Republic of the Philippines

PHILIPPINE STATE COLLEGE OF AERONAUTICS

Institute of Engineering and Technology

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 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Institute of Engineering and Technology

I. Abstract

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 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Institute of Engineering and Technology

Engine Removal and Return to Service

1. Engine Removal Prerequisites

During all maintenance procedures and inspections, ensure that the

engine ignition switch is in the off position, all power to the aircraft is

disconnected, and all personnel are clear of the propeller’s rotational arc.

A. Before engine removal from the aircraft:

(1) Make sure that all electrical switches, circuit breakers, Ignition Switch,

and the Fuel Selector Valve are in the OFF position.

(2) In accordance with the aircraft manufacturer’s instructions, remove all

cowling, baffling and nacelle access panels to enable engine removal.

(3) Disconnect the ground terminal of the battery.

(4) Disconnect the positive terminal of the battery.

(5) Disconnect and examine the leads and wiring for damage or frayed

wiring.

(6) Remove the propeller in accordance with the aircraft manufacturer’s

instructions and/or propeller manufacturer’s instructions.

(7) Drain oil from engine. Refer to the “Oil Change Procedure” in Chapter

12-10.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
Institute of Engineering and Technology

(8) Remove accessories.

(9) If the engine is to be stored, complete the engine preservation

procedure before engine removal. Refer to instructions in the IO-390-C

Series Engine Installation and Operation Manual.

2. Engine Removal Procedure

A. Remove the engine as follows:

(1) Complete the prerequisites in the section “Engine Removal

Prerequisites” in this chapter.

(2) During removal of tubes or engine parts, look for indications of scoring,

burning or other unacceptable conditions.

(3) Disconnect all connecting control cables.

(4) Disconnect any relays, gages, or other indicating devices as per the

aircraft manufacturer's procedure. (Use care to prevent dust, dirt, safety

wire, nuts, safety cable, washers or other foreign matter from entering the

engine. During engine removal, if items accidentally fall into the engine,

stop work, find and remove all of the dropped articles. Use correct plugs,

caps, and other coverings to cover exposed openings. Install dust caps

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 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Institute of Engineering and Technology

over, not in, tube ends. do not put tape or plugs inside open lines or

fittings.)

(5) Apply a cap over oil and fuel lines and connections to prevent spillage

and debris from entering the engine

(6) Apply tags to identify ports, clips, tubes, wires, etc. for reference to

make correct connections during engine installation. Identify the location

of each part during removal. Attach a tag to unserviceable parts and units

for examination or replacement.

(7) Disconnect the alternator from the engine.

(8) Remove all wiring bundle attaching clamps and hardware.

(9) Remove the manifold pressure gage line and aircraft fuel supply lines

in accordance with the aircraft manufacturer’s instructions.

(10) Refer to the aircraft manufacturer's instructions to disconnect any

accessory connection or to remove any external accessories to enable

removal of the engine from the aircraft.

(11) Make sure that all wires, lines, and attachments between the engine

and airframe are disconnected and capped.

(12) Reinstall the spark plug in each cylinder.

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 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Institute of Engineering and Technology

(13) Attach an engine-lifting cable (with a minimum capacity of 750 lb (340

kg)) to the lifting straps on the engine

Lifting Straps

(14) Use a crane or overhead hoist (with a minimum load of 750 lb (340

kg)) to take up slack on the lifting cable until there is enough tension to

hold the weight of the engine.

(15) Remove the nuts and bolts from the engine mounts that are supplied

by the airframe manufacturer. (Make sure the area is clear when lifting the

engine. Do not allow the front, rear, sides or bottom of the engine to bump

or strike any objects to prevent damage to the engine or its components.)

(16) Carefully lift the engine slowly out of the airframe.

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 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Institute of Engineering and Technology

(17) Put the engine on an engine stand, transport dolly, or engine shipping

container base.

3. Engine Installation Preparation Requirements

To prevent delays on engine re-installation, have the following materials

and new spare parts identified in Table 1 available (Refer to the IO-360-P1A

Illustrated Parts Catalog). Follow the procedures in Table 1 to prepare the

engine for installation (if the engine was not in storage). If the engine was in

storage, refer to the IO-360-P1A Engine Installation and Operation Manual for

instructions to prepare an engine that has been in storage

Materials and Procedures to Prepare a Serviced Engine for Installation

New gaskets, seals, O-rings, and Always install new gaskets, seals,

packing (Make sure the new parts O-rings, or packing.

are not brittle, torn, cut, or cracked

and do not have flashings,

deterioration/wear or deformities.)

New safety wire/cable, lock nuts,

lock washers, tab washers, and

cotter pins

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 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Institute of Engineering and Technology

New replacement part for any part

that had to be discarded*

Oil per specifications in Appendix A “Add Oil to the Engine”

of the IO360-P1A Engine

Installation and Operation Manual

Cleaning solvents and lint-free

wipes
Before installing a component, complete a check of the shelf-life of the

part as per the latest revision of Service Letter No. L247

After all inspections and maintenance tasks are complete, install the

engine per the IO-360-P1A Engine Installation and Operation Manual.

During engine re-installation:

A. Refer to and follow the "Maintenance Practices" in Chapter 05-00.

B. Replace any gaskets, seals or packing that were removed with new

parts. C. Replace any part that was damaged or that could not be repaired

with a new part.

D. Install external accessories as per the aircraft manufacturer's

instructions.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
Institute of Engineering and Technology

E. Examine the engine mounts to make sure they are not damaged or

bent.

4. Operational Ground Check

The purpose of this check is to make sure the installed engine operates in

the aircraft according to specifications in Appendix A of the IO-360-P1A

Engine Installation and Operation Manual.

A. Per the component manufacturer's instructions, calibrate the cylinder

head temperature gage, oil temperature gage, oil pressure gage,

manifold pressure gage, and tachometer prior to testing.

B. Make sure that all of the engine gages operate correctly.

C. Make sure that the vent and breather lines are correctly installed and

secured in accordance with the aircraft manufacturer’s instructions.

D. Install the cowling and all of the aircraft baffles per the aircraft

manufacturer’s instructions.

E. Position the aircraft into the wind.

F. Complete the applicable procedures in either the “Engine Initiation”

chapter or “Engine Operation” chapter of the IO-360-P1A Engine

Installation and Operation Manual.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
Institute of Engineering and Technology

5. Idle Speed and Mixture Adjustment

A. Start the engine and operate it until the oil and cylinder head

temperatures are in the specified operating range.

B. Set the throttle stop screw to let the engine idle at idling rpm speed

(1) When the idle speed is stable, move the cockpit mixture control lever

with a very slow, steady pull toward the IDLE CUT-OFF position, do not let

the engine stop. While monitoring the tachometer, steadily move the

mixture control lever to the FULL RICH position.

(2) An increase of more than 50 rpm during fuel mixture adjustment is an

indication of an excessively rich idle mixture. An immediate decrease in

rpm (without an initial momentary increase) is an indication that the idle

mixture is too lean.

C. After the adjustment, run up the engine again to 2000 rpm. Complete

the previous steps until the idle speed check shows a momentary increase

of approximately 25 to 50 rpm.

D. Make the final idle speed adjustment for the desired idling rpm with a

closed throttle.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
Institute of Engineering and Technology

E. If the idle speed setting is not stable after repeated attempts, complete

a check of the idle linkage. Look for loose connections which could cause

erratic idling. Also take into account weather conditions and field altitude

which could affect the idle speed mixture adjustment.

6. Engine Mounting Bracket Inspection

A. Examine the airframe engine mounts for looseness. Tighten any loose

hardware. Refer to the aircraft manufacturer’s instructions.

B. Examine the rubber engine mounts and mounting hardware for signs of

deterioration or damage. Replace worn or damaged engine mounts or

hardware in accordance with the aircraft manufacturer’s instructions.

C. After the first 100 hours of operation, make sure that the engine

fastening nuts and bolts for the engine mounts are torqued correctly. For

torque values, refer to the aircraft manufacturer’s instructions.

7. Return to Service Procedure

 Make sure that you correct all problems and complete all of the

necessary maintenance.

 Complete the “Operational Ground Check” in this chapter.

 Specifically monitor:

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 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Institute of Engineering and Technology

o Power output (static and idle rpm)

o Fuel and oil pressure

o Cylinder and oil temperatures

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