Module 8
PPT2133
Preparation for Overhaul
Exercise 1-1

Answer the following questions using your Study Guide and FAA8083-32 Powerplant textbook reading
assignments.
1. List the four internal changes that may cause a need to overhaul the engine.
Low engine compression, high oil consumption, excessive engine vibration and backfiring or misfiring

8083-32B 8-1

2. What must be done with steel engine parts that are cleaned with soap and water?
Dried and sprayed with en

3. During overhaul, where can the mechanic find procedures for the overhaul?

4. Generally, what are the two types of cleaning used on engine parts at overhaul?

5. What are the three engine inspection categories?

6. Ball bearings should be visually inspected for what condition?

7. What kind of defects will Fluorescent Penetrant Inspection locate?

8. Who is qualified to rebuild an aircraft engine?

9. Which engine parts can be inspected with Magnetic Particle Inspection?

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Student Exercises – Preparation for Overhaul
10. Most of the values listed in the manufacturer's table-of-limits are ________________rather
than actual sizes or diameters of engine parts.

11. Which limit in the manufacturer's table-of-limits applies to the parts in an engine being
overhauled?

12. What is the purpose of dimensional engine inspection?

13. What section in the overhaul manual lists limits for dimensional parts?
Table of limits 8083-32B page 10-7

14. Define: Major Overhaul

The disassembly, cleaning, and inspection of an engine and the repair and replacement of all parts that do not meet the manufacturers
specifications. 8083-32B page G-17

15. Define: Top Overhaul

An overhaul of the cylinders of an aircraft. 8083-32B page G28

16. What is a Zero Time engine?

17. What is a Rebuilt engine?

A used engine that has been completely disassembled, inspected, repaired as necessary, and reassembled, tested and approved in the
same manner and to the same tolerances and limits as a new engine, using either new or used parts. 8083-32B page G-23

18. deglazing
Deglazing cylinders is accomplished with a _______________ hone.

19. Pistons can be reused if _____________________________________________.

20. List the recommended and mandatory replacement parts.

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Student Exercises – Preparation for Overhaul

Powerplant Module 8
PPT2133
Preparation for Overhaul
Exercise 1-2

Define the following terms using your Study Guide and FAA8083-32 Powerplant textbook reading
assignments and your Aircraft Technical Dictionary.
1. Abrasion:
an area of roughened scratches or marks usually caused by foreign matter between moving parts or
surfaces. 8083-32B page 10-3

2. Brinelling:
one or more indentations on bearing races, usually caused by high static loads or application of force
during installation or removal. 8083-32B page 10-3

3. Burning:
surface damage due to excessive heat. It is usually caused by improper fit, defective lubrication, or
over-temperature operation. 8083-32B page 10-3

4. Burr:
a sharp or roughened projection of metal usually resulting from machine processing. 8083-32B page
10-3

5. Chafing:
a condition caused by a rubbing action between two parts under light pressure that results in wear.

8083-32B page 10-3

6. Chipping:
breaking away of pieces of material, that is usually caused by excessive stress concentration or
careless handling. 8083-32B page 10-3

7. Corrosion:
loss of metal by a chemical or electrochemical action. 8083-32B page 10-3

8. Crack:
a partial separation of material usually caused by vibration, overloading, internal stresses, defective
assembly, or fatigue. 8083-32B page 10-3

9. Dent:
a small, rounded depression in a surface usually caused by the part being struck with a rounded
object. 8083-32 page 10-3

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Student Exercises – Preparation for Overhaul
10. Elongation:

11. Flaking:
the breaking loose of small pieces of metal or coated surfaces, that is usually caused by defective
plating or excessive loading. 8083-32B page 10-3

12. Fretting:
a condition of surface erosion caused by minute movement between two parts usually clamped
together with considerable unit pressure. 8083-32B page 10-3

13. Galling:
a severe condition of chafing or fretting in which a transfer of metal from one part to another occurs.

8083-32B page 10-3

14. Gouging:
a furrowing condition in which a displacement of metal has occurred (a torn effect). 8083-32B page
10-3

15. Grooving:
a recess, or channel, with rounded and smooth edges usually caused by faulty alignment of parts.
8083-32B page 10-3

16. Indentation:
Caused by the movement of an improperly tightened bolt. 8083-32B page 8-5

17. Nick:
a sharp-sided gouge or depression with a V-shaped bottom, that is generally the result of careless
handling of tools and parts. 8083-32B page 10-3

18. Oxidation:

19. Pitting:
small hollows of irregular shape in the surface, usually caused by corrosion or minute mechanical
chipping of surfaces. 8083-32B page 10-3

20. Run out:

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Student Exercises – Preparation for Overhaul
21. Scoring:
a series of deep scratches caused by foreign particles between moving parts or careless assembly or
disassembly techniques. 8083-32B page 10-3

22. Scratches:
shallow, thin lines or marks, varying in degree of depth and width, caused by presence of fine foreign
particles during operation or contact with other parts during handling. 8083-32B page 10-3

23. Scuffing (Pickup)

a buildup or rolling of metal from one area to another, that is usually caused by insufficient
lubrication, clearances, or foreign matter. 8083-32B page 10-3

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Student Exercises – Preparation for Overhaul

Powerplant Module 8
PPT2133
Preparation for Overhaul
Exercise 1-3

Answer the following questions using your FAR’s for Aviation Technicians.
1. Which FAR covers Definitions and Abbreviations?
14 CFR part 1

2. Which FAR covers Certification Procedures for Products and Parts?

14 CRF part 21

3. Which FAR covers Repair Stations?

14 CFR part 145

4. Which FAR covers General Operating and Flight Rules?

14 CFR part 91

5. Which FAR covers Maintenance, Preventative Maintenance, Rebuilding and

Alteration?
14 CFR part 43

6. Which FAR covers Airworthiness Standards; Aircraft Engines?

14 CFR part 33

7. For maintenance record purposes, what is the definition of engine running

time(time in service)?

8. Who can sign off and return to service the top overhaul of an IO-470 aircraft engine?

9. Who is responsible for maintaining engine airworthiness?

Owner/ Operator

10. Who is responsible for keeping (maintaining) the records on the engine?

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Student Exercises – Preparation for Overhaul

11. Who is authorized to sign off the installation of a set of chrome cylinders on a IO -470
aircraft engine?

12. Which FAR requires engine maintenance records to be kept?

13. For the mechanic, the engine maintenance records must include:

.a

b.

c.

d.
.

14. Which FAR covers the Rebuilding Requirements for engines?

15. Conversion of an engine to a different model number, involving a change in the

compression

ratio is a ___________________ ______________________ .

16. Welding on the crankcase of an IGSO-480 aircraft engine is a _______________

________________________ .

17. How many copies of the Form 337 must be executed for an engine major repair?

18. A signed copy of the Form 337, for the overhaul of an IGSO - 480 engine, must be
forwarded to

the local FAA district office within ____ hours after ___________ for return to service
.

19. Instead of the customary Form 337 , certified repair stations can use a customer

______________________ ____________________ .

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Student Exercises – Preparation for Overhaul
20. The repair station must retain a duplicate copy of the customer work order for __
______ years.

Powerplant Module 8
PPT2133
Preparation for Overhaul
Exercise 1-4

Answer the following questions using the Continental O-470 Overhaul Manual * (contained in your
student Note Guide)
1. Why should ball bearings not be spun with an air blast?

2. What should be done with steel parts immediately after cleaning?

3. In addition to degreasing, crankshafts should also be ___________________.

4. Which cleaning equipment, processes and materials are satisfactory for use on the O-470
engine?

5. Why should strong alkaline not be used for cleaning aluminum parts?

6. Why should automotive ring groove scrapers not be used for cleaning aircraft piston ring
grooves?

7. Why should putty knives not be used for scraping engine parts?

8. How are valve stems to be cleaned?

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Student Exercises – Preparation for Overhaul

9. Should sand, metal (steel) grit, or shot be used for blasting engine parts?

10. What kind of solutions can be used for loosening carbon from engine parts?

11. After visual inspection, parts are categorized into (1) of (3) groups:

_________________, ____________________ , and ____________________ .

12. Before magnetic particle inspection, small holes in parts must be plugged with

_______________, _____________ , or _______________ ______________ .

13. On crankcases, if there is definite evidence that the cylinder was loose at any time, how many
studs must be replaced?

14. What is the amperage required for magnaflux inspection on the crankshaft?

15. Which machine component (coil or plate) is required to perform magnetic inspection on piston
pins?

16. How are the piston pins prepared for magnaflux inspection?

17. If the crankshaft out-of-round exceeds the serviceable limit, what is the repair?

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