Engine Overhaul Process

Initial Inspection

Every employee at The New Firewall Forward knows that when a customer awards the business of overhauling an aircraft engine to us, this agreement represents the highest level of trust. We honor that trust, following established & proven procedures, to ensure only the highest quality engines (supported by the best warranty in the business).


Upon arrival at our facility, an initial inspection is conducted to assess its current condition and identify any major unforeseen issues.  If we are removing the engine, aircraft items related to engine operations are inspected and concerns are addressed with the aircraft owner.

Photos are taken throughout the process, to ensure that reassembly is, exactly (or better than) it was when it came in.

 Component Inspection

Components slated for reuse are visually inspected, NDT inspected, and measured to verify the items are within tolerances and meet “factory new” specifications.  Our engines meet or exceed factory new specifications and tolerances so they perform as well as or better than a factory new engine. Only airworthy parts are reused.


Engines are reassembled to exacting st andards and new components are purchased from top-tier suppliers. The New Firewall Forward uses a “one person–one engine “ assembly process, unlike the first time the engine was assembled by the factory. Each assembler takes an engine from its individual components all the way to final assembly and comprehensive testing, so it can be certified as “airworthy”.  Every engine is assembled according to the manufacturer’s approved Overhaul Manual.

The assembler’s work is inspected by multiple technicians, following detailed checklists.  Only then does the engine move to the testing phase.


Finally, to ensure the engine will perform better than new and meet our high expectation of excellence, we test it thoroughly (either on the aircraft or on our calibrated Dynamometer).  Our testing helps to ensure correct piston ring seating and measure/record engine torque and horsepower output. Using an elaborate computer-linked data acquisition system, each engine receives an average hour and a half to two-hour test run.  During this test, we monitor RPM, temperatures, pressures, and flows so we can confirm the performance & conformance to Factory st andards.