Lycoming TEO-540-C1A User Manual

Lycoming TEO-540-C1A

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© 2018 Avco Corporation. All Rights Reserved.

Engine Maintenance Manual

(Principal Manual)

TEO-540-C1A Engine

November 2018

Part No. MM-TEO-540-C1A

Table of Contents

Record of Revisions3
Service Document List5
- Table of Contents9
Table of Contents10
Abbreviations and Acronyms19
Introduction23
Airworthiness Limitations29
Required Maintenance31
- General31
- List of Tools for Service and Maintenance31
Time Limits / Inspections37
- Engine Inspection Schedule for TEO-540-C1A Engines37
Required Engine Inspections for TEO-540-C1A Engines39
- Engine Inspections39
- Visual Inspection for TEO-540-C1A Engines39
- Operational Leak Check Sheet for TEO-540-C1A Engines46
- 10-Hour Initial Engine Inspection for TEO-540-C1A Engines47
- 25-Hour Engine Inspection for TEO-540-C1A Engines49
- 50-Hour Engine Inspection for TEO-540-C1A Engines51
- 100-Hour or Annual Engine Inspection for TEO-540-C1A Engines54
- 250-Hour Engine Inspection for TEO-540-C1A Engines59
- 400-Hour Engine Inspection for TEO-540-C1A Engines60
- 1000-Hour Engine Inspection for TEO-540-C1A Engines62
Cleaning65
- Cleaning Guidelines65
- Crankshaft Cleaning68
- Crankshaft Counterbore Cleaning68
- Crankshaft Trigger Gear Assembly Cleaning69
- Tappet Cleaning70
- Crankcase Cleaning70
- Grit-Blasting70
- Soft Carbon Removal71
- Hard Carbon Removal72
- Cylinder Cleaning72
- Piston Cleaning73
- Steel, Aluminum, or Magnesium Parts Cleaning73
- Spark Plug Cleaning74
- Lead Deposit Removal74
- Volcanic Ash Removal75
- Cleaning Guidelines for a Soaked Engine75
- Cleaning Methods for Non-Destructive Testing76
Subject65
Unscheduled Corrective Maintenance77
- Lightning Strike - after a Lightning Strike77
- Engine Overspeed77
- Engine Overboost80
- Incorrect Fuel or Fuel Contamination80
- Soaked Engine81
- Engine on Fire or Near a Fire82
- Hydraulic Lock83
- Volcanic Ash/Particulate Contamination83
- Table 2 - Action to Take in Volcanic Ash Conditions84
- Valve Sticking85
- Oil Starvation/Sudden Loss of Oil Pressure85
- Metal Contamination of the Lubrication System86
- NTO & TLO Illumination on the Control Panel86
- Propeller Strike, Sudden Engine Stoppage or Loss of a Propeller Blade Tip87
- Non-Destructive Testing91
- (Magnetic Particle Inspection and Fluorescent Penetrant Inspection.)94
Subject95
Servicing - Replenishing95
- Refueling95
- Oil Level Check95
- Oil Consumption96
- Oil Type and Viscosity96
- Add Oil to the Engine96
- Oil Leak Check97
- Oil Servicing Schedule97
- Oil Change Procedure98
- Engine Pre-Oil Procedure99
- Oil Suction Screen Removal/Inspection/Cleaning/Installation101
Subject102
- Oil Filter Replacement102
Crankcase Maintenance (Cont.)102
- Oil Filter Inspection103
- Identification of Metallic Solids after Oil Servicing103
- Visual Inspection of the Oil Filter Element and Oil Suction Screen103
- And Chips & Corrective Action105
- Recommended Corrective Action Options109
- Oil Contamination Check110
Fault Isolation111
- Recommended Approach to Fault Isolation111
Engine Removal and Return to Service131
- Engine Removal Prerequisites131
- Engine Removal Procedure131
- Engine Installation Preparation Requirements133
- Operational Ground Check134
- Engine Mount Inspection135
- Return to Service Procedure135
Subject137
Engine Disassembly137
- Engine Disassembly Procedure137
Engine Assembly143
- Corrosion Prevention143
- Painting the Engine and Engine Components143
- Limits and Clearances145
- Inspections145
  - Engine Assembly Procedure146
  - Engine Assembly Checklist152
Propeller Flange Bushing Replacement157
- Propeller Flange Bushing Removal157
- Propeller Flange Bushing Installation157
Crankcase Maintenance159
- Exterior Crankcase Inspection159
- Connecting Rod Removal160
- Crankcase Disassembly160
- Crankshaft Disassembly166
- Interior Crankcase Inspection169
- Crankshaft Inspection172
- Crankshaft Bearing Surface Inspection181
- Bearing Shell Surface Inspection182
- Gear Inspection182
- Screwed Fitting Inspection182
- Camshaft Disassembly and Inspection183
- Connecting Rod Inspection184
- Connecting Rod Bushing Replacement188
- Connecting Rod Parallelism / Squareness Check189
- Tappet Inspection190
- Crankshaft Assembly194
- Piston Cooling Nozzle Installation (if Removed)204
- Oil Plug Installation (if Removed)204
- Tappet Assembly Installation205
- Crankshaft Bearing and O-Ring Installation206
- Propeller Governor Drive Installation207
- Camshaft Assembly and Installation209
- Crankshaft Installation212
- Crankcase Assembly213
- Crankshaft End Play Clearance Check218
- Propeller Oil Control Leak Test219
- Crankshaft Oil Seal Installation221
- Crankshaft Trigger Gear Assembly and Crankshaft Idler Gear Installation224
- Crankshaft-To-Camshaft Timing Check229
Accessory Housing Maintenance231
- Accessory Housing Removal231
- Oil Pump Removal232
- Oil Pump Installation232
- Accessory Housing Installation233
Cylinder Maintenance235
- General235
- Visual Cylinder Inspection235
- Cylinder Compression Check236
- Intercylinder Baffle Inspection241
Cylinder Maintenance (Cont.)242
Subject242
- Cylinder Borescope Inspection242
- Exhaust Valve and Guide Inspection243
- Cylinder Removal248
- Piston Removal253
- Cylinder Assembly Inspection254
- Piston Inspection260
- Piston Ring Replacement264
- Piston Installation265
- Intake Valve Replacement266
- Exhaust Valve Replacement267
- Corrective Action for Valve Sticking275
- Intake and Exhaust Valve Guide Replacement277
- Heli-Coil ® Replacement278
- Hour Turbocharger Inspection283
Turbocharger Maintenance284
- Hour Turbocharger Inspection284
- Turbocharger Installation286
- Exhaust Bypass Valve Replacement287
Lubrication System Maintenance289
- Oil Pressure Adjustment289
- Oil Hose Replacement (General Instructions for any Oil Hose)290
Lubrication System Maintenance (Cont.)291
Subject291
- Oil Filler Extension and Oil Level Gage Assembly Installation291
- Oil Cooler Bypass Valve Removal292
- Oil Sump Removal293
- Oil Sump Inspection294
Accessory Drives297
- Accessory Drive Inspection297
Electrical System Maintenance299
- Wiring Inspection299
- Alternator Belt Inspection300
- Alternator and Bracket Removal302
- Alternator Belt Replacement303
- Power Box and PMA304
- Wiring Harness Connectors305
- Sensor Replacement Procedures312
- Engine-To-Firewall Wiring Harness Removal323
- Engine-To-Firewall Wiring Harness Installation325
- Airframe Interface Wiring Harness Removal326
- Airframe Interface Wiring Harness Installation327
Electrical System Maintenance (Cont.)328
Subject328
- ECU Removal328
- Power Box Removal329
- Starter Replacement330
- Starter Ring Gear Support Replacement331
- Starter Ring Gear Replacement332
Induction System Maintenance335
- Induction System Inspection335
- Fuel Drain Valve Adapter Assembly Inspection337
- Air Inlet Housing Replacement338
Engine Fuel and Control - Distribution339
- Fuel System Inspection339
- Fuel Hose Inspection341
- Table 1 - Corrective Action for Fuel Hoses343
- Fuel System Inspection Checklist344
- Fuel Hose Replacement347
- Fuel Injector Rail Assembly Replacement349
- Fuel Injector Replacement351
- Fuel Injector Adapter Replacement352
- Fuel Pump Filter Replacement353
- Fuel Pump Replacement354
- Fuel Pressure Regulator Replacement355
Subject359
Engine Fuel and Control - Controlling359
- Ignition Lead Removal361
- Spark Plugs363
- Spark Plug Inspection364
  - Spark Plug Fouling365
  - Spark Plug Cleaning366
- Spark Plug Installation367
- Coil Box Access369
Coil Assembly and Coil Box Maintenance370
- Coil Assembly Replacement370
- Coil Box Removal371
- Coil Box Installation372
Exhaust System Maintenance373
- Heat Shield Removal373
- Hour Exhaust System Inspection374
- Heat Shield Installation377
- Exhaust System Installation378
Appendix A381
Subject381
Appendix A381
- Stud Replacement381
- Air Bleed Nozzle Installation382
- Wiring Diagrams383
Appendix B389
- Schematic T-11327-Y389
- Communications Bus Data397
Appendix C399
Appendix C399
- Field Service Tool User Manual Abbreviations and Acronyms399
- System Requirements401
- Software Installation403
- ECU to FST Connection411
- Access the Field Service Tool413
- Sending Data to Lycoming Technical Support421
- Field Service Tool - Software Problems423
Appendix D425
Appendix D425
- Troubleshooting Guide Abbreviations and Acronyms425
- Troubleshooting Guide426

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Lycoming TEO-540-C1A Specifications

General

Brand	Lycoming
Model	TEO-540-C1A
Category	Engine
Language	English

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