Lycoming YO-233-B2A

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TEO-540-A1A Engine Maintenance Manual

Page ii February 2021

YO-233-B2A Engine Maintenance Manual

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Record of Revisions3
Service Document List5
- Table of Contents7
Table of Contents13
Abbreviations and Acronyms13
Introduction15
- General21
- Tools for Maintenance21
Required Maintenance25
- Corrosion Prevention25
- Painting the Engine and Engine Components25
- Limits and Clearances27
- Inspections27
Time Limits / Inspections29
- General29
- Engine Inspection Schedule for YO-233-B2A Engines29
Time Limits / Maintenance Checks-Scheduled Maintenance Checks31
- Visual Inspection31
- 10-Hour Initial Engine Inspection for YO-233-B2A Engines34
- 25-Hour Engine Inspection for YO-233-B2A Engines35
- 50-Hour Engine Inspection for YO-233-B2A Engines38
- 100-Hour or Annual Engine Inspection for YO-233-B2A Engines44
- 400-Hour Engine Inspection for YO-233-B2A Engines49
- 500-Hour Engine Inspection for YO-233-B2A Engines51
- 1000-Hour Engine Inspection for YO-233-B2A Engines52
Subject53
Cleaning53
- Cleaning Guidelines53
- Grit-Blasting55
- Soft Carbon Removal56
- Hard Carbon Removal57
- Cylinder Cleaning57
- Piston Cleaning58
- Steel, Aluminum, or Magnesium Parts Cleaning59
- Spark Plug Cleaning59
- Lead Deposit Removal60
- Volcanic Ash Removal60
- Cleaning Guidelines for a Soaked Engine60
- Cleaning Methods for Non-Destructive Testing61
Time Limits / Maintenance Checks - Unscheduled Maintenance63
- Lightning Strike - after a Lightning Strike63
- Engine Overspeed63
- Incorrect Fuel or Fuel Contamination65
- Soaked Engine66
- Engine on Fire or Near a Fire67
- Hydraulic Lock67
- Volcanic Ash/Particulate Contamination67
- Valve Sticking69
- Oil Starvation/Sudden Loss of Oil Pressure70
- Metal Contamination of the Lubrication System71
- Non-Destructive Testing78
Subject79
Servicing - Replenishing79
- Refueling79
- Oil Level Check79
- Oil Consumption80
- Oil Type and Viscosity80
- Add Oil to the Engine81
- Oil Leak Check81
- Oil Servicing Schedule81
- Oil Change Procedure82
- Oil Filter Replacement84
- Oil Suction Screen Removal/Installation85
- Oil Filter/Oil Suction Screen Inspection85
- Identification of Metallic Solids after Oil Servicing85
- Visual Inspection of the Oil Filter Element and Oil Suction Screen86
- Recommended Corrective Action Options91
Fault Isolation93
- General93
- Fault Isolation Guide93
Subject94
Ignition System - Spark Plug Maintenance (Cont.)94
Reciprocating Engine - Removal/Operational Ground Check107
- Engine Removal Prerequisites107
- Engine Removal Procedure107
- Engine Installation Preparation Requirements109
- Engine Installation110
- Operational Ground Check after Maintenance110
- Idle Speed Mixture Adjustment110
- Engine Mount Inspection111
- Return to Service Procedure111
Subject113
Reciprocating Engine - Crankcase113
- Crankcase System Description113
- Crankcase Maintenance113
- Crankcase Inspection Procedure113
Reciprocating Engine - Cylinder Inspections115
- General115
- Visual Cylinder Inspection115
- Cylinder Compression Check116
- Intercylinder Baffle Inspection121
- Cylinder Borescope Inspection122
- Exhaust Valve and Guide Inspection123
- Cylinder Removal129
- Piston Removal132
- Connecting Rod Removal133
- Cylinder Assembly Inspection134
- Piston Inspection139
- Connecting Rod Inspection143
- Connecting Rod Bushing Replacement146
- Connecting Rod Parallelism/Squareness Check148
- Connecting Rod Installation149
- Piston Ring Replacement151
- Piston Installation152
- Intake Valve Replacement153
- Exhaust Valve Replacement153
- Cylinder Installation154
- Corrective Action for Valve Sticking162
- Intake and Exhaust Valve Guide Replacement163
- Intake and Exhaust Valve Seat Replacement163
- Barrel Glaze and Varnish Removal from Interior Cylinder Barrel164
- Heli-Coil ® Replacement164
Subject169
Reciprocating Engine - Lubrication169
- System Description169
- Lubrication Maintenance169
Reciprocating Engine - Accessory Drives171
- 100-Hour Accessory Drive Inspection Procedure171
Reciprocating Engine - Electrical System173
- General173
- 100-Hour Wiring Inspection173
- Wiring Inspection173
- Alternator Belt Inspection174
- Alternator Belt Tension Adjustment174
- Starter Ring Gear Support Replacement Procedure174
Induction System175
- System Description175
- Induction System Inspection Procedure175
Engine Fuel and Control - General177
- System Description177
Engine Fuel and Control - Distribution179
- Fuel System Inspection Procedure179
- Fuel Filter Inspection Procedure179
Ignition System Maintenance181
- Ignition System Description181
Ignition System - Spark Plug Maintenance183
- Examine the Ignition Lead Routing183
- Remove the Spark Plug183
- Examine Spark Plugs and Ignition Leads184
- Spark Plug Fouling185
- Spark Plug Port Seal Inspection185
- Clean the Spark Plugs186
- Set Spark Plug Gap186
- Spark Plug Rotation186
- Spark Plug Installation186
Electronic Ignition System189
- Champion EIS Ignition System189
  - Remove the EIS189
  - Install the EIS189
- Light Speed Plasma III and Magneto Ignition System189

Lycoming YO-233-B2A - Page 4

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