Module 16. Piston Engine

Piston Engine EASA Module 16 for Aviation Maintenance Technician
	CONTENTS
		WELCOME
		FORWARD
		PREFACE
		REVISION LOG
	SUB-MODULE 01 FUNDAMENTALS
		Knowledge Requirements
		Piston engine-Fundamentals
			Operating Principles
				Fundamental Reciprocating Engine Operating Principles
				Operating Cycles
				Four-Stroke Cycle
				Intake Stroke
				Compression Stroke
				Power Stroke
				Exhaust Stroke
				Two-Stroke Cycle
				Rotary Cycle
				Diesel Cycle
				Engine Configuration
				Inline Engines
				Opposed or O-Type Engines
				V-Type Engines
				Radial Engines
				Piston Displacement
				Area of a Circle
				Compression Ratio
		Efficiencies
			Mechanical Efficiency
			Thermal Efficiency
				Example
			VOLUMETRIC EFFICIENCY
			Firing Order
			Single-Row Radial Engines
			Double-Row Radial Engines
		Questions
	SUB-MODULE 0 2ENGINE PERFORMANCE
		Knowledge Requirements
		Engine Performance
			Reciprocating Engine Power
			Work
			Horsepower
			Factors Affecting Engine Power
			Nature’s Variables to Engine Performance
				Ambient Pressure
				Temperature
				Humidity
			Mechanical Issues Affecting Engine Performance
				Ignition problems
				Internal Magneto Timing
				Magneto-to-Engine Timing
				Other Ignition Problems
				Fuel Metering Issues
				Exhaust System
				Compression
			Mixtures
			Fuel/Air Mixtures
			Detonation
			Pre-ignition
		Questions
	SUB-MODULE 03 ENGINE CONSTRUCTION
		Knowledge Requirements
		Piston engine-Engine Construction
			CRANKCASE SECTIONS
			Crankshafts
			Cylinders
			Cylinder Heads
			Valves
			Valve Construction
			Valve Operating Mechanism
			Cam Rings
			Camshaft
			Tappet Assembly
			Solid Lifters/Tappets
			Hydraulic Valve Tappets/Lifters
			Push Rod
			Rocker Arms
			Valve Springs
			Cylinder Barrels
			Pistons
			Piston Construction
			Piston Pin
			Piston Rings
			PISTON RING CONSTRUCTION
			Compression Ring
			Oil Control Rings
			Oil Scraper Ring
			Connecting Rods
			Plain-Type Connecting Rods
			Fork-and-Blade Rod Assembly
			Master-and-Articulated and Split-TypeRod Assemblies
			Knuckle Pins
			Propeller Reduction Gearing
			Propeller Shafts
			ACCESSORY SECTION
			Accessory Gear Trains
			Sumps
			Induction Systems
			RECIPROCATING ENGINE EXHAUSTSYSTEMS
			Radial Engine Exhaust Collector Ring System
		Questions
	SUB-MODULE 04 ENGINE FUEL SYSTEMS
		Knowledge Requirements
		Engine Fuel Systems
			Carburetors
			Characteristics of the Float Carburetor
			Design of a Float Carburetor
			Fuel Inlet and Filtering
			Needle Valve, Valve Seat, and Float Mechanism
			Main Discharge System
			Mixture Controls
			Mechanical Blocker Type Mixture Controls
			Back Suction Mixture Controls
			Automatic Mixture Controls (AMCs)
			Main Air Bleed
			IDLE CIRCUIT
			Throttle System
			Acceleration System Interconnect
			Power Enrichment Interconnect
			Safety Spring
			POWER ENRICHMENT
			Direct Fuel Adder
			Air Bleed Restrictor
			Manipulating Fuel Metering Forces
			Acceleration
			Acceleration Systems
			Operation of a Float Carburetor
			Idle Operation
			MAIN CIRCUIT
			Pressure Carburetion
			General Description
			Air Throttle Body
			Regulator
			Fuel Control Unit
			Discharge Nozzle
			Small Pressure Carburetors
			Throttle Body
			Regulator
			Forces Acting Within the PS Series Regulator
			Chambers A and B
			Chamber D
			Chamber E
			Basic Operation of the PS Series Regulator
			Automatic Mixture Control
			Fuel Controller
			Manual Power Enrichment System
			AIRFLOW POWER ENRICHMENT SYSTEM
			Acceleration System
			Discharge System
			LARGE PRESSURE CARBURETORS
			Throttle Body
			Regulator
			Fuel Control Unit
			DISCHARGE SYSTEM
		Fuel Injection Systems
			Types of Fuel Injection
			Direct Fuel Injection
			Injector Pump
			Injector Nozzle
			BENDIX CONTINUOUS FLOW FUELINJECTION
			Bendix RSA Fuel Injection
			Design and Operation of the RSA FuelInjection System
			Throttle Body
			Fuel Control Unit
			Regulator
			Theory of Operation
			Operation
			System Pressures
			Flow Divider
			Fuel Lines
			Nozzles
			RSA AUTOMATIC MIXTURE CONTROL
			CONTINENTAL FUEL INJECTION
			Engine-Driven Fuel Pump
			Fuel/Air Controller
			Unmetered Fuel Pressure
			Manifold Valve
			Fuel Nozzles
		Electronic Engine Control
			Low-Voltage Harness
			Electronic Control Unit (ECU)
			PowerLink Ignition System
		Questions
	SUB-MODULE 05 STARTING & IGNITION SYSTEMS
		Knowledge Requirements
		Starting and Ignition Systems
			Reciprocating Engine Starting Systems
			Inertia Starters
			Direct Cranking Electric Starter
			Direct Cranking Electric Starting System for LargeReciprocating Engines
			Direct Cranking Electric Starting System for Small Aircraft
			Reciprocating Engine Starting System Maintenance Practices
			Preheat Systems
			Reciprocating Aircraft Engine Ignition Systems
			Magneto-Ignition System Operating Principles
			High-Tension Magneto System Theory of Operation
			The Magnetic Circuit
			The Primary Electrical Circuit
			Secondary Electrical Circuit
			Magneto and Distributor Venting
			Ignition Harnesses
			IGNITION SWITCHES
			Single and Dual High-Tension System Magnetos
			Magneto Mounting Systems
			Low-Tension Magneto System
			Limited Authority Spark AdvanceRegulator (LASAR)
			Starting Aids
			Booster Coil
			High-Tension Retard Breaker Vibrator
			Low-Tension Retard Breaker Vibrator
			Impulse Coupling
			Spark Plugs
		Questions
	SUB-MODULE 06 INDUCTION, EXHAUST & COOLINGSYSTEMS
		Knowledge Requirements
		Induction, Exhaust, and Cooling Systems
			Basic Carburetor Induction System
			Induction System Filtering
			Carburetor Heat Systems
			Induction System Icing
			Carburetor Heat System Operational Check
			Exhaust System Construction
			Reciprocating Engine Cooling Systems
		Questions
	SUB-MODULE 07 SUPERCHARGING/TURBOCHARGING
		Knowledge Requirements
		Supercharging/Turbocharging
			Principles and Purpose of Supercharging
			Internally Driven Superchargers
			Turbochargers
			Turbines
			Compressors
			Waste Gate System
			Lycoming Turbocharging System
			Lycoming Controllers and Relief Valve
			Density Controller
			Differential Pressure Controller
			Absolute Pressure Relief Valve
			Cessna Controllers and Relief Valve
			Absolute Pressure Controller
			Variable Absolute Pressure Controller
			Pressure Ratio Controller
			Rate of Change Controller
			Manifold Pressure Relief Valve
		Questions
	SUB-MODULE 08 LUBRICANTS AND FUELS
		Knowledge Requirements
		Lubricants and Fuels
			Functions of Lubricants
			Reducing Friction
			Serving as a Cushion
			Enhancing Sealing Between Parts
			Transferring Heat for Engine Cooling
			Cleaning the Interior of the Engine
			Serving as a Hydraulic Fluid
			Minimizing Corrosion
			Types of Lubricants
			Types of Aviation Engine Oils
			Properties of Lubricants
			Oil Grade Designations
			Aviation Fuels
			Aviation Gasoline
			Gasoline Ratings
			Gasoline Additives
			Anti-Detonate Injection
			Jet Fuel
			Safety Precautions
		Questions
	SUB-MODULE 09 LUBRICATION SYSTEMS
		Knowledge Requirements
		Lubrication Systems
			Reciprocating Engine Lubrication Systems
			Combination Splash and Pressure Lubrication
			Lubrication System Requirements
			Dry Sump Oil Systems
			Oil Tanks
			Oil Pump
			Oil Filters
			Oil Pressure Regulating Valve
			Oil Cooler
			Oil Cooler Flow Control Valve
			Surge Protection Valves
			Airflow Controls
			DRY SUMP LUBRICATION SYSTEM OPERATION
			Wet-Sump Lubrication System Operation
			Oil Dilution
			Lubrication System Maintenance Practices Draining Oil
			Oil and Filter Change and Screen Cleaning
			Oil Filter Removal Canister Type Housing
			Pressure and Scavenge Oil Screens
			Oil Filter/Screen Content Inspection
			Assembly and Installation of Oil Filters
			Oil Analysis
			Chip Detectors
		Questions
	SUB-MODULE 10 ENGINE INDICATING SYSTEMS
		Knowledge Requirements
		Engine Indicating Systems
			Engine Instrumentation
			Typical Instrument Markings
			Tachometer
			Manifold Pressure Gauge
			Torquemeter
			Exhaust Gas Temperature
			Cylinder Head Temperature
			Coolant Temperature
			Oil Pressure Gauge
			Oil Temperature Gauge
			Fuel Pressure Gauge
			Fuel Flow Meter
			Carburetor Air Temperature Gauge
			Electrical System
			PNEUMATIC SYSTEM
			Hour Meter
			MULTIFUNCTION DISPLAY (MFD)
		Questions
	SUB-MODULE 11 POWERPLANT INSTALLATION
		Knowledge Requirements
		Power Plant Installation
			Firewall
			Cowling
			Engine Mounts
			Hoses and Tubing
			Control Cables and Push-Pull Rods
			Lifting Points
			Drains
			Wiring Looms and Connectors
			Acoustic Panels and Insulation
		Questions
	SUB-MODULE 12 ENGINE MONITORING & GROUND OPERATION
		Knowledge Requirements
		Engine Monitoring and Ground Operation
			Procedures for Starting and Ground Run-Up
			Prestart Inspection
			Engine Priming and Starting
			Engine Priming
			Normal Engine Start
			Flooded Engine Starting Procedures
			Vapor Lock
			Vapor Lock Removal of a Continental InjectedPower Plant
			After Start Operation and Testing
			Engine Testing, Evaluating, Interpretation, andTroubleshooting
			Boost Pump Pressure Check Before Starting Engine
			OIL PRESSURE
			Oil Pressure in General
			Low Oil Pressure
			High Oil Pressure
			Oil Pressure Fluctuation
			Oil Temperature
			Oil Temperature Defects
			High Oil Temperature
			Cool Oil Temperature
			Oil Temperature Fluctuations
			Inoperative Oil Temperature
			Fuel Pressure
			HIGH FUEL PRESSURE
			Low Fuel Pressure
			Checking the Generator or Alternator System
			Output Defects
			Low, or No, Output
			Excess Output
			Checking Magneto Operation
			Low-RPM Magneto Check
			High-RPM Magneto Check
			Items To Be Checked While Performing AMagneto Drop Check
			Maximum RPM Drop
			RPM SPREAD
			Smooth Magneto Drop
			Rough Magneto Drop
			Exhaust Gas Temperature Change
			Manifold Pressure Change
			Reasons For Smooth, Excessive RPM Drops
			E-Gap Adjustment
			Magneto-To-Engine Timing
			Other Defects
			Reasons For Rough Magneto Drops
			Carburetor Heat/Alternate Air Check
			Pneumatic System Check
			Cylinder Head Temperature
			Exhaust Gas Temperature
			Propeller Checks
			Propeller Cycle Check
			Constant RPM Check
			Under-Speed and Over-Speed Check
			Static RPM Power Check
			Failure To Reach Static RPM
			Engine Response to Power Changes
			Idle Speed and Mixture
			Magneto Switch Ground Out Check
			Reciprocating Power Plant Shutdown
			Post-Testing Evaluation
			Compression Tests
			Differential Compression Test
			Test Theory
			Testing Procedure
			Steps for Conducting the DifferentialCompression Test
			Compression Test Results
			Pinpointing Defects
			Summary of Differential Compression Test
			Direct Compression Test
			Test Theory
			Testing Procedure
			Interpreting Readings
			Pinpointing Defects
			Summary of Direct Compression Test
			Borescope
			APPLICABILITY
			Inspecting Cylinders with the Borescope
			SUMMARY TO BORESCOPE
			Oil Filter Examination
		Questions
	SUB-MODULE 13 ENGINE STORAGE AND PRESERVATION
		Knowledge Requirements
		Engine Storage and Preservation
			Flyable Storage
			Temporary Storage
			INDEFINITE STORAGE
			Storage Containers
			PRESERVATION ANDDEPRESERVATION OF FUELMETERING DEVICES
				Float Carburetors
				Pressure Carburetors and RSA Fuel Injectors
			Power Plant Pre-Oiling
			PRE-OILING STEPS
			Summary of Pre-Oiling
		Questions
	SUB-MODULE 14 LIGHT SPORT AIRCRAFT ENGINES
		Knowledge Requirements
		Light Sport Aircraft Engines
			Engine General Requirements
			Personnel Authorized To Perform Inspection AndMaintenance On Light Sport Engines
			Authorized Personnel That Meet Faa Regulations
			Types Of Light-Sport And Experimental Engines
			Light-Sport Aircraft Engines
			Two-Cycle, Two Cylinder Rotax Engine SingleCapacitor Discharge Ignition (SCDI) Dual CapacitorDischarge Ignition (DCDI)
				Rotax 447 UL (SCDI) and Rotax 503 UL (DCDI)
				Rotax 582 Ul Dcdi
			Description Of Systems For Two-Stroke Engines
				Cooling System Of Rotax 447 UL SCDI AndRotax 503 UL DCDI
				Cooling System Of The Rotax 582 UL DCDI
			Lubrication Systems
				Oil Injection Lubrication Of Rotax 503 UL DCDE,582 UL DCDI, And 582 UL DCDI
			Electric System
			Fuel system
				Fuel/Oil Mixing Procedure
			Opposed Light-Sport, Experimental, andCertified Engines
			Rotax 912/914
			Description of systems
				Cooling System
				Fuel System
				Lubrication System
				Electric System
				Turbocharger And Control System
			hks 700T Engine
			Jabiru Light-Sport Engines
				Jabiru 2200 Aircraft Engine
			Aeromax Aviation 100 (Ifb) Aircraft Engine
			Direct Drive Vw Engines
			Great Plains Aircraft Volkswagen(VW) Conversions
			Teledyne Continental 0-200 Engine
			Lycoming 0-233 Series Light-Sport Aircraft Engine
			General Maintenance Practices On Light-SportRotax Engines
			Maintenance Schedule Procedures AndMaintenance Checklist
			Carburetor synchronization
			Pneumatic Synchronization
			Idle Speed Adjustment
			Optimizing Engine Running
			Checking the Carburetor Actuation
			Lubrication System
				Oil Level Check
				Oil Change
				Cleaning The Oil Tank
				Inspecting The Magnetic Plug
			Checking The Propeller Gearbox
			Checking The Friction Torque In Free Rotation
			Daily Maintenance Checks
			Pre-Flight Checks
			Troubleshooting And Abnormal Operation
				Troubleshooting
				Abnormal Operating
			Engine Preservation
			Engine Maintenance Practices For The Light-SportJabiru Engines
				Engine And Engine Compartment Inspection
				Lubrication System
				Carburetor Adjustment And Checks
				Spark Plugs
				Exhaust System
				Head Bolts
				Tachometer And Sender
			Engine Inspection Charts
		Questions
	APPENDIX
	INDEX