Design/methodology/approach The engine disassembly procedure was carried out based on the IO540 operation manual part number 60297-10-1-7 document. Except for the normal disassembly and assembly of the engine and the measurement of parts, the main test contents included break-in run operation, cylinder pressure test, oil consumption run, pretest calibration run, post-test calibration test and the most critical endurance test. The Lycoming IO-540-V4V5 engine and the customized Hartzell CK319 propeller were selected for the test run. Findings The deposits were mainly composed of C, O, B, Al, Br and Pb, which were mainly sourced from fuel, lubricating oil and body materials. XPS analysis showed that the presence of O determined the richness of the deposit components, giving the deposit structure with organic and inorganic components. Originality/value This work provides certain data support and reference for subsequent aircraft maintenance, fuel formula and lubricating oil formula. The long-term stability and safety of the aircraft run can be ensured through continuous research, improvement and optimizing the operating of the engine. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-08-2024-0300/