Total Training Support's Integrated Training System. We are sure you will need no other reference material to pass your EASA Part-66 exam in this Module.

These notes have been written by instructors of EASA Part-66 courses, specifically for practitioners of varying experience within the aircraft maintenance industry, and especially those who are self-studying to pass the EASA Part-66 exams.

They are specifically designed to meet the EASA Part-66 syllabus and to answer the questions being asked by the UK CAA in their examinations.

The EASA Part-66 syllabus for each sub-section is printed at the beginning of each of the chapters in these course notes and is used as the “Learning Objectives”.

We suggest that you take each chapter in-turn, read the text of the chapter a couple of times, if only to familiarise yourself with the location of the information contained within. Then, using your club66pro.co.uk membership, attempt the questions within the respective sub-section, and continually refer back to these notes to read-up on the underpinning knowledge required to answer the respective question, and any similar question that you may encounter on your real Part-66 examination. Studying this way, with the help of the question practice and their explanations, you will be able to master the subject piece-by-piece, and become proficient in the subject matter, as well as proficient in answering the CAA style EASA part-66 multiple choice questions.

The course notes are written to suit Licence category 'B1' but also covers Licence category 'A'.

602 pages (in 2 volumes)

CONTENTS

VOLUME 1

Module 16.1 Fundamentals

Development of Power

The Otto Engine

• The 4-Stroke Cycle
• Valve Timing
• Ignition Timing
• Valve Operation
• Pre-Ignition

Two-Stroke Engine

Diesel Engines

• 2-Stroke Diesel
• 4-Stroke Diesel

Linear Measurements

Compression Ratio

Efficiencies

• Mechanical Efficiency
• Thermal Efficiency
• Volumetric Efficiency

Arrangement of Cylinders

Arrangement of Valves

Arrangement of Camshaft

Glossary of Piston Engine Terms

Module 16.2 Engine Performance

What is Power?

• General
• Horsepower Definitions
• Horsepower Conversions

Measurement of Power

• Definitions
• Power Measuring Machines

Factors Affecting Power

• Temperature and Density of Air
• Humidity
• Fuel Mixture
• Detanation
• Compression
• Fuel Metering
• Idle Mixture
• The Induction Manifold
• Operational Effect of Valve Clearance
• Ignition System
• Propeller Governor
• Overlapping Phases of Engine Operation
• Engine Power Troubleshooting

Module 16.3 Engine Construction

Constructional Arrangement

• Internal Arrangements
• Engine Type Classification
• Engine Cylinder Numbering
• External Component Arrangements

Crankcases

• In-line Engines
• Radial Engines

Crankshaft

• Nomenclature
• Journals
• Crank Pins
• Crank Cheeks or Arms
• Crankshaft Balancing
• Crankshaft Arrangements

Camshafts

Connecting Rods

• Function
• The Plain Connecting Rod
• The Fork and Blade Connecting Rod
• The Master and Articulated Rod

Cylinders

• General Arrangement
• Cylinder Heads
• Cylinder Barrels

Pistons

• General Assembly and Types
• Piston Rings

Valves Mechanisms

• Valves
• Valve Gear

Propeller Reduction Gearboxes

• Parallel Spur Gears
• Epicyclic Reduction Gears
• Compound Spur Epicyclic
• Gear Train / Epicyclic

Power Take-Off Provision

Module 16.4 Engine Fuel Systems

Carburettors

Intake Icing

Carburettor Icing

Fuel

• Fuel Grade
• Air/Fuel Ratio
• Mixture

The Float Chamber Carburettor

• Construction
• Operation
• Throttle Valve and Maine Jet
• Slow Running, Idle and Cut Off
• Pressure Balance Duct (PBD)
• The Diffuser
• The Air Bleed
• Control of Mixture Ratios
• Automatic Mixture Control
• Economy
• Power and Enrichment Jet
• Acceleration
• The Whole System

Fuel Injection Systems

Construction and Operating Principles

• The Throttle Body
• The Regulator
• Operation
• The Metering Section
• The Discharge Nozzle
• Mass Airflow

A Typical Pressure Injection Carburettor

• Fuel Control Unit (FCU)
• Manual Mixture Control
• Auto Lean
• Auto Rich
• Power
• Idle
• The Regulator
• The Throttle Body

Alternative Metering Systems

Bendix RSA Injection System

• Airflow Section
• Regulator Section
• The Flow Divizer
• Injection Nozzles
• Automatic Mixture Control (AMC)

Teledyne Continental Injection System

• General Layout
• The Fuel Pump Assembly
• The Fuel/Air Control Unit
• Manifold Fuel Valve
• The Injection Discharge Nozzle
• Supercharged and Turbocharged Engines

Full Authority Digital Engine Control (FADEC)

Introduction

Advantages

• Computer controlled
• Ignition
• Fuel Injection
• Vapour lock
• Fuel savings

Typical FADEC Layout

• ECU Architecture
• Fail Safe Control
• Maine Interfaces and Limits

Module 16.5 Starting and Ignition Systems

High Tension (HT) Ignition Systems

• The Primary or Low Tension (LT) Circuit
• The Secondary or High Tension (HT) Circuit
• Ignition Harness
• Operation of the Combined Circuits

Magnetos

• Magneto Operation
• Ignition Switches
• The Contract Breaker (CB)
• The Distributor
• Magneto Venting
• Magneto Speeds
• The Four Pole Magnet
• The Dual Magneto
• The Rotating Armature Magneto
• Magneto Mounting and Drives

Ignition Leads (HT)

• Construction
• Testing

Spark Plugs

• Construction
• Inspection and Servicing of Sparking Plugs
• Storage
• Plug Fitting
• Ground Checking

Auxiliary Ignition Systems

• Impulse Starters
• Booster Coils

Ignition Timing

• General
• Engine Speed
• Manifold Pressure
• Mixture Strength
• Automatic Timing Control
• Magneto Timing (Bendix)
• The "E" (Efficiency) Gap
• Timing Magneto to Engine

Starters

• Types of Starter
• Manual Cranking Inertia Starter
• Electrical Inertia Starters
• Combination Inertia Starters
• Direct Cranking Starters
• Solenoid or Pre-engaged
• Electric Starter Circuit
• Bendix Drive
• Starter Relay
• Bonding/Earthing Straps
• Troubleshooting and Maintenance

Module 16.6 Induction, Exhaust and Cooling Systems

Engine Exhaust Systems

Cylinder Cooling

• Air Cooled Engines
• Liquid Cooled Engines

Induction System

• The Air Intake
• Filters
• The Induction Manifold

VOLUME 2

Module 16.7 Supercharging / Turbocharging

Introduction

Aspirated Engines

Supercharged Engines

• The Impeller and Diffuser
• The Two Speed Supercharger
• The Two Stage Supercharger

The Supercharger

• The Roots Supercharger
• The Vane Supercharger
• The Centrifugal Supercharger
• Boost and Manifold Air Pressure
• System Layout
• Power From Supercharging
• Supercharger Control
• Manifold Pressure Control
• Variable Datum Control
• Boost Reversal
• Supercharger Drives
• The Centrifugal Friction Clutch

The Turbocharger

• The Waste Gate
• The Waste Gate Actuator
• The Absolute Pressure Controller
• The Variable Pressure Controller
• The Dual Unit Control System
• The Density Controller
• The Differential Pressure Controller
• The Triple Unit Control System

Module 16.8 Lubricants and Fuel

Lubrication

Types of Lubrication

• Boundary Lubrication
• Hydrodynamic Lubrication
• Elastrohydrodynamic Lubrication

Oil Viscosity

• Determining the Oil Viscosity
• The Effect of Temperature

Selection and Properties of Oil

• Society of Automotive Engineeers (SAE)
• Monograde Oil
• Multigrade Oil
• Straightgrade Oil
• Extreme Pressure Additive (Oil Extreme Pressure - OEP)
• Ashless Dispersant Additives
• Detergent Additives
• Use of Automotive Engine Oil

Condition Monitoring

• Spectrographic oil Analysis Programme

Engine Oil Use

• Protective Coating
• Moisture Formation
• Acids
• Location
• Oil and Filter Change

Fuel

General

Grade, Octane and Lead

• Calorific Value
• Volatility
• Anti-Knock Properties

Avgas

• Avgas 100
• Avgas 100LL
• Avgas 82 UL
• Avgas Density
• Some History of Avgas
• Identification

Mogas

• General
• Adverse Effects
• Testing for Alcohol in Mogas

Diesel

• General
• Bio Diesel
• Cold Weather

Aviation Fuel - Qualities and Requirements

• Anti-Knock Rating
• Volatility
• Vapour Lock
• Oil Dilution
• Corrosion
• Performance Number
• Mogas

Module 16.9 Lubricants Systems

Lubrication

• Film Lubrication
• Boundary Lubrication

Other Oil Functions

• Cooling
• Sealing
• Cleaning

Wet Sump System

• Crankcase Sump
• Oil Pump
• Pressure Relief Valve
• Oil Filter
• Oil Circuit
• Pressure Sensing
• Example: Lycoming Wet Sump System

Dry Sump System

Oil Tank

• Engine Driven Pumps

Anti-Drain Valve

Oil Temperature Sensing

Oil Cooling

• Oil Cooler
• By Pass Flow
• Non-Cooling Flow
• Cooling Flow

Oil Filtration and Filter Assemblies

Oil Dilution Systems

• Precautions When Oil Diluting
• Period of Effectiveness

Pressure Control

• Pressure Relief Valve
• Pressure Regulator

Lubrication Supply - Oil Distribution

Crankshaft Sealing

Oil Indications

• Low Oil Pressure
• High Oil Consumption
• High Oil Temperature

Module 16.10 Engine Indication Systems

Engine Indication Layout

Engine Speed (RPM)

• Mechanical Tachometers
• Mechanical Indicators
• Electrical Tachometers
• Tacho Generators
• Indicators
• Maintenance Practices

Synchroscope

Pressure Measurement

• Piston Type Gauges
• Direct Reading Gauges
• Bourdon Tube Instrument
• Capsule Instrument
• Transmitting Pressure Gauges
• Electrical Transmitters

Manifold Pressure and Boost Pressure Gauges

• Construction and Action
• Fuel Trap
• Testing Boost Gauges
• Oil Pressure

Measurement of Temperature

• Bimetallic Strip
• Resistance Bulbs
• Resistance Thermometers
• Wheatstone Bridge Temperature Sensor
• DC Ratiometer
• Thermocouple Sensors
• Piston Engine Ground Running Temperatures
• Engine Cylinder Head Temperature (CHT)
• Exhaust Gas Temperature
• Oil and Carburettor Temperature

Fuel Pressure and Flow

• Fuel Pressure Indicator
• Fuel Plowmeter
• Vane Type Fuel Flowmeter
• Synchronous Fuel Flowmeter (Motor driven)
• The Motorless Integrated Fuel Flow Transmitter
• The Synchronous Integrated Fuel Flowmeter
• Maintenance Practices

Module 16.11 Powerplant Installation

Engine Mounts

Engine Controls

• Throttle Control
• Propeller Controls
• Mixture Control
• Carburettor Heat

Control Systems

• General Requirements
• Push Pull Control Rods
• Bowden Controls
• Teleflex Controls

Engine Removal and Replacement

• General
• Reasons for Removal of Reciprocating Engines
• Preparation of Reciprocating Engines for Installation
• QECA Build-up of Radial Engines
• Draining the Engine
• Electrical Disconnects
• Disconnection of Engine Controls
• Disconnection of Lines
• Other Disconnections
• Hoisting the Engine

Engine Installation

• Hoisting and Mounting the Engine for Installation
• Connections and Adjustments

Preparation of Engine for Ground and Flight Testing

• Pre-oiling
• Fuel System Bleeding
• Propeller Check

Check and Adjustments after Engine Run-Up and Operation

Removal and Installation of an Opposed-Type Engine

Typical Removal and Installation Procedure

• Engine Removal
• Engine Installation

Module 16.12 Engine Monitoring and Ground Operation

Ground Running

• Ground Running Check
• Ground Running Precautions
• Pre-Start Checks
• Engine Shut Down

Overhaul Periods

• Private Category Aircraft
• Public Transport and Aerial Work Category Aircraft
• Engine Inspection Procedures for Extension to Overhaul Life
• Crop Spraying Aircraft
• Extension to Overhaul Periods
• Overhaul Periods (Light Aircraft)

Engine Overhaul

• Top Overhaul
• Major Overhaul

General Overhaul Procedures

• Disassembly
• Inspection
• Repair and Replacement

Cylinder Assembly Reconditioning

• Cylinder Head
• Cylinder Barrel
• Valves and Valve Springs
• Rocker Arms and Shafts
• Piston and Piston Pin
• Re-facing Valve Seats
• Valve Reconditioning
• Valve Lapping and Leak Testing
• Piston Repairs

Crankshaft Inspection

• Sludge Chambers

Connecting Rods

• Visual Inspection
• Checking Alignment

Block Testing of Reciprocating Engines

• Block Test Purpose
• Block-Test Requirements
• Mobile Stand Testing of Reciprocating Engines
• Block Test Instruments
• Carburettor Air Temperature Indicator
• Fuel Pressure Indicator
• Fuel Flowmeter
• Manifold Pressure Indicator
• Oil Temperature Indicator
• Oil Pressure Indicator
• Tachometer Indicator
• Cylinder Head Temperature Indicator
• Torquemeter
• Oil-Weighing System
• Metering Differential Manometer
• General Instrumentation

Reciprocating Engine Operation

• General
• Engine Instruments
• Engine Staring
• Engine Warm-Up
• Ground Check
• Propeller Pitch Check
• Power Check
• Ignition System Operational Check
• Cruise Mixture Check
• Idle Speed and Idle Mixture Cheecks
• Two-Speed Supercharder Check
• Acceleration and Deceleration Checks
• Engine Stopping
• Basic Engine Operating Principles
• Backfiring
• After-Firing

Cylinder Maintenance

• Hydraulic Lock
• Valve Blow-by
• Cylinder Compression Tests
• Direct Compression Tester
• Differential Pressure Tester
• Cylinder Replacement
• Cylinder Removal
• Cylinder Installation
• Valve and Valve Mechanism
• Valve Clearance
• Valve Spring Replacement
• Cold Cylinder Check

Module 16.13 Engine Storage and Preservation

Engine for Removal

Inhibiting

• Corrosion-Preventive Materials
• Corrosion-Preventive Compounds
• Dehydrating Agents
• Corrosion-Preventive Treatment

Packing and Sealing

• Recors
• Fuel System Inhibiting
• Blacks
• Engine Shipping Containers

Inspection of Stored Engines

Removal from Storage

• De-preservation of an Engine
• Inspection and De-preservation of Accessories
• Inspection and Replacement of Powerplant External Units and Systems