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Overhaul. In the general aviation industry, the term engine overhaul has two identifications
that make a distinction between the degrees of work done on an engine:
A major overhaul consists of the complete disassembly of an engine, inspected,
repaired as necessary, reassembled, tested, and approved for return to service within
the fits and limits specified by the manufacturer's overhaul data. This could be to new
fits or limits or serviceable limits. The determination as to what fits and limits are used
during an engine overhaul should be clearly understood by the engine owner at the
time the engine is presented for overhaul. The owner should also be aware of any parts
that are replaced, regardless of condition, as a result of a manufacturer's overhaul data,
service bulletin, or an ariworthiness directive.
Top Overhaul consists of the repair of parts outside of the crankcase and can be
accomplished without completely disassembling the entire engine. It can include the
removal of cylinders, inspection and repair to cylinders, inspection and repair to
cylinder walls, pistons, valve-operating mechanisms, valve guides, valve seats, and the
replacement of pistons and piston rings. A top overhaul is not recommended by all
manufacturers. Some manufacturers indicate that if a powerplant requires work to this
extent, it should be given a complete overhaul.
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