Reciprocating Engine Overhaul

Question 1

Process in which the valves, pistons, and cylinders are overhauled, but crankcase is not opened.

Answer 1

Top overhaul

Question 2

6 steps of a major overhaul

Answer 2

Disassembly,
Cleaning,
Inspection,
Repair,
Reassembly,
Testing.

Question 3

Compliance with_____ and _____ must be checked during overhauls.

Answer 3

Airworthiness directives,

Sevice directives.

Question 4

Manufacturer’s recommended maximum time period that an aircraft engine should run before being overhauled.

Answer 4

TBO

Time between overhauls

Question 5

T/F

When a TBO is reached, the engine must receive a major overhaul.

Answer 5

False

TBO is only a recommendation.

Question 6

After starting an engine, watch for an indication of ______.

Answer 6

Oil pressure

Question 7

T/F

If there is no indication of oil pressure after 30 seconds the engine should be shut down.

Answer 7

True

Question 8

Aircraft operating instructions are found in the ______.

Answer 8

POH

Pilot’s operating handbook

Question 9

Moving the mixture control to the forward limit is called _____.

Answer 9

Full Rich.

Question 10

7 parts that are routinely replaced during an overhaul include:

Answer 10

Gaskets,
Oil seals,
Bearing inserts,
Stressed nuts and bolts,
Exhaust valves,
Piston rings,
Ignition cables.

Question 11

T/F

Longitudinal magnetism is intended to detect faults that extend lengthwise through the part.

Answer 11

False

Circular magnetism

Question 12

A measure of the amount a shaft, flange or disc is bent or fails to run true.

Answer 12

Runout

Question 13

T/F

A top overhaul may be used to extend the TBO of an engine.

Answer 13

False

Question 14

T/F

After completing a major overhaul, the engine operating time is set back to zero.

Answer 14

False

Question 15

T/F

An engine that is rebuilt by the manufaturer or a manufacturer approved agency has zero hours of operating time.

Answer 15

True

Question 16

T/F

All usable parts of an engine are kept together and assembled in a rebuilt engine.

Answer 16

False

Overhauled engines only

Question 17

T/F

Carburetors, magnetos and spark plugs are normally installed on an engine when it is sent to an overhaul facility.

Answer 17

True

Question 18

Piston ring grooves may be cleaned with a _____.

Answer 18

Cotton string

Question 19

The two most widely used types of nondestructive inspection are _____ and _____.

Answer 19

Magnetic particle inspection.

Fluorescent penetrant inspection.

Question 20

Two types of mag particle inspection are ____ and ____.

Answer 20

Continuous.

Residual.

Question 21

_____ detects faults that extend lengthwise through the part

Answer 21

Circular magnetism

Question 22

_____ detects faults that extend across the part

Answer 22

Longitudinal magnetism

Question 23

T/F

Magnetic particle inspection can detect SUBSURFACE faults.

Answer 23

True

Question 24

T/F

For a fluorescent penetrant inspection to detect a fault, the fault must extend to the surface.

Answer 24

True

Question 25

T/F

Abrasive blasting should not be used before fluorescent penetrant inspection.

Answer 25

True

Question 26

Cylinder bore is measured with a _____ or an outside micrometer with a _____.

Answer 26

Inside micrometer caliper.

Telescoping gauge.

Question 27

If a part is larger than the hole into which it is to be installed, the fit is called an _______.

Answer 27

Interference fit.

Question 28

Three important piston ring measurements:

Answer 28

End gap.
Side clearance.
Tension.

Question 29

Damaged stud holes can be repaired by installing ______.

Answer 29

Heli-Coil

Question 30

Bearing journals on a crankshaft are hardened by ______.

Answer 30

Nitriding.

Question 31

Cylinder heads are inspected for cracks by ______.

Answer 31

Fluorescent penetrant.

Question 32

Valve guides and valve seats are installed with an _______.

Answer 32

Interference fit.

Question 33

Two methods for making cylinder walls hard and wear resistant:

Answer 33

Nitriding. (Blue paint)

Chrome plating. (Orange paint)

Question 34

Yellow paint on the cylinder fins between spark plug and rocker box means:

Answer 34

Long-reach spark plugs required.

Question 35

Intake valves are ground to an angle of _______ degrees relative to the plane of the seat.

Answer 35

30 degrees

Question 36

Exhaust valves are ground to an angle of ______ relative to the plane of the seat.

Answer 36

45 degrees

Question 37

A feathered edge on a valve face can become so hot that it can cause ______.

Answer 37

Preignition.

Question 38

T/F

Valve seats are ground so that their angle is 0.5 to 1 degree less that the angle of the valve face

Answer 38

False.

Greater than 0.5 - 1 degree.

Question 39

Full forward position on the mixture control is called ______.

Answer 39

Full Rich

Question 40

Full forward position of the propeller pitch control is called:

Answer 40

Low pitch (high rpm)