Engine Inspection and Service
6-6. Inspection Checklists
Inspection checklists are included as a convenient record of inspection progress and
findings. Using a copy of the form ensures a blank form will be available for the next
scheduled inspection. When an inspection is due, make a copy of the inspection checklist
to record inspection progress and findings while following the steps in the inspection
procedures. The checklists are not designed to replace the procedures; only augment them.
File the completed checklists in the aircraft records.
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Table 6-26. Engine Operational Checklist
Aircraft Make & Model: Aircraft Registration #:
Engine Model: Engine Position: Left Right Front Rear
Engine Serial Number: Engine Total Time:NewOverhaul
Date Location: Elevation: Outside Air Temp.: Altitude:
Operational Check
RPM Magneto Drop Check MAP Cylinder Head Temp. - °F EGT TIT
Spec Actual L R Drop/Spread Spec Actual 1 2 3 4 5 6 °F °F
Adjustments
IDLE Fuel Pressure (psi) Full Power Fuel Pressure (psi) Oil
Adjustments Adjustments Pressure Temp. Adjustments
Spec Actual Spec Actual
CW CCW CW CCW PSI °F CW CCW
Check Flight Data
Pressure
Altitude EGT °F TIT °F CHT °F
RPM MAP Set altimeter to 29.92” Spec Actual Spec Actual Spec Actual
Fuel Flow Oil PSI Oil Temp. °F Indicated Airspeed
Spec Actual Spec Actual Spec Actual
Remarks:
Signature:
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Table 6-27. 25-Hour Initial Operation Inspection Checklist
Engine Model Number: ___________________ Engine Serial Number: _________________
Total Time Engine has been in Service: _______________
Time Since Major Overhaul (TSMOH): __________________ Engine in Storage? ________
Date Inspection Performed: ________ Inspection Performed by:_____________________
Complete the 25-hour inspection according to the instructions referenced in the table, heeding all warnings,
cautions and notes. Initial the block beside the procedure upon completion. Note discrepancies in the Inspector
Comments or Remarks sections.
Inspection Item Initials Inspector Comments
“Visual Inspection” (Section 6-4.6)
Check Oil Consumption (Section 6-4.2)
“Induction System Inspection” (Section 6-4.14)
“Induction System Drain Inspection”(Section 6-4.20)
Change Engine Oil and Filter (Section 6-4.8.2)
Engine Run (Section 7-3.2)
•Idle RPM:
•Idle Mixture Cutoff Rise
•Acceleration
Remarks:
Approval Block:
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Table 6-28. 50-Hour Engine Inspection Checklist
Engine Model Number: ___________________ Engine Serial Number: _________________
Total Time Engine has been in Service: _______________
Time Since Major Overhaul (TSMOH): __________________ Engine in Storage? ________
Date Inspection Performed: ________ Inspection Performed by:_____________________
Complete the 50-hour inspection according to the instructions referenced in the table, heeding all warnings, cautions
and notes. Initial the block beside the procedure upon completion. Note discrepancies in the Inspector Comments or
Remarks sections.
Inspection Item Initials Inspector Comments
Oil Consumption and Trend Monitoring
Collect oil sample (Section 6-4.8.4) and Establish Oil
Analysis Profile (Section 6-4.8.5)
Oil Analysis Laboratory used?
Date of last oil sample analysis:
Silicone content of last sample:
Oil consumption quantity noted during oil change:
Is oil consumption excessive? Yes No
“Visual Inspection” (Section 6-4.6)
Oil and Filter Change (Section 6-4.8.2)
“Induction System Inspection” (Section 6-4.14)
“Induction System Drain Inspection” (Section 6-4.20)
For specified turbocharged engines only, lubricate the
wastegate butterfly valve (Section 6-4.21) and clean the
turbocharger oil supply check valve (Section 6-4.21.1)
Engine Run (Section 7-3.2)
•Idle RPM:
•Idle Mixture Cutoff Rise
•Acceleration
Remarks:
Approval Block:
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Table 6-29. 100-Hour Engine Inspection Checklist
Engine Model Number: ___________________ Engine Serial Number: _________________
Total Time Engine has been in Service: _______________
Time Since Major Overhaul (TSMOH): __________________ Engine in Storage? ________
Date Inspection Performed: ________ Inspection Performed by:_____________________
Complete the 100-hour inspection according to the instructions referenced in the table, heeding all warnings,
cautions and notes. Initial the block beside the procedure upon completion. Note discrepancies in the Inspector
Comments or Remarks sections.
Inspection Item Initials Inspector Comments
Engine Operational Check(Section 6-4.7)
Oil Consumption and Trend Monitoring
Oil Analysis Profile Established? (Section 6-4.8.5)
Oil Analysis Laboratory used?
Date of last oil sample analysis:
Silicone content of last sample:
Oil consumption quantity noted during oil change:
Is oil consumption excessive? Yes No
“Visual Inspection” (Section 6-4.6)
Accessory Mounting and Security Inspection (Step 19 in
Section 6-4.4)
“Cylinder Inspections”(Section 6-4.11) using the
Cylinder Inspection Checklist (Table 6-31 on page 177)
“Crankcase Inspection”(Section 6-4.12)
“Engine Mount Inspection” (Section 6-4.13)
“Induction System Inspection” (Section 6-4.14)
“Ignition System Inspection” (Section 6-4.15)
“Engine Gauge Inspection” (Section 6-4.16)
“Fuel System Inspection” (Section 6-4.17)
“Engine Control Linkage Inspection” (Section 6-4.19)
“Induction System Drain Inspection”(Section 6-4.20)
“Turbocharger and Exhaust System Inspection”
(Section 6-4.21)
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Table 6-29. 100-Hour Engine Inspection Checklist
Engine Model Number: ___________________ Engine Serial Number: _________________
Total Time Engine has been in Service: _______________
Time Since Major Overhaul (TSMOH): __________________ Engine in Storage? ________
Date Inspection Performed: ________ Inspection Performed by:_____________________
Oil and Filter Change (Section 6-4.8.2)
Engine Operational Check (Section 6-4.7)
Remarks:
Approval Block:
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Table 6-30. 500-Hour Engine Inspection Checklist
Engine Model Number: ___________________ Engine Serial Number: _________________
Total Time Engine has been in Service: _______________
Time Since Major Overhaul (TSMOH): __________________ Engine in Storage? ________
Date Inspection Performed: ________ Inspection Performed by:_____________________
Complete the 500-hour inspection according to the instructions referenced in the table, heeding all warnings,
cautions and notes. Initial the block beside the procedure upon completion. Note discrepancies in the Inspector
Comments or Remarks sections.
Inspection Item Initials Inspector Comments
Engine Operational Check(Section 6-4.7)
Oil Consumption and Trend Monitoring
Oil Analysis Profile Established? (Section 6-4.8.5)
Oil Analysis Laboratory used?
Date of last oil sample analysis:
Silicone content of last sample:
Oil consumption quantity noted during oil change:
Is oil consumption excessive? Yes No
“Visual Inspection” (Section 6-4.6)
Accessory Mounting and Security Inspection (Step 19
in Section 6-4.4)
Paper Induction Filter Replacement (Section 6-4.5)
“Cylinder Inspections”(Section 6-4.11) using the
“Cylinder Inspection Checklist” (Table 6-31)
“Crankcase Inspection”(Section 6-4.12)
“Engine Mount Inspection” (Section 6-4.13)
“Induction System Inspection” (Section 6-4.14)
“Ignition System Inspection” (Section 6-4.15)
500-Hour (Continental) Magneto Inspection or (non-
Continental) Magneto Replacement (Section 6-4.15)
“Engine Gauge Inspection” (Section 6-4.16)
“Fuel System Inspection” (Section 6-4.17)
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Table 6-30. 500-Hour Engine Inspection Checklist
Engine Model Number: ___________________ Engine Serial Number: _________________
Total Time Engine has been in Service: _______________
Time Since Major Overhaul (TSMOH): __________________ Engine in Storage? ________
Date Inspection Performed: ________ Inspection Performed by:_____________________
“Engine Control Linkage Inspection” (Section 6-4.19)
“Induction System Drain Inspection”(Section 6-4.20)
“Turbocharger and Exhaust System Inspection”
(Section 6-4.21)
“Alternator Inspection” (Section 6-4.22)
Oil and Filter Change (Section 6-4.8.2)
Engine Operational Check (Section 6-4.7)
Remarks:
Approval Block:
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Table 6-31. Cylinder Inspection Checklist
Engine Model Number: ___________________ Engine Serial Number: _________________
Total Time Engine has been in Service: _______________
Time Since Major Overhaul (TSMOH): __________________ Engine in Storage? ________
Date Inspection Performed: ________ Inspection Performed by:_____________________
Inspection Item Inspector Comments
Complete the cylinder inspection according to the instructions referenced in the table, heeding all warnings,
cautions and notes. Initial the block beside the procedure upon completion. Note discrepancies in the Inspector
Comments or Notes sections.
Complete a visual inspection of the cylinder exterior and power
stroke areas for signs of cracks, leaks, rust or
pitting (Section 6-4.11.1).
Cylinders
1 2 3 4 5 6
Complete a visual inspection of cylinder head, barrel, fins, ports
and bosses for evidence of fuel, oil or soot (Section 6-4.11.1)
Cylinders
1 2 3 4 5 6
Inspect the cylinder to crankcase mounting deck for visible signs
of RTV sealant (Section 6-4.11.4).
Cylinders
1 2 3 4 5 6
Differential Pressure Check (Section 6-4.11.2)
Baseline Master Orifice Calibrated Pressure Reading:
Cylinder Pressure Reading
1 2 3 4 5 6
NOTES:
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Table 6-31. Cylinder Inspection Checklist
Engine Model Number: ___________________ Engine Serial Number: _________________
Total Time Engine has been in Service: _______________
Time Since Major Overhaul (TSMOH): __________________ Engine in Storage? ________
Date Inspection Performed: ________ Inspection Performed by:_____________________
Cylinder Borescope Findings (Section 6-4.11.3)
Place a check mark in the column of any cylinder exhibiting the characteristics described in the left column.
Condition 1 2 3 4 5 6
Normal Wear.
Light rust (acceptable in absence of
excessive oil consumption or leaks)
Small areas of heavy rust (less than
½ inch diameter)
Heavy rust (greater than ½ inch)
Pitting of on cylinder wall.
Heavy wear
Scoring
Static seal leakage
Other discrepancies
Cylinder Inspection Summary
Place a check mark in the column of any cylinder exhibiting the characteristics described in the left column.
Cylinders exhibiting the following characteristics must be removed and repaired or replaced according to the
instructions in Section 10-6, “Cylinder Repairs.”
Condition 1 2 3 4 5 6
Heavy rust, characterized by pitting
of the cylinder wall
Scoring or scratches in the honed
surface of the cylinder wall (or bore)
Blistered paint on the cylinder
barrel/other evidence of excessive
wear and internal heat
Cylinder subjected to overheating/
detonation/piston scoring or piston
pin damage to the cylinder bore.
Cylinder with radial fin crack
extending to the root of a fin
Cylinder with barrel fin crack
Cylinder head turned in relation to
barrel flange
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Table 6-31. Cylinder Inspection Checklist
Engine Model Number: ___________________ Engine Serial Number: _________________
Total Time Engine has been in Service: _______________
Time Since Major Overhaul (TSMOH): __________________ Engine in Storage? ________
Date Inspection Performed: ________ Inspection Performed by:_____________________
Condition 1 2 3 4 5 6
Heavy bore wear
Cylinder leaks
Low differential pressure/ excessive
oil consumption
Static seal leakage/head to barrel
leakage, or crack in head or barrel
Inspection Follow-up
Check all column(s) that apply to the scope of inspection and repair.
Condition 1 2 3 4 5 6
Cylinder passed inspection
Repaired Cylinder
Replaced Cylinder
Remarks:
Approval Block:
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