Penn Yan Aero Quality

Many people ask us about our process, wondering what is our secret in turning out smooth running, long lasting Penn Yan Aero overhauled Lycoming and Continental, and experimental aircraft engines. The secret is there is no secret. All it takes is knowledge, experience, attention to detail, and good old fashioned work.

Penn Yan Aero is an independent engine facility and does not perform removals or installations or aircraft maintenance. Our first and only priority is to produce the world’s best overhauled Lycoming and Continental engines, and experimental aircraft engines.

Penn Yan Aero’s success has always begun and ended with excellent people who understand the importance of discipline and structure, patients, and team work; people who are motivated to do the best job possible, no matter what the task is; goal oriented people who thrive working with like minded people in a team environment who understand that the sum of their efforts far and away exceed their individual contributions.

Penn Yan Aero people are trained, certified, and licensed in their area’s of expertise and participate in continuous, on-going training programs in FAA and EASA procedures, management, purchasing, manufacturing, and operations.

Penn Yan Aero people have access to the world’s most comprehensive and current libraries of Lycoming, Continental, FAA, PMA, and aftermarket engine information.

The talented Penn Yan Aero team works in our one facility which is dedicated to producing the world’s best overhauled Lycoming and Continental certified engines and experimental aircraft engines. The Penn Yan Aero engine facility contains the finest tools and technology to support the Penn Yan Aero staff.

Penn Yan Aero's work flow begins with you and your request for a quotation. Penn Yan Aero services engines installed in over 3,708 certified aircraft applications. Each engine model has about 8 and as many as 21 prices, depending on options and level of service. On the Penn Yan Aero master spread sheet there are over 200,000 engine prices. Penn Yan Aero has various promotional programs that you may qualify for depending on your aircraft and where you live. This explains why Penn Yan Aero asks you for such explicit information. We want to get it right.

When you receive your quotation form Penn Yan Aero, you’ll notice that the clear and concise information provided is for your aircraft only. At Penn Yan Aero we place a high value on concise, straight forward, and accurate information. Once you’ve determined your needs and have initiated the purchase, your engine arrives at Penn Yan Aero and is received by our Warehouse Manager. The Manager pulls all paperwork (quotation, sales sheet, purchase contract and the Bill of Lading) and submits it to Production.

Production checks and photographs the engine and contents of the engine crate, checks all paperwork and justifies it to the engine received, immediately resolves any discrepancies, and flags any special circumstance or conditions. Once justified, Production assigns a commitment date, Work Order number, and forwards Pull Sheets to Purchasing for Mandatory Replacement Parts.

Next, the engine is completely disassembled and thoroughly cleaned by Penn Yan Aero’s tear down/pre-inspection department. Special focus is paid to the crankcase, crankshaft, and camshaft. Any problems or concerns are communicated and resolved. The disassembled and cleaned engine parts are placed on an engine cart. Rejected parts are customer property and are optionally returned or destroyed in accordance with the customer’s wishes. The disassembled and carted engine goes to inspection where all parts are inspected, tested, and measured using a variety of technology including magnetic particle, liquid penetrate, and ultrasonic. All current Air worthiness Directives, Manufacturers Service Bulletins, and Service Instructions are checked and complied to. All sub components are transferred to their relevant specialized departments for overhaul. New bushings are installed in connecting rods and rocker arms and machined to size. Second level parts are ordered and added to cart.

The engine cart is then sent to the Build Shop where the crankshaft and ring gear are dynamically balanced to within 0.20 ounce/inches of OEM specification and re-inspected. Connecting rods are matched to crankshaft at this time. The engine is then meticulously assembled in accordance with data approved by or acceptable to the FAA OEM Factory Workshop Manual and Checked for OEM new fits and tolerances by a master mechanic and all work is double checked (checked for correct main and rod bearings, for correct torque on all bolts, for correct internal timing, for magneto timing, for valve lash, for cylinder match, and all sub-assemblies are double checked) by a second master mechanic.

Next, the assembled engine goes to the Paint Shop for zinc chromate, anti corrosive primer and Penn Yan Aero’s super durable, environmentally friendly finish paint. The painted engine returns to the Build Shop and is dressed with fuel delivery systems (applicable turbo, carburetor, fuel injection, fuel pump), ignition (mag(s), new Ignition harness and spark plugs), and any other accessories that are included.

Now, the Penn Yan Aero overhauled engine goes to test. But not just any test. The overhauled engine is fully tested to OEM standards and beyond to Penn Yan Aero quality standards. The engine is fitted with the proper test club to accurately simulate the correct load. Cooling shrouds are installed to simulate installation in the aircraft, test probes are installed, and brake in mineral oil is added. The engine is test run for a minimum of 1.5 Hours through the entire RPM range including a continuous 30 minute full power run. During the run time tests oil pressure, oil temperature, fuel flow, fuel pressure, crankcase pressure, manifold pressure, cylinder head temperature, and exhaust gas (Turbo Models Only) temperature is monitored. Plus, a magneto drop test is performed, the oil filter is examined, compression in all cylinders is checked, and the engine oil is drained and examined. All test results and approvals are documented.

Once an engine has passed our tests, it is removed from test cell and prepared for check out; the work order is checked, all parts to be returned are identified and inventoried, the paperwork package is checked (Air worthiness Directive Compliance Sheet, Service Bulletin Compliance Sheet, Test Run Data Sheet, Break-in Instructions, and logbook). The engine is again inspected and, if acceptable and complete, the Chief Inspector completes the Final Sign Off. Then, the engine is wrapped, packed, and shipped.