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Options for Continuing Flight Operations During Engine Overhaul

Options for Continuing Flight Operations During Engine Overhaul
Maintaining Reliability Amidst Aging Engines
William J. Wuorinen has piloted his Osprey 2 amphibian, equipped with a Lycoming O-320-E2A engine converted to 160 horsepower, every summer for the past 24 years. With nearly 5,000 flight hours since new and 975 hours since its last overhaul, the engine has demonstrated remarkable reliability. Wuorinen’s diligent maintenance regimen includes winter storage with Aeroshell 2F, Camguard, and desiccant plugs, alongside routine oil sampling and cylinder borescope inspections, all contributing to the engine’s continued flawless performance.
Despite this dependable record, Wuorinen is contemplating an overhaul—not due to any immediate performance concerns but because it has been 35 years since the engine’s last major service. However, he faces a significant obstacle: overhaul facilities are currently quoting turnaround times of six to eight months or longer, a delay largely attributed to workforce shortages. This predicament reflects a broader industry trend, exemplified by the experience of CFM International’s CFM56-powered narrowbody fleet in late 2023, where extended ground times for inspections and repairs caused operational disruptions and increased maintenance demand.
Navigating Replacement and Compatibility Challenges
Reluctant to ground his aircraft for such an extended period, Wuorinen is exploring alternatives to maintain flight operations during the overhaul. One option under consideration is acquiring another 160-horsepower engine—either new or used—to overhaul and install as a temporary replacement. This approach would allow continued flying while the original engine undergoes servicing. However, sourcing a suitable engine is proving difficult. New engines reportedly have lead times extending up to 900 days, and locating a used Lycoming O-320-E2A for overhaul and conversion remains a challenge.
Wuorinen has also investigated alternative Lycoming models, such as the O-320-D2A or D2G, guided by Lycoming’s SSP-204 documentation. Yet, compatibility concerns arise, particularly regarding carburetor placement and engine dimensions, which must conform to the Osprey 2’s tightly cowled design. The routing of throttle and mixture cables through a narrow tunnel above the cabin further complicates engine fitment, necessitating precise matching. Additionally, Wuorinen questions whether the O-320-E2D, which features an O-235 main bearing, could be converted to 160 horsepower and whether this bearing design offers any advantages.
Industry-Wide Implications and Strategic Considerations
These challenges are not isolated to individual operators. Across the aviation sector, both commercial airlines and private owners are contending with extended maintenance cycles and supply chain disruptions. As older aircraft remain in service longer, engine manufacturers such as GE Aerospace are experiencing heightened demand for inspections and repairs. In response, competitors are expanding aftermarket services and adapting to ongoing supply chain constraints.
For Wuorinen and others facing similar dilemmas, the decision involves balancing operational requirements with the realities of the current maintenance landscape. Whether by sourcing a replacement engine or enduring the overhaul queue, sustaining flight operations during engine maintenance demands careful planning, with close attention to technical compatibility and market availability.

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