Alabama
Department of
Postsecondary Education
Representing Alabama’s Public Two-Year College System
AMP 122
Reciprocating Engine Overhaul
Plan Of Instruction
Effective Date: 2004
Version Number: Base Document
This course may be taught in its entirety in career/technical education degree
programs, non-degree programs, and Training for Business and Industry
programs. Individual instructional modules may be taught in customized
training, adult education work-based project learner activities, and short-term
training.
COURSE DESCRIPTION: This course is a study of theory, construction, operation,
and timing mechanisms associated with aircraft reciprocating Powerplant; overhaul
to include disassembly, cleaning, measuring, inspecting, reassembly and
troubleshooting in accordance with appropriate FAA and manufacturers’ regulations
and practices. Emphasis is placed on overhauling a reciprocating engine. Upon
completion, students should be able to overhaul a reciprocating engine. CORE
CONTACT/CREDIT HOURS (applicable if entire course is taught in a career/technical education
degree or non-degree program)
Theory Contact/Credit Hours
Lab Contact/Credit Hours
Total Contact/Credit Hours
3/3 hours
6/2 hours
9/5 hours
40 hours (1:1)
100 hours (3:1)
140 hours
NOTE: Colleges may schedule lab hours as manipulative (3:1) or experimental (2:1). Adjustments in contact
hours must be made accordingly.
PREREQUISITE COURSES (applicable if entire course is taught in a career/technical education
degree or non-degree program)
AMT 100, AMT 101, AMT 102 or equivalent
CO-REQUISITE COURSES (applicable if entire course is taught in a career/technical education
degree or non-degree program)
Determined by college unless stated otherwise
Reciprocating Engine Overhaul
AMP 122
INDUSTRY COMPETENCIES
RECIPROCATING ENGINE OVERHAUL
Overhaul reciprocating engines
App. D, Sec IA Item 2, Level 2
Inspect, check, service, and repair reciprocating engines and engine installations
App. D, Sec IA Item 3, Level 3
ENGINE ASSEMBLY
Install, troubleshoot, and remove reciprocating engines
App. D, Sec IA Item 4, Level 3
COURSE OBJECTIVES
The cognitive objective of this course is for each student to comprehend
foundational knowledge needed to perform stated entry-level industry competencies.
The performance objective of this course is for each student to apply foundational
knowledge to problems and exercises encountered in class.
CRITERION OBJECTIVES
Industry Competency
Student Performance Objectives
MODULE A RECIPROCATING ENGINE OVERHAUL
Overhaul reciprocating
Given instruction in this course, an aircraft reciprocating
engines
engine requiring overhaul, general and specialized
App. D, Sec IA Item 2,
tools, overhaul, component assembly/disassembly,
Level 2
inspection procedures and specifications, and verbal
instructions, overhaul the reciprocating engine to
simulated airworthiness specifications.
Inspect, check, service,
and repair reciprocating
engines and engine
installations
App. D, Sec IA Item 3,
Level 3
Given instruction in this course, reciprocating engine,
test equipment, general and specialized tools, ground
power unit, reciprocating engine inspection, checkout,
servicing, and repair manuals, procedural guides and
specifications, and verbal instructions, inspect, check,
service, and repair the reciprocating engine to meet
simulated airworthiness specifications.
Given instruction in this course, installed reciprocating
engine, general and specialized tools, ground power
unit, reciprocating engine installation, inspection,
checkout, and servicing manuals, procedural guides
and specifications, and verbal instructions, inspect,
check, and service, the installed reciprocating engine to
meet simulated airworthiness specifications
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Reciprocating Engine Overhaul
AMP 122
ENABLING OBJECTIVES/KEY ENABLERS
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Describe the engine overhaul shop organization
Identify safety procedures associated with engine overhaul
Explain the safety procedures associated with engine overhaul
Identify the equipment used in engine overhaul
Explain the purpose of each piece of equipment
Identify precision measuring tools used in engine overhaul
Explain the purpose of each measuring tool
Identify the manufacturer’s publications used in engine overhaul
Identify the FAA publications used in engine overhaul
Identify the records used to document engine overhauls
Describe the engine overhaul preparation procedures
Summarize the engine removal procedures
Explain the engine disassembly procedures
Describe the cleaning of various engine parts
Identify the crankcase assembly
Describe the construction of the crankcase assembly
Summarize the inspection of the crankcase assembly
Explain crankcase assembly repair
State the purposes of reduction gearing
Describe the construction of reduction gearing
Explain reduction-gearing repair
Identify accessory gears
State the purpose of accessory gears
Identify crankshaft and connecting rods
State the purpose of crankshaft and connecting rods
Describe the purpose of various crankshaft designs
Explain the operating principles and construction of spur and pinion type and planetary type
propeller reduction gearing
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Explain the principles of construction and operation of accessory gear drive trains on
reciprocating engines
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Explain how to inspect cast and forged crankcase assemblies
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Explain how to remove and install studs in engine crankcase and accessory sections
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Describe the construction of crankshaft and connecting rods
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Summarize the inspection of crankshaft and connecting rods
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Identify types of engine bearings
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State the purpose of engine bearings
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Describe engine-bearing lubrication
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Summarize the inspection of engine bearings
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Describe the indications of failed or failing engine bearings
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Describe how to perform crankshaft “runout”
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Identify engine cylinder assemblies
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Explain the function of cylinder assemblies in an engine
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Describe the construction of engine cylinder assemblies
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Identify the different measurements of cylinder assemblies
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Explain the processes used to harden cylinder walls
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Describe the purpose and applicability of choke type or taper ground cylinders
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Describe the wear characteristics of engine cylinder walls
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Describe the result of operating an engine at high power settings before the lubricating oil has
come to operating temperature
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Explain the measurement procedure for inside diameter taper and out of round cylinder bore
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Describe how to install cylinders and tighten holddown nuts
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Describe the construction characteristics of air-cooled engine cylinders
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Explain how to perform cylinder compression tests
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AMP 122
Describe how to detect and determine the cause of a “cold cylinder”
Identify the different types and arrangements of piston rings
Explain the function of pistons in an engine
Describe the construction characteristics of aircraft engine pistons
Summarize the inspection of pistons
Explain piston repair
Identify piston rings types
Explain the function of piston rings in an engine
Explain the purpose of using relatively large piston to cylinder wall clearances in aircraft
engines
Describe how to check a piston ring for correct end and side end clearance
Explain how to repair a cored aluminum piston
Describe the installation of piston rings
Identify engine valves
Explain the purpose of engine valves
Describe the construction of engine valves
Explain function of engine valve timing
Describe engine valve timing adjustment
Summarize the inspection of engine valves
Explain how to check and adjust engine valve clearances
State the purpose of valve overlap in some engines
Explain the purpose of using more than one spring on aircraft engine piston valves
Describe the effects of various poppet-type valve face angles
Describe the characteristics of various types of valve operating mechanisms
Describe the operating characteristics of zero-lash hydraulic valve lifters
Explain how to install valve guides
Explain how to grind and resurface valves and valve seats
Describe the effect of excessive or insufficient valve clearance on engine operation
Explain the relationship between operating valve clearance and cold valve clearance
MODULE B ENGINE ASSEMBLY
Install, troubleshoot, and
remove reciprocating
engines
App. D, Sec IA Item 4,
Level 3
Given instruction in this course, aircraft with engine,
test equipment, general and specialized tools, ground
power unit, engine removal/installation and
troubleshooting procedural guides and specifications,
and verbal instructions, Remove and install the engine
and troubleshoot as necessary to return the engine and
aircraft to simulated airworthiness specifications.
ENABLING OBECTIVES/KEY INDICATORS
 Describe how to time engine valves during engine assembly
 Describe the installation of cylinder assembly
 Summarize the procedures for engine removal
 Summarize the procedures for engine installation
 Summarize the engine troubleshooting procedures
 Describe the installation and timing of a magneto
 Summarize the process of hoisting and lifting engines during removal and installation
 Explain the operation of mechanical push-pull control systems
 Describe the factors affecting engine operation
 Explain the effect of induction system air leaks on engine operation
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AMP 122
Define detonation
Explain the result of incorrect air-fuel mixture adjustments
Identify the indications of a leaking primer during engine operation
Summarize ignition system operational checks
Summarize how to perform compression checks
Explain how to perform and ignition system operational check
Describe how to determine the condition of cable operated engine control system
Explain how to check and adjust engine idling speed
Describe the purpose of establishing one or more critical ranges for certain propeller
combinations
Identify the operating indications of a worn or weak engine
Describe the effect of leaking oil dilution valve on engine operation
Describe the effect of low oil supply on engine operation
Identify the indications of a correctly functioning engine oil system
Identify the possible cause of oil being thrown out of the breather of a wet sump engine
Determine the source and cause of metallic particles found on the oil screen during engine
inspection
Describe the effect of an unbalanced propeller on engine operation
Identify the power settings for most desirable protracted engine operation
Explain the process of engine oil dilution in preparation for cold weather starting operations
Describe the purpose and operating principles of engine dynamic suspension systems
Describe the effect throttle position upon fuel air mixture in the cylinders during starting
Summarize how to pre-oil an engine before starting
Explain how to install air-cooled engine baffles
Describe the method for hoisting and lifting engines during removal and installation
Explain the effect of increased engine manifold pressure on master rod bearing load
Explain the effect of air density on engine power output
Identify the causes of engine backfire
Describe the basic operational sequence of increasing or reducing the power output of an engine
equipped with a constant speed propeller
Explain the factors that affect an engine’s tendency to detonate
Describe the effects of induction system air leaks on engine operation
Identify the indications of leaking primer systems during engine operation
Describe the effect of exhaust backpressure on engine power output
Identify the result of incorrect fuel air mixture
Identify the indication of carburetor icing
Explain how to operate and adjust mechanical push-pull control systems
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COURSE CONTENT OUTLINE
AMP 122
FAA AUTHORITY 147
SAFETY INSTRUCTION
 General
 Fire Drills
 Severe Weather
 Shop Safety
 Flight Line Safety
MODULE A RECIPROCATING ENGINE OVERHAUL
 Overhaul shop organization and safety
App. D, Sec IA Item 2, Level 2
o Personnel
o Equipment and precision measuring tools
o Safety
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Engine Removal
o Reasons for removal
o Preparation for removal
o Engine hoisting
o Engine Compartment
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Overhaul
o Top overhaul
o Major overhaul
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Overhaul procedures
o Disassembly
o Cleaning
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Visual Inspection
o Surface defects
 Crankcase
 Gears
 Bearings
 Crankshaft
 Connecting rods
 Piston and Piston Rings
 Cylinders
 Camshafts
 Valves and Valve Mechanisms
 Threaded Fasteners
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Structural Inspection
o Magnetic Particle Inspection
o Liquid Penetrant Inspection
Alabama College System
App. D, Sec IA item 4, Level 3
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Reciprocating Engine Overhaul
AMP 122
o Eddy Current Inspection
o Radiographic Inspection
Progressive Examination #1
ENGINE ASSEMBLY
 Dimensional Inspection
o Crankcase
o Crankshaft
o Connection Rods
o Piston, Rings, and piston pins
o Cylinders
o Camshafts
o Valves and valve mechanisms
o Oil pump housing
o Crankcase assembly
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Repairs
o Crankcase
o Crankshaft
o Connecting rods
o Pistons
o Valves and valve mechanisms
o Cylinders
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Reassembly
o Crankshaft
o Cylinders
o Pistons and Rings
o Final assembly
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Block Testing
o Log entries
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Engine Installation
o Hoisting for installation
App. D, Sec IA item 4, Level 3
o Mounting the engine
o Connections and adjustments
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Ground test preparation
o Pre-oiling
o Fuel system bleeding
o Cowl flap rigging
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AMP 122
Post-run checks and adjustments
o Factors effecting engine operation
o Effects of induction system air leaks
o Detonation
o Result of incorrect fuel-air mixture
o Indications of leaking primer
o Ignition system timing and check
o Compression checks
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Engine Preservation
o Storage
o Inspection of stored engines
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Manufactures’ and FAA publications and records
Progressive examination #2 conducted at this time
NOTE:
Practical exercise I-A, IB, IC, and IIA to be conducted at this point.
Final Examination
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AMP 122
RECOMMENDED METHODS OF EVALUATION: The table of specifications below
identifies the number of enabling objectives/key indicators per cognitive domain level
of learning (Knowledge, Comprehension, Application) per module. The instructor
should develop 1-3 test questions per Knowledge Level of Learning, 2-4 test
questions per Comprehension Level of Learning, and 5-6 questions per Application
Level Learning. The instructor should use the following test item types for each level
of learning:
Knowledge: Alternative Response test items (true/false or yes/no)
Comprehension: Multiple Choice
Application: Multiple Choice, Short Answer Exercises
The instructor should ensure each student meets the performance and standards
published in each criterion objective. See FAA AC 147-3 Certification And Operation
Of Aviation Maintenance Technician Schools Appendix 1 for evaluation instrument
guidance and development.
Domain of
Learning/
Content
Module A
Module B
Number of
indicators per
level
TABLE OF SPECIFICATIONS
Cognitive Domain
Total
Cognitive
Total
Performance
Knowledge Comprehension Application
30
10
40
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30
77
1
1
77
41
118
3
1
4
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AMP 122
RECOMMENDED INSTRUCTIONAL METHODOLOGIES: The table below links
the teaching methods and activities most effective for facilitating student
achievement of learning outcomes published in this plan of instruction.
Cognitive Level
(Thinking)
Knowledge
Descriptive Verbs:
Defines, Lists, States,
Describes, Identifies
Comprehension
Descriptive Verbs:
Describe, Explains,
Summarizes
Goal For Students
Teaching Methods
Knows common terms,
specific facts, methods,
procedures, basic
concepts, principles
Lecture
Computer Based
Instruction
Video
Demonstration
Mnemonics
Examples or Illustrations
Repetition
Summaries
Reviews
Understands facts and
principles
Informal Lecture
Discussion
Demonstration
Participation
Interactive Computer
Based Instruction
1. Teach to the Knowledge
Level
Interprets verbal material
Interprets charts and
graphs
Translates verbal
material to mathematical
formulas
Justifies methods and
procedures
Descriptive Verbs:
Uses, Solves, Operates,
Produces,
Demonstrates, Constructs
Applies concepts and
principles to new
situations
Applies laws and
theories to practical
situations
4. Put students in a new
situation, and the students
solve the new situation
using the concept, principle,
or procedure while
instructor supervises.
Demonstration
Individual Research
Lab Exercises
Case Studies
Experiments
Constructs charts,
graphs, or simple
mechanism
Psychomotor Level
(Doing)
Mechanism
Descriptive Verbs:
Assembles, calibrates,
constructs, measures, fixes,
dismantles, sketches
Alabama College System
Learned responses have
become habitual and
can be performed with
some confidence and
proficiency
5. Reteach as required
1. Teach to the Knowledge
Level
2. Teach to the
Comprehension Level
3. Student must identify the
concept, principle, or
procedure and use it to
solve new scenario
Solves mathematical
problems
Demonstrates correct
usage of a method or
procedure
Goal For Students
2. Explains and
demonstrates concept,
principle or procedure
learned
3. Put students in new
situation, and instructor and
students co-solve
employing the indicated
concept, principle, or
procedure.
Estimates future
consequences
Application
Teaching Activities
4. Reteach as required
Teaching Methods
Teaching Activities
Lab Exercises
Case Studies
Experiments
1. Demonstration
2. Observation
3. Feedback
4. Reteach as required
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Plan of Instruction
(POI)
Industry
Competencies
Course Objectives
Criterion Objectives
Enabling
Objectives/Key
Indicators
Table of
Specifications
Cognitive Domain
Psychomotor Domain
Course Description
Course
Prefix/numbers
Co-requisite Course
Modules
Course Content
Outline
Contact/Credit hours
Prerequisite
Knowledge
Recommended
Methods of Evaluation
Alabama College System
AMP 122
Glossary of Terms
A teaching-learning plan which includes student centered
instructional objectives, outlined content, instructional and
evaluation strategies, and other relevant information
needed to guide the development and/or revision of
learning experiences such that students achieve stated
educational outcomes.
Entry-level skills students must acquire during enrollment in
the course.
The overall goal of the course of instruction stated in broad
terms.
The terminal outcome each student is required to meet.
Criterion objectives are directly related to industry
competencies. There will be one or more criterion
objectives published for each industry competency.
The required knowledge and/or skill each student must
acquire in order to have the best chance of achieving the
stated performance in the criterion objective.
Used to ensure adequate sampling of student knowledge as
specified by the enabling and criterion objectives.
The domain of learning typified by thinking and focused on
the development of intellectual capabilities.
The domain of learning typified by performing or doing and
focused on the development of motor skills.
Section Explanation
A broad description of key elements in a given course.
Used to identify courses taught in multiple disciplines.
Course required in conjunction to the specified course often
in the form of a lab
A grouping of interrelated knowledge and skills representing
a sub-element of a course.
A listing of topics for instruction in a particular course
Specifies the recommended contact to credit hours for each
course. Mandates the total credit hours awarded for each
course.
Intellectual capabilities required for handling the academic
rigors of the discipline.
Suggests test item options for measuring student
achievement of enabling objectives. Suggests the number
of test items required to adequately measure student
achievement of enabling objectives. Mandates the
evaluation of criterion objectives.
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Recommended
Instructional
Methodologies
AMP 122
Suggests the most effective instructional methods for
achieving stated learning levels
Directions for Use
1.
2.
3.
4.
5.
6.
Review the entire document.
Assess the industry competencies specified in the POI keeping in mind that
the stated skills are the target outcomes for the course.
Assess the criterion objectives written for each competency keeping in mind
the objective specifies the behavior each student must exhibit in order to
achieve the competency.
Adjust performance evaluation instruments to ensure each criterion objective
is addressed.
Develop additional performance evaluations as needed
Assess enabling objectives/key indicators specifying student outcomes
Adjust objective evaluations based on the guidance provided in the POI table
of specification to ensure adequate sampling of student learning outcomes.
7.
8.
9.
10.
11.
12.
13.
14.
Evaluate current classroom curriculum and determine if learning experiences
support student achievement of skills identified in criterion objectives. Adjust
as necessary.
Review recommended instructional methodologies for teaching activities
appropriate to specified levels of learning.
Develop appropriate learning experiences for those skills not addressed.
Ensure specified contact hours are enough to cover existing and new learning
experiences developed.
Ensure adequate time exists to evaluate each student on all criterion
objectives.
Adjust course syllabus to reflect changes made.
If necessary, adjust school surveys to reflect changes made.
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