Name: Lycoming IO-390-D Series
Brand: Lycoming
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IO-390-D Series Engine Maintenance Manual

March 2020 Page iii

IO-390-D Series Engine Maintenance Manual

RECORD OF REVISIONS

Revision

Date

Revised

Revision Description

Original

Original Release of Maintenance Manual –

Part No. MM-IO-390-D Series

Airworthiness Limitations3
Record of Revisions5
Service Document List7
Table of Contents11
Abbreviations and Acronyms21
Introduction23
Required Maintenance27
General27
List of Tools for Service and Maintenance27
Time between Overhaul (TBO)28
Safety Precautions - before Engine Maintenance29
Maintenance Practices29
General Engine Inspection Criteria31
Requirements for Engine Maintenance31
Approved Parts31
Unscheduled Corrective Maintenance (Cont.)31
Time Limits / Service Checks33
Engine Inspection Schedule for IO-390-D Series Engines33
Required Engine Inspections for IO-390-D Series Engines35
Engine Inspections35
Visual Inspection for IO-390-D Series Engines35
Operational Leak Check Sheet for IO-390-D Series Engines41
10-Hour Initial Engine Inspection for IO-390-D Series Engines42
25-Hour Engine Inspection for IO-390-D Series Engines43
50-Hour Engine Inspection for IO-390-D Series Engines46
100-Hour or Annual Engine Inspection for IO-390-D Series Engines49
400-Hour Engine Inspection for IO-390-D Series Engines54
500-Hour Engine Inspection for IO-390-D Series Engines56
1000-Hour Engine Inspection for IO-390-D Series Engines57
Cleaning59
Cleaning Guidelines59
Crankshaft Cleaning62
Crankshaft Counterbore Cleaning62
Crankshaft Gear Cleaning63
Tappet Cleaning64
Crankcase Cleaning64
Grit-Blasting64
Soft Carbon Removal65
Hard Carbon Removal66
Cylinder Cleaning66
Piston Cleaning67
Injection Nozzle Cleaning67
Steel, Aluminum, or Magnesium Parts Cleaning68
Spark Plug Cleaning69
Lead Deposit Removal69
Volcanic Ash Removal69
Cleaning Guidelines for a Soaked Engine70
Cleaning Method for Non-Destructive Testing70
Unscheduled Corrective Maintenance73
Lightning Strike - after a Lightning Strike73
Engine Overspeed73
Incorrect Fuel or Fuel Contamination76
Soaked Engine77
Engine on Fire or Near a Fire78
Hydraulic Lock79
Volcanic Ash/Particulate Contamination79
Valve Sticking81
Oil Starvation/Sudden Loss of Oil Pressure81
Metal Contamination of the Lubrication System82
Propeller Strike, Sudden Engine Stoppage or Loss of a Propeller Blade Tip82
Engine Inspection Checklist after Propeller Strike for IO-390-D Series Engines82
Cleaning Methods for Non-Destructive Testing90
Servicing - Replenishing91
Refueling91
Oil Level Check91
Oil Consumption92
Oil Type and Viscosity92
Add Oil to the Engine92
Oil Leak Check93
Oil Servicing Schedule93
Oil Change Procedure94
Engine Pre-Oil Procedure95
Oil Suction Screen Removal/Inspection/Cleaning/Installation97
Oil Pressure Screen Removal/Inspection/Cleaning/Installation98
Crankcase Maintenance (Cont.)98
Electrical System Maintenance (Cont.)98
Oil Filter Replacement99
Oil Filter Inspection99
Identification of Metallic Solids after Oil Servicing100
Visual Inspection of the Oil Filter Element, Oil Pressure Screen, and Oil Suction Screen100
Ignition System Maintenance (Cont.)100
Recommended Corrective Action Options106
Oil Contamination Check107
Fault Isolation109
Recommended Approach to Fault Isolation109
Fault Isolation Guide109
Engine Removal and Return to Service127
Engine Removal Prerequisites127
Engine Removal Procedure127
Engine Installation Preparation Requirements129
Operational Ground Check130
Idle Speed and Mixture Adjustment130
Engine Mount Inspection131
Return to Service Procedure132
Engine Disassembly133
Engine Assembly139
Corrosion Prevention139
Painting the Engine and Engine Components139
Limits and Clearances141
Inspections141
Engine Assembly Procedure142
Engine Assembly Checklist148
Propeller Flange Bushing Replacement153
Propeller Flange Bushing Removal153
Propeller Flange Bushing Installation153
Crankcase Maintenance155
Crankcase Inspection before Disassembly155
Connecting Rod Removal155
Crankcase Disassembly156
Tappet, Main Bearing and O-Ring Removal157
Propeller Governor Drive Removal/Disassembly (Engines with Front-Mounted Propeller Governor Drives)159
Oil Plug Removal160
Crankshaft Idler Gear Shaft Removal160
Piston Cooling Nozzle Removal161
Crankshaft Disassembly161
Counterweight Removal162
Crankcase Dimensional Inspection164
Crankshaft Inspection166
Alignment Dowel Inspection175
Crankshaft Bearing Surface Inspection176
Camshaft Inspection177
Connecting Rod Inspection178
Connecting Rod Bushing Replacement180
Connecting Rod Parallelism / Squareness Check182
Tappet Inspection183
Crankshaft Assembly183
Alignment Dowel Replacement183
Crankshaft Gear Installation184
Expansion Plug Installation186
Solid-Ring Crankshaft Oil Seal Installation187
Connecting Rod Installation189
Counterweight Installation190
Piston Cooling Nozzle Installation (if Removed)192
Crankshaft Idler Gear Shaft Installation192
Oil Plug Installation (if Removed)193
Tappet Assembly Installation194
Crankshaft Bearing and O-Ring Installation194
Propeller Governor Drive Installation (Engines with Front-Mounted Propeller Governor Drives)195
Camshaft Assembly and Installation197
Crankshaft Installation199
Crankcase Assembly200
Crankshaft Oil Seal Installation205
Crankshaft Idler Gear Installation207
Crankshaft Endplay Clearance Check207
Propeller Oil Control Leak Test208
Propeller Governor Removal (Engines with Front-Mounted Propeller Governor Drives)210
Propeller Governor Installation (Engines with Front-Mounted Propeller Governor Drives)210
Crankshaft-To-Camshaft Timing Check210
Accessory Housing Maintenance211
Accessory Housing Removal211
Oil Pump Removal212
Oil Pump Installation212
Fuel Pump Plunger Removal213
Fuel Pump Plunger Inspection213
Fuel Pump Plunger Installation213
Accessory Housing Installation213
Propeller Governor Replacement (Engines with Rear-Mounted Propeller Governor Drives)215
Cylinder Maintenance217
General217
Visual Cylinder Inspection217
Cylinder Compression Check218
Intercylinder Baffle Inspection223
Cylinder Borescope Inspection224
Exhaust Valve and Guide Inspection225
Cylinder Removal230
Piston Removal234
Cylinder Assembly Inspection235
Piston Inspection239
Piston Ring Replacement243
Piston Installation244
Intake Valve Replacement245
Exhaust Valve Replacement246
Cylinder Installation247
Corrective Action for Valve Sticking253
Intake and Exhaust Valve Guide Replacement254
Intake and Exhaust Valve Seat Replacement254
Barrel Glaze and Varnish Removal from Interior Cylinder Barrel255
Heli-Coil ® Replacement255
Lubrication System Maintenance257
Oil Pressure Adjustment257
Oil System Inspection257
Oil Line Inspection257
Oil Line Replacement258
Oil Level Gage Tube and Assembly Removal258
Oil Level Gage Tube and Assembly Installation258
Oil Pressure Relief Valve Removal259
Oil Pressure Relief Valve Inspection259
Oil Pressure Relief Vale Installation259
Oil Cooler Bypass Valve Removal260
Oil Cooler Bypass Valve Cleaning260
Oil Cooler Bypass Valve Installation260
Oil Pressure Screen Housing Removal261
Oil Pressure Screen Housing Installation261
Oil Filter Base Removal261
Oil Filter Base Installation261
Oil Sump Removal262
Oil Sump Installation262
Propeller Governor Oil Line Removal (Engines with Rear-Mounted Propeller Governor Drives)265
Propeller Governor Oil Line Installation (Engines with Rear-Mounted Propeller Governor Drives)265
Accessory Drives267
Accessory Drive Inspection267
Propeller Governor Drive Replacement (Engines with Rear-Mounted Propeller Governor Drives)267
Electrical System Maintenance269
Wiring Inspection269
Alternator Belt Inspection269
Alternator Belt Tension Check/Adjustment269
Alternator and Bracket Removal272
Alternator and Bracket Installation272
Alternator Belt Replacement273
Starter Replacement273
Starter Ring Gear Support Replacement274
Starter Ring Gear Replacement275
Induction System Maintenance277
Induction System Inspection277
Intake Pipe Replacement277
Fuel Drain Valve Adapter Assembly Inspection278
Engine Fuel and Control - Distribution Maintenance279
Fuel System Inspection279
Fuel Line Inspection281
Fuel Injector Leak Check285
Fuel System Inspection Checklist285
Fuel Line Replacement287
Fuel Injector Replacement290
Injection Nozzle Replacement291
Injection Nozzle Fuel Flow Check293
Fuel Manifold Replacement293
Fuel Pump Replacement295
Ignition System Maintenance297
Spark Plugs297
Spark Plug Removal297
Ignition Lead Inspection298
Spark Plug Inspection298
Spark Plug Fouling299
Spark Plug Port Seal Inspection300
Spark Plug Cleaning300
Spark Plug Gap Setting300
Spark Plug Rotation301
Spark Plug Installation301
Ignition Harness Removal302
Ignition Harness Inspection302
Ignition Harness Installation303
Electronic Ignition System / Magneto Maintenance305
Lycoming Electronic Ignition System (EIS)305
EIS Inspection305
EIS Replacement306
EIS Removal306
EIS Installation307
Install the Drive Gear (Magneto Gear)307
Internally Time the EIS308
Mount the EIS on the Engine309
EIS Timing Check310
Traditional Magnetos (Optional)310
Magneto Inspection310
Magneto-To-Engine Timing Check310
Magneto Adjustment Procedure313
Magneto Replacement Procedure314
Exhaust System Inspection317
Stud Replacement319
Fin Stabilizer Installation320
Install Stud at Oil Filter Pad (if Required)321
Install the Fitting for the Manifold Pressure Line in Cylinder #3322

Lycoming IO-390-D Series Maintenance Manual

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Brand	Lycoming
Model	IO-390-D Series
Category	Engine
Language	English