Norvic overhauls and repairs all current Lycoming and Continental engines.

I Engine Receiving (Customer Property) II Engine Disassembly III Parts Removal IV Engine Cleaning V New Part Requirement VI Overhaul Part Requirements

I Engine Receiving (Customer Property)

1. Engine is to be received into the system and a complete inventory taken of accessories, fittings and any extra or unusual items.

2. Engine will be photographed and a visual inspection performed for any external damage. If damage is recorded the customer will be notified immediately.

3. Work order is issued recording Engine model, Spec and Serial Number.

II Engine Disassembly

1. Engine is disassembled with all parts remaining together and stored on an Engine cart. One engine per cart.

2. The recording of both Crankshaft and Crankcase serial number will be recorded at this time.

3. Smaller parts will be consolidated and identified by work number with a tag.

4. During disassembly a written report is to be made noting anything unusual.

III Parts Removal

1. Any parts removed and sent for repair/overhaul to Norvic's certified repair facility will be noted in the work order file.

2. This will include the reason for removal, date and inspector.

IV Engine Cleaning

1. All Parts will be cleaned and washed in accordance with acceptable industry practice.

2. All oil galley plugs, caps and tubes are removed and any sludge build up is removed.

V New Part Requirement

1. All 100% replacement parts unless specified otherwise will be installed at time of overhaul in accordance with TCM SB97-6 or Lycoming SB240 or latest revision.

VI Overhaul Part Requirements

1. All parts must meet manufacturers tolerances.

2. Steel parts are to be inspected using one or more of the following procedures: Magnetic particle, ultrasonic, 10-power visual and dimensional inspections as appropriate.

3. Aluminium parts to be 10-power visual, F.P.E and flat stone inspected.

4. Gears, castings, counter weights and housings are to be dimensional inspected and replaced as required.

5. Rocker arms will require magnaflux, new bushings installed and refaced.

6. Connecting rods, magnaflux, inspect all critical dimensions: (bore, alignment, twist convergence). Rebush and bore to new limits as required.

7. Camshafts reprofiled or replaced with new cam.

8. Crankshafts

Magnaflux, (ultrasonic inspect when required), detailed dimensional inspectin, Micro-Polish journals.

Rebush counterweight blades and assemble counter weights if required.

Resize journals to next bearing size (if required).

9. Crankcase

Visual inspection for fretting. F.P.I inspect for cracks.

Dimensionally inspect all machined surfaces.

Oil Galleys cleaned and pressure tested all studs torque checked and replaced as required.

Crankcase to be resurfaced and line bored as necessary.

10. Oil cooler to be cleaned. Pressure test and overhaul (Extra charges may apply)

11. Starter adapters on TCM engines are to be repaired or overhauled as necessary.

12. Accessories

*All accessories will be overhauled by Norvic certified accessory shop or replaced with factory rebuilt and new units when necessary.

*Rebuilt and new accessories will come with the manufacturers standard warranty.

13. Available Cylinder options

Factory New Cylinder Assy (OEM - Original Equipment Manufactured parts).

Overhauled Cylinder Assy (subject to inspection)

14. Engine Build Records

Record dimension and non-destructive inspection results for all parts to be reused in the engine.

New replacement parts installed shall be listed by the exact part number and serial number if applicable.

Rebored and overhaul parts must have correct certification documents (i.e FAA,CAA,EASA) and copy of the certification must be recorded in the builds records.

During build up the clearances and torque values are to be used as specified by the approved data.

All accessories to be supplied with engine shall be recorded by the part number, serial number, batch number.

15. All Work will be performed to acceptable aviation standard of practices

*The lead inspector shall be responsible that the measurements and recorded dimensions on all reused parts meeting manufacturers limits when installed in the engine.

*That all parts listed in the build records are installed in the engine.

*That all reworked and overhaul parts are properly certified prior to installation and recorded in the build records.

*Compliance with all technical data. Airworthiness directives and service bulletins.

*Monitoring all steps during the engine overhaul process and ensuring that the engine build records are complete and properly filed.

*Lead inspector will sign a document that certifies engine specifications and requirements have been complied with. Document will be filed in engine build records and inserted in the log book.

*Documentation records will be maintained.

16. Assembly Requirements.

*Engines are to be assembled in accordance with FAA approved data or international equivalent.

*All Airworthiness Directives (AD’s), mandatory service bulletins will be complied with.

*All external features of the engine will be Lycoming engine colour, TCM Gold colour as specified by the customer.

17. Engine Test Requirements

Engine will be run in the Norvic Aero Engines test house on a dynamometer.

18. Skill Personnel

All technical work is done by EASA Part 145 certified personnel

I.A.W. The company’s EASA Part 145 Approval No.UK.145.01182.

19. Release Documents

EASA FORM 1 with log book entry or FAA release to service as required.

20. Warranty

Please see Norvic Aero Engines contract and warranty terms and conditions.

 

If you would like more information about our overhaul procedures or to discuss work you would like carried out, please do not hesitate to contact one of our dedicated team members.