AMT 1104-Laboratory Module 1 (Midterm)

Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS

INSTITUTE OF ENGINEERING AND TECHNOLOGY
AIRCRAFT MAINTENANCE TECHNOLOGY DEPARTMENT
Piccio Garden, Villamor, Pasay City
AMT1104
AIRCRAFT POWERPLANT I
(Reciprocating Engine)
MIDTERM LABORATORY
MODULE #01
“MAJOR ENGINE PARTS.

CRANKCASE, BEARINGS,
CONNECTING ROD,
CAMSHAFT AND TAPPET BODY
ASSEMBLY ACTIVITY”
Prepared by:
AMT Faculty
AMT1104 Aircraft Powerplant I (Reciprocating Engine)

1|P age
LEARNING OUTCOME
Course Learning
Module Learning
CLO 9. Demonstrate and discuss
the correct installation of piston Topic Learning
rings and results of incorrectly
installed or worn rings. MLO 1. Discuss the function of TLO 1. Familiarization of
accessories installed in the
engine before disassembly. reciprocating external
CLO 10. Discuss the
purpose/function/operation of MLO2. Recognize the different parts/accessories.
various piston engine parts and components of an TLO 2. Familiarization of major
components, including, but not aircraft reciprocating engine and engine parts of reciprocating
how they are installed.
limited to, any of the following: engines.
crankshaft dynamic dampers,
multiple springs for valves,
piston rings, and reduction
gearing.
CLO 14.Learn different

terminology used in aviation
industry.
TIMEFRAME:
The student should complete this
module within 12 hours and
comply with all the given
activities.

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TABLE OF CONTENTS
CONTENT PAGE
NO.
Cover Page 1
Learning Outcome 2
Timeframe 2
Table of Contents 3
Reference 3
Reassembly of Crank Case, Bearings, Camshaft and Tappet Bodies
4
Reassembly of Crank Shaft, Connecting Rod and Bearings, Oil Sump,
Induction Housing, Idler Gears and Accessory Cover 6
Power Plant Laboratory Engine Reassembly Procedures 9

Rubrics 10
Honestly Clause 10
REFERENCES:
Engine Maintenance Manual (Principal Manual) IO-360-N1A Engine (2016) retrieved from
https://www.lycoming.com/sites/default/files/MM-IO-360-N1A%20-%203-31-2016.pdf

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REF.NO. 7-73, 7-81, 7-82, 7-83,
PAGE 7-16A -LYCOMING ENGINE OVERHAUL MANUAL
A. REASSEMBLY OF CRANK CASE,

BEARINGS, CAMSHAFT AND TAPPET BODIES
1. After the crank case has been cleaned, dimensional inspection of main bearing
and camshaft journals are performed, put the crank case on a suitable working
table with the interior of the crank case facing upward.
2. Using the engine oil, pre-lubricate the bearings journals. Place the center and
rear bearings in the crank case and pre lubricate with engine oil. Make sure that
the tang of each bearing must fit into the recess of the crankcase bearing
journals.

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3. Temporarily put the front main bearing in the left crank case half. Ensure that
the bearing is properly seated on the two dowels in the crankcase front bearing
journal. The front main bearing unlike the center and rear bearings is separated
in two halves.
4. Use a pencil mark to mark a reference

on the bearing and the crank case.
These marks are necessary to ensure
proper seating of the bearing halves in
the crank case dowels when the crank
shaft is placed into the crank case.
5. Lubricate the face and tappet bodies and lay the camshaft in position in the
right crank case half.

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B. REASSEMBLY OF CRANK SHAFT, CONNECTING ROD AND BEARINGS,

OIL SUMP, INDUCTION HOUSING, IDLER GEARS AND ACCESSORY
COVER
1. After the crank shaft has been cleaned, inspected and dimensional inspection
is performed, place the crank shaft in the engine stand with the propeller flange
bolted in the stand and crank pins are ready for connecting rod installation.
2. Pre-lubricate the journals and crank pins. Assemble the connecting rods. Pre-
lubricate the bearings. Install the bearings in the connecting rods and
connecting rod caps. Make sure that the tang of each bearing enters the slot in
the connecting rod and connecting rod cap. Proper numbering of the cap and
the rod should be followed. Install each connecting rod in the proper number in
the crank pin and tighten the nuts with the proper torque value.
3. Remove the front bearing in the left crank case and assemble the bearing in
the crank shaft. Using the reference mark made previously adjust the front main
bearing so that the halves are seated properly in the crank case dowels.
4. Install the left crank case half in the crank shaft. Using the reference mark in
the front main bearing make sure that the front main bearing is seated properly
in the crank case dowels.

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5. Install the right crank case half. After the crank case
are together, tap the right half of the with a rubber
mallet to seat the crank case securely. Install the crank
case bolts and nuts. Follow the proper sequence in
tightening the bolts and nuts and torque value.
OBJECTIVES
To know the parts installed inside the crankcase. The proper sequence,
measurement of dimensions, location of parts, proper bearing position. To know the
importance of pre-lubrication to avoid failure of bearings on engine test.
LEARNING OUTPUT
The students can set the crank case and bearings. They can install and identify
the proper markings for installation. They can set the tappet housing and identify the
tolerances. The proper position of the camshaft when installing the crank case. They can
use the proper seals and O-rings.

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Power Plant Laboratory Engine Reassembly Procedures
CRANK CASE, BEARINGS, CAMSHAFT AND TAPPET BODIES

1. After the crank case has been cleaned, dimensional inspection of main bearing
and camshaft journals are performed, put the crank case on a suitable working
table with the interior of the crank case facing upward.
2. Using the engine oil, pre-lubricate the bearings journals. Place the center and
rear bearings in the crank case and pre lubricate with engine oil. Make sure
that the TANG of each bearing must fit into the recess of the crankcase bearing
journals.
3. Temporarily put the front main bearing in the left crank case half. Ensure that
the bearing is properly seated on the two dowels in the crankcase front bearing
journal. The front main bearing unlike the center and rear bearings is separated
in two halves.
4. Use a pencil mark to mark a reference on the bearing and the crank case.
These marks are necessary to ensure proper seating of the bearing halves in
the crank case dowels when the crank shaft is placed into the crank case.
5. Lubricate the face and tappet bodies and lay the camshaft in position in the
right crank case half.
OBJECTIVES
To know the parts installed inside the crankcase. The proper sequence,
measurement of dimensions, location of parts, proper bearing position. To know
the importance of pre-lubrication to avoid failure of bearings on engine test.
CRANK SHAFT, CONNECTING ROD AND BEARINGS

1. After the crank shaft has been cleaned, inspected and dimensional inspection
is performed, place the crank shaft in the engine stand with the propeller flange
bolted in the stand and crank pins are ready for connecting rod installation.
2. Pre-lubricate the journals and crank pins. Assemble the connecting rods. Pre-
lubricate the bearings. Install the bearings in the connecting rods and
connecting rod caps. Make sure that the tang of each bearing enters the slot in
the connecting rod and connecting rod cap. Proper numbering of the cap and
the rod should be followed. Install each connecting rod in the proper number in
the crank pin and tighten the nuts with the proper torque value.
3. Remove the front bearing in the left crank case and assemble the bearing in
the crank shaft. Using the reference mark made previously adjust the front main
bearing so that the halves are seated properly in the crank case dowels.
4. Install the left crank case half in the crank shaft. Using the reference mark in
the front main bearing make sure that the front main bearing is seated properly
in the crank case dowels.
5. Install the right crank case half. After the crank case are together, tap the right
half of the with a rubber mallet to seat the crank case securely. Install the crank
case bolts and nuts. Follow the proper sequence in tightening the bolts and nuts
and torque value.

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6. Rotate the crank case, make sure it moves freely and the bearings are properly
seated to avoid damage. Position the crank pin and connecting rod no. 1 in the
top dead center position.
7. Assemble the accessory drive gears. Position the idler gears to proper
markings in the crank shaft, cam shaft and magneto. The gear position is
important for proper opening and closing of valves and engine timing. The
magneto drive gear marking is important for ignition timing. Assemble the
accessory drive gears, oil pump, fuel pump lobes.
8. Attach the oil sump and induction housing to the crank case. Before installing
the accessory housing cover, check all the accessory drive gears are installed
in their proper position.
OBJECTIVES
To familiarize the students in the parts of the crank shaft, parts of the
connecting rods and proper bearing position. To know the location of parts and how they
are installed. Proper tightening and torque values of the assemblies. To know the proper
position of the accessory drive gears for proper engine and ignition timing and their proper
position before the accessories are installed. This will also familiarize the students to the
proper torque values.

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ACTIVITY
Timeframe: 10-15mins.
1. Discuss the ff. (10 items) own words.
a. Reassembly of Crank Case, Bearings, Camshaft and Tappet Bodies

b. Reassembly of Crank Shaft, Connecting Rod and Bearings, Oil Sump,
Induction Housing, Idler Gears and Accessory Cover.
RUBRICS
CONTENT (70%)
Knowledge on The Topic C1 35%

Information Based on C2
Technical 25%
Manuals/Journals/Books
Quality of Information C3 10%
70%
FORMAT (30%)
Format Based on The Given F1 5%

Instructions
Grammar, Usage, Spelling F2 5%
Word Count& Quality of F3 20%
Writing
30%
Total: 100%
HONESTY CLAUSE:
As a student under the AMT Department of Institute of Engineering and

Technology (InET), with my signature and Parent/Guardian’s signature
below, I declared that my compliance with this module/subject is my
work and adequately documented.
_
Student’s Name and Signature Parent/Guardian’s Signature

10 | P a g e

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Republic of the Philippines

PHILIPPINE STATE COLLEGE OF AERONAUTICS

“MAJOR ENGINE PARTS.

AMT1104 Aircraft Powerplant I (Reciprocating Engine)

CLO 14.Learn different

AMT1104 Aircraft Powerplant I (Reciprocating Engine)

Power Plant Laboratory Engine Reassembly Procedures 9

AMT1104 Aircraft Powerplant I (Reciprocating Engine)

REF.NO. 7-73, 7-81, 7-82, 7-83,

PAGE 7-16A -LYCOMING ENGINE OVERHAUL MANUAL

A. REASSEMBLY OF CRANK CASE,

AMT1104 Aircraft Powerplant I (Reciprocating Engine)

4. Use a pencil mark to mark a reference

AMT1104 Aircraft Powerplant I (Reciprocating Engine)

B. REASSEMBLY OF CRANK SHAFT, CONNECTING ROD AND BEARINGS,

AMT1104 Aircraft Powerplant I (Reciprocating Engine)

AMT1104 Aircraft Powerplant I (Reciprocating Engine)

Power Plant Laboratory Engine Reassembly Procedures

CRANK CASE, BEARINGS, CAMSHAFT AND TAPPET BODIES

CRANK SHAFT, CONNECTING ROD AND BEARINGS

AMT1104 Aircraft Powerplant I (Reciprocating Engine)

AMT1104 Aircraft Powerplant I (Reciprocating Engine)

1. Discuss the ff. (10 items) own words.

a. Reassembly of Crank Case, Bearings, Camshaft and Tappet Bodies

Knowledge on The Topic C1 35%

Format Based on The Given F1 5%

As a student under the AMT Department of Institute of Engineering and

AMT1104 Aircraft Powerplant I (Reciprocating Engine)

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