Flight-Ready Engines: MAINTENANCE FIRST

June 10, 2024


PT6 Engine Overhaul
PT6 Engine Overhaul

Regular engine overhaul is fundamental to the successful and safe operation of fixed- and rotor-wing aircraft across all aviation sectors. In addition to line maintenance, base inspections, and performance data analysis, aircraft engines require a complete overhaul after a certain number of flight hours or cycles. While engine overhauls are an investment, regular maintenance helps to minimize operational costs and prevent more expensive repairs or complete engine replacements. Most importantly, they are required to ensure compliance with safety regulations.

Aircraft engines operate under extreme conditions and are subject to significant wear and tear inside and out. The regular overhaul of all engine components supports the primary “hot section” function.


  • Casings & Covers
  • Starter Generators
  • Alternators
  • Ignition Systems
  • Blowers & Compressors
  • Turbines & Blades
  • Exhaust Systems
  • Engine Governors
  • Fuel Heaters
  • Fuel Controls
  • Oil Pumps
  • Fuel Nozzles


The Maintenance, Repair, and Overhaul (MRO) of an aircraft engine is a meticulous process performed by certified technicians.

  1. Disassembly: The engine is completely disassembled down to its fittings, wiring, fuel lines, and accessories.
  2. Inspection: Every system is cleaned and inspected for wear, cracks, or other damage. Using techniques such as magnetic particle inspection, dye penetrants, and ultrasonic testing, flaws can be detected that are not visible to the naked eye. The exact nature and location of any problem is diagnosed using various tools and procedures including ground testing, borescope inspections, and data analysis.
  3. Component Repair/Replacement: Once a fault is identified, affected parts or systems are repaired or replaced. This could require spot welding, machining a new part, replacing it with a new OEM part, or installing a returned-to-service component from an approved MRO provider.
  4. Reassembly and Testing: Once all parts have been inspected and repaired or replaced, the engine is fully reassembled. It then undergoes rigorous testing, including test cell runs when the engine is powered at various settings to ensure it performs correctly under all conditions.


Regulatory bodies such as the Federal Aviation Administration (FAA), European Union Aviation Safety, Agency (EASA) and UK Civil Aviation Authority (CAA) set stringent standards for engine overhaul, including:

  • Only licensed and certified technicians perform the work.
  • Quality control measures must ensure the highest standards throughout the process.
  • Only parts that meet the manufacturer’s specifications and regulatory approval are used.
  • Detailed records of all maintenance, repairs, and overhauls are kept.

Routine scheduled overhauls help identify potential issues early, prevent costly repairs and support overall flight safety.

PAG Engine Services

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About PAG

Others Sell Parts, We Sell Support.

PAG is built on the trust of our customers, and our team members are an important part of our successful, growing business that is committed to customer service. We’ve built our legacy on our ability to respond and deliver the highest quality.

At PAG, employees get the exchange of talent, experiences, and resources of multiple companies all while working for one. With 22 Repair Stations, and over 900,000-square-feet of sales and service facilities in the United States, Canada, Australia, Singapore, and Brazil – PAG’s 24 locations and customer-focused business model serve aviation customers through Supply Chain and Inventory Supported Maintenance, Repair and Overhaul (ISMRO®) services. PAG is one of only 11 companies, outside of OEMs, to collectively hold all FAA certifications.

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