Engine Overhaul
Our engines are renowned for their outstanding reliability, smooth operation and long life. If you want peace of mind, knowing there’s a Valley Aero overhaul turning your prop is just about as good as it gets.
Our overhauls are more than just "by the book" teardown and parts replacement jobs, and they're far more advanced than your typical "field overhaul". A Valley Aero overhaul is a top to bottom, analytical, methodical, technically precise process performed to exacting standards by highly experienced AMEs.
From beginning to end, every engine is treated as a separate entity. Unlike some large engine overhaullers, we never intermix your parts with parts from other engines for batch processing.
In fact, we guarantee that every re-certifiable part that comes out of your engine will go back into your engine.
We offer various levels of overhaul, from complete to engine only. A complete overhaul includes overhauling the engine, all accessories (starter, alternator, vacuum pump, etc,), overhauling the entire fuel system and replacing the entire ignition system with new components. This is the overhaul that engine manufacturers recommend at the end of TBO or time expired by years.
Lesser levels of overhaul are possible when, for example, we're overhauling an engine that has low hours and low years, but may have been subject to abuse or is "making metal". In that case, we do the engine as usual (we never cut corners there), but evaluate the accessories including ignition and fuel system components. If a component passes our technical tests it may be possible to put it back in service without being overhauled. If you choose that route, be aware that you'll most likely have to replace those components sometime before you reach the next TBO. So, in the end, you're not really saving money, just deferring expense.
What's Included in a Typical Valley Aero Engine Overhaul?
A typical complete engine overhaul consists of the following:
Note: these are the highlights only, there are actually thousands of steps to an engine overhaul.
- All parts specified by the engine manufacturer's overhaul manual replaced
- Every moving part inspected and measured to meet manufacturer's published tolerances or replaced
- Crankshaft and all steel parts NDT tested and re-certified or replaced
- Camshaft replaced or reground and re-certified (we prefer to replace as they last longer)
- Connecting rods NDT tested, re-bushed and sized
- Cylinders replaced with new (overhauled cylinders are possible but they may not make another TBO)
- Crankcase Zyglo inspected for incipient stress induced cracks
- Oil cooler flushed and pressure tested
- All internal engine ADs complied with
- Engine fuel system components overhauled
- Turbocharger overhauled – if applicable
- Slick magnetos replaced with factory exchange, Bendix overhauled by us
- Ignition harness replaced
- Spark plugs replaced
- Engine painted
- All hoses and fluid lines replaced
- Lord mounts replaced
- Engine test run to manufacturer's specs prior to first flight
Post Overhaul Service and Monitoring
Once your overhauled engine is back in your airplane we'll give you all the support and service you need to make sure it's broken in properly.
It is critically important that you change oil within 25 hours of overhaul, or after any major engine work for that matter. This gives us a chance to double check your engine to ensure everything is as it should be.
Post overhaul, we don't relax in our pursuit of safety. We use well defined evaluation techniques combined with at least two oil changes at early intervals to ensure your engine is absolutely safe and reliable.