AERO PISTON ENGINE

16.1.1 Introduction
This module unit is designed to equip the trainee with knowledge,
skills and attitudes necessary for the maintenance and operation of
piston engines.

16.1.2 General Objectives

By the end of the module unit the trainee should be able to:
a) outline the historical development of aero piston engines.
b) understand the basic principles of aero piston engines
c) perform service and maintenance on aero piston engines
d) appreciate the need for standards and regulations pertaining to aero
piston engines
e) demonstrate an awareness for safety while handling aero piston
engines

16.1.3 Module Unit Summary and Time Allocation

Code Sub-Module Content Total (Hrs)

Unit Theory Practice Total
16.1.0 Engine  Historical 4 4
1 System development
 Aero piston Heat
engine
16.1.0 Engine  Types 16 4 20
2 components  Construction
 Operation
 Maintenance
 safety
16.1.0 engine cycles  Types 10 4 14
3  Operation
 application
16.1.0 Induction  Types 16 4 20
4 system  Operation
 Application
 Maintenance
 safety
16.1.0 Fuel system  Types 16 4 20
5  Operation
 Application
 Maintenance
 Safety
16.1.0 Ignition  Types 12 4 16
Code Sub-Module Content Total (Hrs)
Unit Theory Practice Total
6 system  Operation
 application
 Maintenance
 Safety
16.1.0 Starting  Types 8 2 10
7 systems  Operation
 Application
 Maintenance
 Safety
16.1.0 Lubrication  Types 12 4 16
8 systems  Operation
 System
Components
 Maintenance
 Safety
16.1.0 Cooling  Types 6 2 8
9 system  Operation
 Maintenance
 safety
16.1.1 Exhaust  types 6 2 8
0 system  Construction
 Operation
 Maintenance
 Safety
16.1.1 Aviation fuels  Types 4 2 6
1  qualities
 Safety
16.1.1 Engine  factors that affect 12 4 16
2 performance engine
performance
 starting
procedures
 engine
Instruments
16.1.1 Maintenance  types 16 20 36
3  methods
 tools and
equipment

Total 0 0 0
16.1.01 ENGINE SYSTEMS

16.1.01C Competence
The trainee should have the ability to relate old and new technology with respect to aero
piston heat engine.

Theory

16.1.01T0 Specific Objectives

By the end of the sub module unit the trainee should be able to
a) outline the historical development of the modern aero piston engine .
b) differentiate the types of aero piston engines

Content
16.1.01T1 Outline the history of the
aero piston engine
i) early inventors
- Denis Papin
- James Watt
- Thomas Newcomen
- Nikolaus Otto
16.1.01T2 Different types of piston
heat engine
i) external combustion
ii) internal combustion

Practice

16.1.01P0 Specific objectives

By the end of the sub module unit the trainee should be able to identify types of aero piston
engines.
16.1.01P1 Simulation of aero piston
engine

Suggested Teaching / Learning Activities

- Demonstrations
- Discussions
- Class Notes

Suggested Teaching / Learning Resources

- Relevant text books
- Computer Slides.
- Charts
- Simulation
- internet
- Videos
- Projector

Suggested Evaluation Methods

- Oral tests
- Timed written tests
 - Assignments

16.1.02 engine components

16.1.02c competence
the trainee should have the ability to service, maintain and repair aero piston engine
components.

Theory

16.1.02T0 Specific objectives

By the end of the sub-module unit, the trainee should be able to:
a) identify types of aero piston engine components
b) describe the construction of the aero-piston engine
c) explain the operation of the aero piston engine
d) practice correct maintenance procedures
e) state safety precautions observed during engine operation

Content
16.1.02T1 Identify aero piston
components
i) cylinders
ii) crankcases
iii) pistons and rings
iv) valves and valve train
v) bearings and springs
16.1.02T2 Describe the
construction of the aero
piston engine.
i) engine configuration
ii) cylinder arrangements
- parts
o crankcase
o crankshaft
o camshafts and sumps
o gear box
- accessory
- reduction
o cylinder and piston assemblies
o connecting rods and valves
o valve mechanisms
o materials
16.1.02T3 Operation of operation of components
i) description
ii) function
16.1.02T4 Maintenance
i) checks
ii) inspections
iii) servicing
iv) dismantling and assembly
16.1.02T5 Safety precautions

Practice

16.1.02P0 Specific Objectives

By the end of the sub- module unit the trainee should be able to dismantle, identify
inspect , describe and assemble engine components.

Content
16.1.02P1 Dismantling a piston
engine
16.1.02P2 Identification of engine
parts
16.1.02P3 Cleaning and
inspection
16.1.02P4 Assembling piston
engine parts
16.1.02P5 Observe safety
precautions

Suggested Teaching and Learning Activities

- Demonstrations
- Discussions
- Class Notes
- Identifying and
arranging assorted engine parts
- Cleaning, labelling and storing appropriately

Suggested Teaching/ Learning Resources

- Relevant text books
- Computer Slides.
- Over haul manual
- Illustrated parts catalogue
- Charts
- Simulation
- Complete piston engine
- Assorted engine parts

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Assignments
- Timed practical tests

16.1.03 ENGINE CYCLES

16.1.03C Competence
The trainee should have the ability to describe the operation of the piston engine

Theory
16.1.03T0 Specific Objectives
By the end of the sub module unit the trainee should be able to
a) describe types of the aero piston engine cycles
b) explain operation of engine cycles
c) state the application of the engine cycles

Content
16.1.03T1 Describe types of
engine cycles
i) two stroke
ii) four stroke
16.1.03T2 Explain operation of
engine cycles
i) two stroke
ii) four stroke Otto cycle
- induction
- compression
- power
- exhaust
- pressure volume
relationship
- piston
displacement and
compression ratio
16.1.03T3 State the application of the engine cycles
i) two stroke
ii) four stroke
iii) power calculation
iv) horse power

Practice

16.1.03P0 Specific Objectives

By the end of the sub- module unit the trainee should be able to demonstrate the operation
cycles of the aero piston engine.

Content
16.1.03P1 Simulation of the two
stroke cycle
16.1.03P2 Simulation of the two
stroke cycle

Suggested Teaching and Learning Activities

- Demonstrations
- Discussions
- Class Notes

Suggested Teaching/ Learning Resources

- Relevant text books
- Computer Slides.
- Charts
 - Video animation
- LCD and slide projector
- Complete Piston engine

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Assignments

16.1.04 INDUCTION
SYSTEMS

16.1.04C Competence
The trainee should have the ability to service, maintain and repair aero piston engine
induction systems.

Theory

16.1.04T0 Specific Objectives

By the end of the sub-
module unit the trainee should be able to:
a) describe types of the modern aero piston engine induction systems
b) explain operation of engine induction systems
c) state the application of the engine induction systems
d) practice correct maintenance procedures
e) observe appropriate safety precautions

Content
16.1.04T1 Describe types of the
induction systems
i) system layout
16.1.04T2 Explain operation of
induction systems
i) principles and
purpose of charging
16.1.04T3 Application of the
induction systems
i) internal (supercharger)
ii) external (turbo charger)
16.1.04T4 Maintenance
i) checks
ii) inspections
iii) servicing
16.1.04T5 Safety precautions

Practice

16.1.04TP0 Specific Objective

By the end of the sub-
module unit, the trainee should be able to identify and service
induction systems
 Content
16.1.04P1 Disassemble and
assemble
i) super charger
ii) turbo charger
16.1.04P2 Maintenance
i) checks
ii) inspections
iii) servicing
16.1.04P3 Safety precautions

Suggested Teaching/Learning Activities

- Demonstrations
- Discussions
- Hangar Visits
- Class Notes

Suggested Teaching/ Learning Resources

- Relevant text books
- Internet research
- Charts
- Simulation

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Assignments
- Timed practical tests

16.1.05 FUEL SYSTEMS

16.1.05C Competence
The trainee should have the ability to service, maintain and repair aero piston engine
carburetion systems

Theory

16.1.05T0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to:
a) identify types of aviation gasoline
b) describe the operation aero-piston engine carburettors
c) explain the construction features and operation of fuel injection systems for the aero-
piston engine
d) Practice correct maintenance procedures
e) Observe appropriate safety precautions

Content
16.1.05T1 Types of aviation
 gasoline
i) grades
ii) fuel contamination
iii) mixture ratio
iv) definitions
- exhaust gas temperature
- flame rate
- detonation
- pre-ignition
16.1.05T2 Operation of the carburettor
i) simple float carburettor
ii) special features
- altitude considerations and variations
- pressure balance
- jets
- accelerator pump
- mixture control
16.1.05T3 Application of fuel injection systems
i) fuel injection
ii) water methanol
iii) components of fuel injection system
- types of injector pumps
- fuel control units
- throttle valve
iv) advantages of fuel injection system
16.1.05T4 Maintenance
i) checks
ii) inspections
iii) servicing
16.1.05T5 safety precautions
i) carburettor intake icing
- throttle ice
- evaporation ice
- impact ice
- carburator intake heating
- effects of induction system icing

Practice

16.1.05 P0 Specific objectives

By the end of the sub module unit the trainee should be able to maintain the aero piston
engine carburetion systems

Content
16.1.05P1 Carburettor assembly
16.1.05P2 Cleaning and inspection
16.1.05P3 Identify parts
16.1.05P4 Assemble carburettor

Suggested Teaching and Learning Activities

 - Demonstrations
- Discussions
- Servicing
- Class Notes

Suggested Teaching/ Learning Resources

- Relevant text books
- Computer Slides.
- Carburettor units
- Charts
- Relevant tools

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Assignments
- Timed practical tests

16.1.0 6 IGNITION SYSTEM

16.1.06C Competence
The trainee should have the ability to service, maintain and repair aero piston engine
ignition systems

Theory

16.1.06T0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to:
a) describe types of aero piston engine ignition systems
b) explain operation of magneto timing
c) describe the application and construction and operation of the aero piston spark plug
d) Practice correct maintenance procedures
e) observe appropriate safety precautions

Content
16.1.06T1 Types
i) coil
ii) magneto systems
- rotating armature type
- polar inductor
- rotating magnet
16.1.06T2 Magneto systems
i) methods of timing
- magneto timing
ii) magneto couplings
16.1.06T3 Aero-piston spark plug
i) construction and operation
16.1.06T4 Maintenance
i) checks
ii) inspections
iii) servicing
16.1.06T5 Safety precautions

Practice

16.1.06P0 Specific Objectives

By the end of the sub module unit the trainee should be able to dis-assemble and assemble
a magneto

Content
16.1.06P1 Disassemble and
assemble a magneto

Suggested Teaching/Learning Activities

- Demonstration
- Discussions
- Class Notes
- Disassembly, cleaning, inspection and assembly

Suggested Teaching/ Learning Resources

- Relevant text books
- Computer Slides.
- Charts
- Projector
- Internet
- Magneto
- Ignition parts
- Relevant tools

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Assignments

16.1.07 STARTING

16.1.07C Competence
The trainee should have the ability to install and maintain the starting system components

Theory

16.1.07T0 Specific Objectives

By the end of the sub-module unit the trainee should be able to:
a) describe types of aero piston engine starting systems
b) describe the operation of aero piston engine starting systems
c) identify parts and components of the systems
d) explain principles, purpose and operation of aero piston engine charging system.
 e) Practice correct maintenance procedures
f) Observe appropriate safety precautions

Content
16.1.07T1 Direct cranking starters
i) small engine
ii) large engine
iii) Auxiliary starting systems
iv) impulse couplings
16.1.07T2 Starting system
components
i) starter motors
ii) spark plugs
16.1.07T3 Charging system
i) dc generator
ii) ac generator
16.1.07T4 Charging methods
i) cut out
ii) voltage control
iii) current control
iv) transistorised
16.1.07T5 Starting system
maintenance
16.1.07T6 Maintenance
i) checks
ii) inspections
iii) servicing
16.1.06T5 Safety precautions

Practice

16.1.07TP0 Specific Objectives

By the end of the sub-
module unit, the trainee should be able to:
a) install starters
b) inspect and service starters

Suggested Teaching/ Learning Activities

- Demonstrations
- Discussions
- Servicing
- Class Notes

Suggested Teaching/ Learning Resources

- Relevant text books
- Computer Slides.
- Charts
- Relevant tools
- Piston engine
 Suggested Evaluation Methods
- Oral tests
- Timed written tests
- Assignments
- Timed practical tests

16.1.08 LUBRICATION
SYSTEM

16.1.08C Competence
The trainee should have the ability to service, maintain and repair aero piston engine
lubrication systems.

Theory

16.1.08T0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to:
a) describe types of aero piston engine lubricating systems
b) describe the operation of aero piston engine lubrication systems
c) identify parts and components of the system.
d) describe the application and construction and of the aero piston engine lubrication
system components
e) Practice correct maintenance procedures
f) observe appropriate safety precautions

Content
16.1.08T1 Types of lubrication
systems
i) wet sump
ii) dry sump
16.1.08T2 Types of oils
i) properties
ii) selection of appropriate types and grades of oil
16.1.08T3 Construction and
operation of
components
16.1.08T4 Functions of the
lubrication system
components
16.1.08T5 Maintenance
i) oil dilution
ii) checks
iii) inspections
iv) servicing
16.1.08T5 Safety precautions

Practice

16.1.08P0 Specific Objectives

 By the end of the sub module unit the trainee should be able to inspect lubrication system
components

Content
16.1.08P1 Identify parts of
lubrication system
16.1.08 P2 Carry out inspection of
lubrication system
components

Suggested Teaching/ Learning Activities

- Demonstrations
- Discussions
- Class Notes

Suggested Teaching/ Learning Resources

- Relevant text books
- Charts
- Relevant tools
- Oil system components

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Assignments
- Timed practical tests

16.1.09 COOLING SYSTEM

16.1.09C Competence
The trainee should have the ability to service, maintain and repair aero piston engine cooling
systems.

Theory

16.1.09T0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to:
a) explain air cooling principles in aero-piston engines .
b) describe liquid cooling system in aero-piston engines .
c) describe types of aero piston engine cooling systems
d) describe the operation of aero piston engine lubrication systems
e) identify parts and components of the system.
f) describe the application and construction and of the aero piston engine lubrication
system components
g) Practice correct maintenance procedures
Observe appropriate safety precautions

Content
16.1.09T1 Types
i) air cooling
ii) liquid cooling
16.1.09T2 operation
i) heat dissipation
- oil
- water
16.1.09T3 Components
i) cooling fins
ii) cooling pumps
16.1.09T4 Maintenance
i) oil dilution
ii) checks
iii) inspections
iv) servicing
16.1.09T5 Safety precautions

Practice

16.1.09P0 Specific Objectives

By the end of the sub module unit the trainee should be able to service the cooling system

Content
16.1.09 P1 Carry out inspection of
Cooling system

Suggested Teaching/Learning Activities

- Demonstrations
- Discussions
- Servicing
- Class Notes

Suggested Teaching/ Learning Resources

- Relevant text books
- Computer Slides.
- Charts
- Relevant tools
- Piston engine

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Assignments
- Timed practical tests

16.1.10 EXHAUST
SYSTEMS

16.1.10C Competence
The trainee should have the ability to service, maintain and repair aero piston engine exhaust
systems.

Theory
16.1.10T0 Specific Objectives
By the end of the sub-
module unit the trainee should be able to:
a) explain the function of the system
b) describe the construction of the exhaust system
c) explain the operation of the system
d) Practice correct maintenance procedures
e) Observe appropriate safety precautions

Content
16.1.10T1 Function
i) materials used in the construction of aero exhaust systems
16.1.10T2 Construction and
operation
16.1.10T3 Maintenance
i) checks
ii) inspections
iii) servicing
16.1.10T4 safety precautions
i) fire protection
ii) fire detection
iii) types of extinguishers
iv) operation

Practice

16.1.10TP0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to inspect and repair the
system

Content
16.1.10P1 Leaks detection and
repair
i) exhaust manifold, muffler and pipe

Suggested Teaching and Learning Activities

- Demonstrations
- Discussions
- Servicing
- Class Notes

Suggested Teaching/ Learning Resources

- Relevant text books
- Computer Slides.
- Charts
- Relevant tools
- Exhaust unit

Suggested Evaluation Methods

- Oral tests
 - Timed written tests
- Assignments
- Timed practical tests

16.1.11 AVIATION FUELS

16.1.11C Competence
The trainee should have the ability to observe safety while handling aircraft fuel

Theory

16.1.11T0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to:
a) state qualities required of aviation fuels
b) identify various types of fuels and fuel additives
c) explain safety precautions practiced when handling aviation fuels

Content
16.1.11T1 General qualities
required of aviation
fuels
i) ease of flow
ii) quick starting of engine
iii) calorific value
iv) corrosion factors
v) by products of combustion
vi) fire hazards
vii) lubricating qualities
16.1.11T2 Types of aviation fuels
and additives
i) AVGAS
ii) AVTUR
iii) AVTAG
iv) AVCAT
16.1.11T3 Precautions when handling aviation fuels
i) fire hazards
ii) storage
iii) handling
fire extinguishers
- types
- checks

Practice

16.1.11P0 Specific Objectives

By the end of the sub module unit the trainee should be able to identify aircraft fuels and
handle them safely

Content
16.1.11P1 Identify aircraft fuels
i) physical identification
 Suggested Teaching and Learning Activities
- Demonstrations
- Discussions
- Servicing
- Class Notes

Suggested Teaching/ Learning Resources

- Relevant text books
- Computer Slides.
- Charts
- Relevant tools
- Piston engine

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Assignments
- Timed practical tests

16.1.12 ENGINE
PERFORMANCE

16.1.12C Competence
The trainee should have the ability to operate the aero piston engine safely

Theory

16.1.12T0 Specific Objectives

By the end of the sub-module unit the trainee should be able to:
a) explain factors that affect engine performance
practice correct engine starting procedures
b) analyse engine operation instruments

Content
16.1.12T1 Factors affecting engine performance
i) altitude
- humidity
- carburettor air temperature
- cruise control
ii) engine design features
- engine power rating
- volume
- compression ratio and speed
- air mixture control
16.1.12T2 Engine ground run
i) procedures
ii) safety precautions
16.1.12T3 Engine monitoring
instruments
 Practice

16.1.12TP0 Specific Objectives

By the end of the sub-module unit, the trainee should be able to practice correct engine
ground running procedures.

Content
16.1.12P1 Live aircraft engine ground run.
i) student to participate in a live aircraft engine ground run

Suggested Teaching and Learning Activities

- Demonstrations
- Discussions
- simulation
- Class Notes

Suggested Teaching/ Learning Resources

- Relevant text books
- Computer Slides.
- Charts
- Relevant tools
- Piston engine
- Computer based simulation

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Assignments
- Timed practical tests

16.1.13 MAINTENANCE

16.1.13C Competence
The trainee should have the ability to carry out specific maintenance of the aero piston
engine

Theory

16.1.13T0 Specific Objectives

By the end of the sub module unit the trainee should be able to
a) describe types of maintenance
b) explain the methods of carrying out maintenance
c) describe the tools and equipment used for maintenance.

Content
16.1.13T1 Types of maintenance
 i) line maintenance
- before flight
- transit(turn round)
- after flight
ii) base maintenance
- non destructive inspection
- repair
- overhaul
16.1.13 T2 Methods of
maintenance
i) scheduled
ii) non scheduled
16.1.13T3 Tools and equipment

Practice

16.1.13TP0 Specific Objectives

By the end of the sub-module unit, the trainee should be carry out correct maintenance
practices.

Content
16.1.13P1 Live aircraft engine
maintenance
i) student to participate in a live aircraft engine servicing

Suggested Teaching and Learning Activities

- Demonstrations
- Discussions
- Servicing
- Class Notes

Suggested Teaching/ Learning Resources

- Relevant text books
- Computer slides.
- Charts
- Relevant tools
- Piston engine

Suggested Evaluation Methods

- Oral tests
- Timed written tests
- Assignments
- Timed practical tests