Maintaining engine fuel and control systems on aircraft (Aviation Maintenance) Revision — Excellence, Achievement & Learning Limited Occupational Qualification

    This unit identifies the training and development required in order that the apprentice can demonstrate that they are competent in being ableto carry out maintenance activities on aircraft engine fuel and control systems, in accordance with the approved aircraft maintenance manual,approved change documentation (service bulletin) and airworthiness requirements. It covers fixed wing and rotary winged aircraft, andincludes both turbine and reciprocating engines. For turbine engines, it covers those units and components and associated mechanical systemsor electrical circuits which deliver or control fuel to the engine beyond the main fuel quick disconnect. This includes engine driven fuel pumpsand filter assembly, main and thrust augmention fuel controls, electronic temperature datum control, temperature datum valve, fuel manifold,fuel nozzles, fuel enrichment system, speed sensitivity switch, relay box assembly and solenoid drip valves. For reciprocating engines, it coversthose units and components which deliver metered fuel and air to the engine, and includes the carburettor master control from the inlet sideto the discharge nozzles, injection pumps, carburettor, injection nozzles and fuel primer. The air portion includes units and components fromthe scoop inlet to the vapour return and impeller chamber. The maintenance activities will include the removal, fitting and testing of a range ofengine fuel system components. They will be expected to use the approved procedure for correctly isolating the fuel supply and the systembefore breaking into the system circuit. They will remove the required components and fit approved replacements, as appropriate. They willthen need to test and adjust the completed system to meet the aircraft maintenance manual, change documentation (service bulletin) andairworthiness requirements.

    Exam Tips

    Common Mistakes

    Key Marking Points

    Maintaining engine fuel and control systems on aircraft (Aviation Maintenance)

    EXCELLENCE-ACHIEVEMENT-AND-LEARNING-LIMITED
    vocational

    This unit covers maintenance of aircraft engine fuel and control systems for fixed and rotary wing aircraft, including turbine and reciprocating engines. It involves removal, fitting, and testing of components per approved manuals.

    0
    Learning Outcomes
    3
    Assessment Guidance
    3
    Key Skills
    1
    Key Terms
    4
    Assessment Criteria

    Assessment criteria

    EAL Level 3 Diploma in Aviation Maintenance (Development Competence)

    Topic Overview

    The EAL Level 3 Diploma in Aviation Maintenance (Development Competence) is a vocational qualification designed for individuals pursuing a career as aircraft maintenance technicians. It covers the fundamental knowledge and practical skills required to maintain, repair, and certify aircraft in compliance with UK Civil Aviation Authority (CAA) and European Aviation Safety Agency (EASA) regulations. This diploma is part of the Apprenticeship Standard for Aviation Maintenance Mechanic and is recognised by employers across the aviation industry.

    The qualification is structured around key areas such as aviation legislation, human factors, materials and hardware, electrical fundamentals, and turbine and piston engine theory. Students develop competence in interpreting technical documentation, using hand tools and test equipment, performing inspections, and completing maintenance records. The course emphasises safety, precision, and adherence to approved data, preparing learners for the demanding environment of aircraft maintenance.

    This diploma sits within the broader Design and Technology curriculum by applying engineering principles to real-world aviation contexts. It bridges theoretical knowledge with hands-on practice, ensuring students can work safely and effectively on aircraft systems. Successful completion can lead to further study for an Aircraft Maintenance Licence (AML) Part-66, opening doors to roles as a licensed aircraft engineer or maintenance manager.

    Key Concepts

    Core ideas you must understand for this topic

    • →Airworthiness and Regulatory Compliance: Understanding CAA, EASA, and FAA regulations, and the importance of maintaining aircraft in a condition for safe operation.
    • →Human Factors in Aviation: Recognising how fatigue, stress, communication, and teamwork affect maintenance performance and safety.
    • →Aircraft Materials and Hardware: Knowledge of metals, composites, fasteners, and sealants used in aircraft construction and repair.
    • →Electrical Fundamentals: Principles of DC and AC circuits, wiring, and avionics systems essential for troubleshooting.
    • →Maintenance Practices: Procedures for inspection, servicing, and documentation including the use of approved data and tool control.

    What You Need to Demonstrate

    Key skills and knowledge for this topic

    • Isolate fuel supply and system correctly before maintenance.
    • Remove and fit engine fuel system components following approved procedures.
    • Test and adjust the completed system to meet airworthiness requirements.
    • Identify components for turbine and reciprocating engines as specified.

    Assessment Criteria

    Key criteria assessors look for in your portfolio

    • Isolate fuel supply and system correctly before maintenance.
    • Remove and fit engine fuel system components following approved procedures.
    • Test and adjust the completed system to meet airworthiness requirements.
    • Identify components for turbine and reciprocating engines as specified.

    Assessment Guidance

    Guidance for achieving higher grades

    • 💡Always refer to the aircraft maintenance manual (AMM) for procedures.
    • 💡Use proper personal protective equipment (PPE) when handling fuel.
    • 💡Understand the differences between turbine and reciprocating engine systems.
    • 💡Always reference the correct regulatory documentation (e.g., CAA CAP 562 or EASA Part-145) in your answers. Examiners look for evidence that you can apply regulations to practical scenarios.
    • 💡When answering questions on human factors, use specific examples like the 'Dirty Dozen' (e.g., complacency, fatigue) to show depth of understanding.
    • 💡For practical assessments, demonstrate clear adherence to the maintenance manual step-by-step. Rushing or skipping steps loses marks, even if the final result is correct.

    Common Mistakes

    Common errors to avoid in your coursework

    • Failing to follow correct isolation procedures, risking fuel spillage.
    • Using incorrect torque settings when fitting components.
    • Overlooking the need for functional testing after maintenance.
    • Misconception: 'If a part looks fine, it doesn't need to be replaced per the maintenance schedule.' Correction: Components must be replaced at specified intervals regardless of visual condition, as internal wear or fatigue may not be visible.
    • Misconception: 'Torque values are just guidelines.' Correction: Torque values are critical for fastener integrity; under- or over-torquing can cause joint failure or structural damage.
    • Misconception: 'I can use any tool that fits.' Correction: Only approved tools should be used; using incorrect tools can damage components or compromise safety.

    Frequently Asked Questions

    Common questions students ask about this topic

    Before You Start

    Prior knowledge that will help with this topic

    • •Basic understanding of physics (forces, motion, electricity) and mathematics (algebra, trigonometry).
    • •Familiarity with engineering drawings and technical documentation.
    • •Completion of Level 2 Diploma in Engineering or equivalent foundation knowledge.

    Key Terminology

    Essential terms to know

    • This unit identifies the training and development required in order that the apprentice can demonstrate that they are competent in being ableto carry out maintenance activities on aircraft engine fuel and control systems, in accordance with the approved aircraft maintenance manual,approved change documentation (service bulletin) and airworthiness requirements. It covers fixed wing and rotary winged aircraft, andincludes both turbine and reciprocating engines. For turbine engines, it covers those units and components and associated mechanical systemsor electrical circuits which deliver or control fuel to the engine beyond the main fuel quick disconnect. This includes engine driven fuel pumpsand filter assembly, main and thrust augmention fuel controls, electronic temperature datum control, temperature datum valve, fuel manifold,fuel nozzles, fuel enrichment system, speed sensitivity switch, relay box assembly and solenoid drip valves. For reciprocating engines, it coversthose units and components which deliver metered fuel and air to the engine, and includes the carburettor master control from the inlet sideto the discharge nozzles, injection pumps, carburettor, injection nozzles and fuel primer. The air portion includes units and components fromthe scoop inlet to the vapour return and impeller chamber. The maintenance activities will include the removal, fitting and testing of a range ofengine fuel system components. They will be expected to use the approved procedure for correctly isolating the fuel supply and the systembefore breaking into the system circuit. They will remove the required components and fit approved replacements, as appropriate. They willthen need to test and adjust the completed system to meet the aircraft maintenance manual, change documentation (service bulletin) andairworthiness requirements.

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