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Lycoming TEO-540-C1A, Maintenance Manual

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TEO-540-C1A Engine Maintenance Manual

 

72-70

 

© 2018 Avco Corporation. All Rights Reserved 

Page 294 

November 2018 

TEO-540-C1A Engine Maintenance Manual

 

NOTICE:

  Refer to Table 2 - Wiring Harness Connector Guidelines, in this chapter, when 

disconnecting the wiring harness from the engine sensors.

 

F.

 

Disconnect the connector A093-P (TIT) (Figure 36) from the sensor for the turbocharger inlet 
on the left side (exhaust bypass valve side) of the engine. 

G.

 

Remove the coil box cover. Refer to the section "Coil Box Access" in Chapter 74-30. 

H.

 

Identify and remove each engine-to-firewall wiring harness connector from its sensor, 
actuator, and coil. 

I.

 

Remove the fasteners from the left and right side harness brackets. Remove the brackets. 

 

CAUTION 

THE HARNESS HAS DIFFERENT DIAMETERS AT VARIOUS 
LOCATIONS.  CLAMPS ARE SIZED SPECIFICALLY FOR EACH AREA 
ON THE HARNESS.  KEEP THE CLAMPS ON THE HARNESS TO BE 
REMOVED. 

J.

 

Remove the harness from left and right side harness brackets. Allow the clamps to remain on 
the harness. 

K.

 

If a harness is to be replaced with a new harness, identify the location of each clamp (Figures 
40 and 41) by a label on the clamp.  

L.

 

Once the harness is disconnected from all attachments, remove the engine-to-firewall wiring 
harness from the engine. 

 

Figure 42 

Wiring Harnesses - Top Left Front 

Summary of Contents for TEO-540-C1A

Page 1: ... 2018 Avco Corporation All Rights Reserved Engine Maintenance Manual Principal Manual TEO 540 C1A Engine November 2018 Part No MM TEO 540 C1A ...

Page 2: ...ycoming com Lycoming s regular business hours are Monday through Friday from 8 00AM through 5 00PM Eastern Time 5 GMT Visit us Online www lycoming com NOTE Lycoming recommends that owners of this manual sign up for email notification on the Technical Publications page of our website https www lycoming com contact knowledge base publications By submitting your email address you will receive notific...

Page 3: ...poration All Rights Reserved Record of Revisions November 2018 Page i TEO 540 C1A Engine Maintenance Manual RECORD OF REVISIONS Revision Revision Date Revised By Revision Description Original Original Release of Maintenance Manual Part No MM TEO 540 C1A ...

Page 4: ...TEO 540 C1A Engine Maintenance Manual Record of Revisions 2018 Avco Corporation All Rights Reserved Page ii November 2018 TEO 540 C1A Engine Maintenance Manual This page intentionally left blank ...

Page 5: ...spection of Crankshaft Flange S B 225 11 18 Replacement of Valve Rocker Thrust Washers S B 240 11 18 Mandatory Parts Replacement at Overhaul and During Repair or Maintenance S B 357 11 18 Engine Inspection After an Engine Has Been Soaked or Immersed S B 369 11 18 Engine Inspection after Overspeed S B 388 11 18 Procedure to Determine Exhaust Valve and Guide Condition S B 398 11 18 Recommended Corre...

Page 6: ... Cylinder Compression S I 1204 11 18 Exhaust Flange Gaskets S I 1238 11 18 Assembly and Torque Procedures for V Band Couplings S I 1241 11 18 Pre oil the Engine Prior to Initial Start S I 1267 11 18 Piston Pin Plug Usage S I 1285 11 18 Non Destructive Testing of Lycoming Engine Parts S I 1301 11 18 Identification of Primer and Fuel Injector Lines S I 1304 11 18 Engine Nameplate Replacement S I 131...

Page 7: ...nes Approves the Use of Safety Cable S I 1573 11 18 Lycoming TEO 540 Engine Series Engine Control Unit ECU Assembly Cross References L114 11 18 Reciprocating Engine and Accessory Maintenance Publications L171 11 18 General Aspects of Spectrometric Oil Analysis L180 11 18 Engine Preservation Guidelines for Active and Stored Aircraft L192 11 18 Spark Plug Fouling L193 11 18 Engine Firing Order L197 ...

Page 8: ...TEO 540 C1A Engine Maintenance Manual Service Document List 2018 Avco Corporation All Rights Reserved Page vi November 2018 TEO 540 C1A Engine Maintenance Manual This page intentionally left blank ...

Page 9: ...recautions Before Engine Maintenance 3 Maintenance Practices 3 General Engine Inspection Criteria 5 Requirements for Engine Maintenance 5 Approved Parts 5 Time Limits Inspections 05 10 Engine Inspection Schedule for TEO 540 C1A Engines 7 Required Engine Inspections for TEO 540 C1A Engines 05 20 Engine Inspections 9 Visual Inspection for TEO 540 C1A Engines 9 Operational Leak Check Sheet for TEO 54...

Page 10: ... Ash Removal 45 Cleaning Guidelines for a Soaked Engine 45 Cleaning Methods for Non Destructive Testing 46 Unscheduled Corrective Maintenance 05 50 Lightning Strike After a lightning strike 47 Engine Overspeed 47 Table 1 Overspeed Values for TEO 540 C1A Engines 48 Engine Overboost 50 Incorrect Fuel or Fuel Contamination 50 Soaked Engine 51 Engine on Fire or Near a Fire 52 Hydraulic Lock 53 Volcani...

Page 11: ...ing 73 Visual Inspection of the Oil Filter Element and Oil Suction Screen 73 Table 2 Guidelines for Identification of Metal Particulates and Chips Corrective Action 75 Table 3 Guidelines for Particle Quantity and Size on Oil Filter or Oil Suction Screen 77 Recommended Corrective Action Options 79 Table 4 Recommended Corrective Action Options 79 Oil Contamination Check 80 Fault Isolation 12 30 Reco...

Page 12: ...f Engine Assembly Procedure 116 Engine Assembly Checklist 122 Propeller Flange Bushing Replacement 72 15 Propeller Flange Bushing Removal 127 Propeller Flange Bushing Installation 127 Crankcase Maintenance 72 20 Exterior Crankcase Inspection 129 Connecting Rod Removal 130 Crankcase Disassembly 130 Crankshaft Disassembly 136 Interior Crankcase Inspection 139 Crankshaft Inspection 142 Crankshaft Bea...

Page 13: ... Point A 183 Table 4 End Play Clearance at Point B 183 Crankcase Assembly 183 Table 5 Crankcase Fastener Torque Values 187 Crankshaft End Play Clearance Check 188 Propeller Oil Control Leak Test 189 Crankshaft Oil Seal Installation 191 Crankshaft Trigger Gear Assembly and Crankshaft Idler Gear Installation 194 Crankshaft to Camshaft Timing Check 199 Accessory Housing Maintenance 72 25 Accessory Ho...

Page 14: ...ment 237 Cylinder Installation 237 Corrective Action for Valve Sticking 245 Intake and Exhaust Valve Guide Replacement 247 Intake and Exhaust Valve Seat Replacement 247 Barrel Glaze and Varnish Removal from Interior Cylinder Barrel 247 Heli Coil Replacement 248 Turbocharger Maintenance 72 40 General 251 50 Hour Turbocharger Inspection 251 100 Hour Turbocharger Inspection 253 250 Hour Turbocharger ...

Page 15: ...Accessory Drives 72 60 Accessory Drive Inspection 267 Vacuum Pump Replacement 267 Vacuum Pump Drive Gear Replacement 267 Electrical System Maintenance 72 70 Wiring Inspection 269 Alternator Belt Inspection 270 Alternator Belt Tension Check Adjustment 270 Alternator and Bracket Removal 272 Alternator and Bracket Installation 273 Alternator Belt Replacement 273 Power Box and PMA 274 The Electrical S...

Page 16: ...uction System Maintenance 72 80 Induction System Inspection 305 Intake Pipe Replacement 305 Fuel Drain Valve Adapter Assembly Inspection 307 Induction Housing Replacement 307 Air Inlet Housing Replacement 308 Engine Fuel and Control Distribution 73 10 Fuel System Inspection 309 Fuel Hose Inspection 311 Table 1 Corrective Action for Fuel Hoses 313 Fuel Injector Leak Check 313 Fuel System Inspection...

Page 17: ...eneral Spark Plug Wear Replacement Guidelines 334 Spark Plug Fouling 335 Spark Plug Port Seal Inspection 335 Spark Plug Cleaning 336 Spark Plug Gap Setting 336 Spark Plug Rotation 336 Table 3 Spark Plug Rotation Scheme 334 Spark Plug Installation 337 Ignition Lead Installation 337 Coil Assembly and Coil Box Maintenance 74 30 Coil Box Access 339 Coil Assembly Replacement 340 Coil Box Removal 341 Co...

Page 18: ...ng Diagrams 353 Table B 1 Wiring Harness Leads and Connection Location 353 Schematic T 11327 Y 359 Communications Bus Data 367 Appendix C Field Service Tool User Manual Abbreviations and Acronyms 369 System Requirements 371 Software Installation 373 ECU to FST Connection 381 Access the Field Service Tool 383 Sending Data to Lycoming Technical Support 391 Field Service Tool Software Problems 393 Ap...

Page 19: ...NK Crankshaft Speed Sensor D DECK P P Primary Induction Air Deck Temperature DECK P S Secondary Induction Air Deck Temperature DECK T Induction Air Deck Temperature DPS Delta Pressure Sensor E ECU Engine Control Unit EECS Electronic Engine Control System EGT Exhaust Gas Temperature F F Fahrenheit FAA Federal Aviation Administration FAR Federal Aviation Regulation FFL Fault Found FPI Fluorescent Pe...

Page 20: ...l L l Liter Lb Pound M MAP Manifold Air Pressure MAT P Primary Induction Air Manifold Temperature Sensor MAT S Secondary Induction Air Manifold Temperature Sensor MEK Methyl Ethyl Ketone mm Millimeter MPI Magnetic Particle Inspection MSB Mandatory Service Bulletin N NDT Non Destructive Testing Nm Newton Meters NPT National Pipe Thread NTO No Take Off O OD Outside Outer Diameter OEM Original Equipm...

Page 21: ...EVIATIONS AND ACRONYMS CONT R rpm Revolutions per Minute S SA Special Advisory SAE Society of Automotive Engineers oil viscosity SB Service Bulletin SI Service Instruction STC Supplemental Type Certificate T TBO Time Between Overhaul TDC Top Dead Center TIR Total Indicator Reading TIT Turbine Inlet Temperature Sensor TLO Time Limited Operation TPS Throttle Position Sensor ...

Page 22: ...TEO 540 C1A Engine Maintenance Manual Abbreviations and Acronyms 2018 Avco Corporation All Rights Reserved Page xx November 2018 TEO 540 C1A Engine Maintenance Manual This page intentionally left blank ...

Page 23: ... which is a microprocessor The EECS continuously monitors and automatically adjusts operating conditions such as ignition timing fuel injection timing and fuel mixture The EECS eliminates the need for magnetos and manual fuel air mixture control Refer to the System Description chapter in the TEO 540 C1A Engine Installation and Operation Manual for more details Figure 1 TEO 540 C1A Engine Model Nom...

Page 24: ... damaged refer to the latest revision of Service Instruction No SI 1304 for data plate replacement information Figure 2 Engine Data Plate Cylinder Number Designations The propeller is at the front of the engine and the accessories are at the rear of the engine In a top view of the engine the left side cylinders are 2 4 6 Cylinder 2 is at the front of the engine Refer to Figure 3 In a top view of t...

Page 25: ...d guidelines in this manual must be followed to maintain continued airworthiness Compliance Requirements WARNING FOR CORRECT ENGINE MAINTENANCE COMPLETE THE NECESSARY MAINTENANCE PROCEDURES IN THIS MANUAL AND APPLICABLE SERVICE DOCUMENTS LYCOMING ENGINES SERVICE DOCUMENTS WRITTEN AT A LATER DATE SUPERSEDE PROCEDURES IN THIS MANUAL UNLESS OTHERWISE SPECIFIED PROCEDURES IN THIS MANUAL MUST BE DONE B...

Page 26: ... could result in minor or moderate injury It also can be used without the safety alert symbol as an alternative to NOTICE NOTICE The preferred signal word to address practices not related to personal injury NOTICE In this manual the word recommend refers to best practices Service Bulletins Service Instructions and Service Letters As advancements in technological applications on this engine continu...

Page 27: ...hapter Checklists are used to display a list of tasks to be completed as part of a specific procedure Checklists are not numbered because they are used as a reference tool contained within the procedure Copyright This publication is a copyrighted work All rights reserved by Lycoming Engines Content in this manual cannot be changed or released as a reprint electronic media output or web communiqué ...

Page 28: ...TEO 540 C1A Engine Maintenance Manual Introduction 2018 Avco Corporation All Rights Reserved Page xxvi November 2018 TEO 540 C1A Engine Maintenance Manual This page intentionally left blank ...

Page 29: ...al Aviation Regulations FAR unless an alternative program has been FAA approved 2 Mandatory Inspection Exhaust Valve and Guide At every 1000 hours of operation for TEO 540 C1A engines examine the exhaust valve and guide conditions Refer to the section Exhaust Valve and Guide Inspection in Chapter 72 30 3 Mandatory Inspection EECS NTO Faults Take off is prohibited with Electronic Engine Control Sys...

Page 30: ...EO 540 C1A Engine Maintenance Manual Airworthiness Limitations 2018 Avco Corporation All Rights Reserved Page xxviii November 2018 TEO 540 C1A Engine Maintenance Manual This page intentionally left blank ...

Page 31: ...ngine lift procedure engine preservation and storage depreservation engine installation requirements engine installation engine start operation and stop procedures engine initiation break in flight test fuels and oil to be used and operating specifications are included in the TEO 540 C1A Engine Installation and Operation Manual 3 List of Tools for Service and Maintenance Table 1 identifies tools u...

Page 32: ...cial Socket Spark Plug Wire Nut 64526 2 Block Cylinder 64530 Connecting Rod Parallelism and Squareness Gage 64535 Connecting Rod Bushing Removal Drift 64536 Replacement Drift 64580 Connecting Rod Bushing Burnisher 64593 Expanding and Staking Tool 0 71 in 18 mm Spark Plug Heli Coil Insert 64594 Inserting Tool 18 MM Spark Plug Heli Coil Insert 64595 Removing Tool 18 MM Spark Plug Heli Coil Insert 64...

Page 33: ...VENT INJURY OR DEATH ON ENGINE START UP A Disconnect the battery B Pull and attach a tag to the Electronic Engine Control System EEEC Power circuit breaker C Remove access panel s cowling s and or baffles for access to areas 6 Maintenance Practices A Obey all safety precautions B Unless otherwise directed do not reuse a gasket O ring or seal Install a new gasket O ring or seal during component ins...

Page 34: ...n No SB 240 identifies parts which must be replaced after they are removed in the case where other parts are removed it is recommended practice prior to installation to examine each part for damage or wear and replace the part as needed in accordance with accepted practices and standards to ensure that serviceable parts are installed on the engine G Unless otherwise specified in this manual refer ...

Page 35: ...ines approved methods and procedures B Refer to the latest revision of Service Bulletin No SB 240 for a list of parts that must be replaced whenever they are removed 9 Approved Parts CAUTION LYCOMING DOES NOT GIVE APPROVAL FOR USE OF PARTS MANUFACTURER APPROVAL PMA PARTS ON ITS ENGINES LYCOMING INSTALLATION INSTRUCTIONS DO NOT APPLY TO PMA PARTS EQUIPMENT FAILURE COULD OCCUR IF LYCOMING INSTRUCTIO...

Page 36: ...TEO 540 C1A Engine Maintenance Manual 05 00 2018 Avco Corporation All Rights Reserved Page 6 November 2018 TEO 540 C1A Engine Maintenance Manual This page intentionally left blank ...

Page 37: ...pplemental Type Certificates STCs Engine Inspection Schedule for TEO 540 C1A Engines When to Complete Inspection Refer to Chapter 05 20 Before each time interval inspection and during engine servicing or maintenance Visual Inspection Initial 10 hour engine inspection 10 Hour Initial Engine Inspection After the first 25 hours of operation or the first 4 months since the engine was placed into servi...

Page 38: ...TEO 540 C1A Engine Maintenance Manual 05 10 2018 Avco Corporation All Rights Reserved Page 8 November 2018 TEO 540 C1A Engine Maintenance Manual This page intentionally left blank ...

Page 39: ...aft before each routine 25 50 100 250 400 and 1000 hour inspection and every time before you service maintain or clean the engine WARNING BEFORE ANY ENGINE INSPECTION OR SERVICE PROCEDURE MAKE SURE THE IGNITION SWITCH IS SET TO OFF AND THAT ALL POWER TO THE ENGINE IS DISCONNECTED ENSURE ALL OBJECTS PERSONNEL ARE CLEAR OF THE PROPELLER S ROTATIONAL ARC IF POWER IS ON A LOOSE OR BROKEN WIRE CAN CAUS...

Page 40: ...ulate Contamination section in Chapter 05 50 Examine all hoses lines connections wiring fittings and baffles for loose connections and any damage Tighten any loose hardware as per the Standard Torque Tables in the latest revision of the Service Table of Limits SSP 1776 Replace field serviceable damaged components Otherwise send the engine to Lycoming Engines or an FAA authorized repair facility fo...

Page 41: ...2 50 Examine all oil hoses for leaks wear and secure attachment Make sure that all hoses and associated cushion clamps are secure and cannot move or vibrate excessively Ensure that there are no sharp bends in the oil hose routing and that no hoses are near heat sources that could damage them Identify and correct the cause of any leak Refer to the Oil Hose Inspection procedure in Chapter 72 50 Corr...

Page 42: ...t or clean with definite edges Identify and correct the cause Examine the exhaust system exhaust flange and port connections for leaks in connections between the exhaust system and exhaust ports of cylinders look for burnt paint around the spark plug and exhaust flange bosses or for light gray deposits near the leaks look for a warped exhaust flange which can cause a leak Identify and correct the ...

Page 43: ...depth Visually examine the alternator alternator belt and attaching hardware Refer to Chapter 72 70 Wiring Harness Make sure that the Engine Control Unit ECU Power Box Data Logger if applicable and engine ground straps are attached correctly and tightly Examine the ECU Power Box and associated connectors for secure attachment and signs of damage Replace any damaged component per procedures in Chap...

Page 44: ...ire is broken frayed or chafed or if a sensor connector is broken or damaged Refer to Appendix B in this manual for wiring harness connections Ensure that all engine wiring harness cushion clamps are secure and not worn or damaged Tighten any loose clamps Replace any worn or damaged clamps Turbocharger Examine all V band clamps to ensure they are tight and undamaged Refer to Chapter 72 40 Make sur...

Page 45: ...uring inspection in the engine compartment are securely in place and not loose Remove any foreign object debris FOD from the engine compartment 5 Start the engine and run up per instructions in the Engine Initiation chapter of the TEO 540 C1A Engine Installation and Operation Manual 6 Operate the engine for 3 minutes on the ground per the TEO 540 C1A Engine Installation and Operation Manual Comple...

Page 46: ...hoses for leaks wear and secure attachment Make sure that the oil hoses are secure and not vibrating Make sure that there are no sharp bends in the oil hose routing and that the oil hoses are not near heat sources that could damage the oil hose Identify and correct the cause of any leak Refer to the Oil Hose Inspection procedure in Chapter 72 50 Examine all fuel hoses for leaks wear and secure att...

Page 47: ...CAN LEAD TO A PROPELLER STRIKE SERIOUS INJURY OR DEATH NOTICE Copy the blank checklist and complete this checklist as a record of engine maintenance Put the completed checklist in the engine logbook 10 Hour Initial Engine Inspection Checklist for TEO 540 C1A Engines Engine Serial Number ____________________ Engine Time _________________________ Date Inspection Done _________________ Inspection don...

Page 48: ...gine Inspection Checklist for TEO 540 C1A Engines Cont Inspection Item Comments Results Notes Done Complete the Operational Ground Check in Chapter 72 00 Look for leaks Identify and correct the cause of any leak Correct any problem to make sure the engine operates correctly to specifications in Appendix A of the TEO 540 C1A Engine Installation and Operation Manual ...

Page 49: ...E MAKE SURE THE IGNITION SWITCH IS SET TO OFF AND THAT ALL POWER TO THE ENGINE IS DISCONNECTED ENSURE ALL OBJECTS PERSONNEL ARE CLEAR OF THE PROPELLER S ROTATIONAL ARC IF POWER IS ON A LOOSE OR BROKEN WIRE CAN CAUSE THE ENGINE TO START AND THE PROPELLER TO TURN WHICH CAN LEAD TO A PROPELLER STRIKE SERIOUS INJURY OR DEATH 25 Hour Engine Inspection Checklist for TEO 540 C1A Engines Engine Serial Num...

Page 50: ...is found record and identify the blockage metal carbon etc Remove any blockage and clean the oil suction screen Refer to the section Oil Suction Screen Removal Inspection Cleaning Installation in Chapter 12 10 Examine the engine for fuel or oil leaks NOTICE During the first hours of service engines can have some leakage at the cylinder head This initial leakage is not harmful or detrimental to the...

Page 51: ...AN CAUSE THE ENGINE TO START AND THE PROPELLER TO TURN WHICH CAN LEAD TO A PROPELLER STRIKE SERIOUS INJURY OR DEATH 50 Hour Engine Inspection Checklist for TEO 540 C1A Engines Engine Serial Number ____________________ Engine Time _________________________ Date Inspection Done __________________ Inspection done by ______________________ Inspection Item Comments Results Notes Done Complete the Visua...

Page 52: ...on Refer to the 50 Hour Turbocharger Inspection in Chapter 72 40 Ignition System Remove spark plug connector nuts and examine spark plug cable leads and ceramics for corrosion and deposits Replace spark plugs as necessary per Chapter 74 20 Clean the cable ends spark plug walls and ceramics Corrosion and deposits are evidence of leaking spark plugs or of improper cleaning of the spark plug walls or...

Page 53: ...80 Engine Cylinders Examine the rocker box covers for oil leaks Identify and correct the cause of oil leaks Chapter 72 30 For possible causes and corrections refer to the section Fault Isolation Guide in Chapter 12 30 Cyl 1 Cyl 2 Cyl 3 Cyl 4 Cyl 5 Cyl 6 Alternator Make sure the alternator belt support bracket and mountings are tight Tighten all loose hardware per torque values in the Standard Torq...

Page 54: ...URE MAKE SURE THE IGNITION SWITCH IS SET TO OFF AND THAT ALL POWER TO THE ENGINE IS DISCONNECTED ENSURE ALL OBJECTS PERSONNEL ARE CLEAR OF THE PROPELLER S ROTATIONAL ARC IF POWER IS ON A LOOSE OR BROKEN WIRE CAN CAUSE THE ENGINE TO START AND THE PROPELLER TO TURN WHICH CAN LEAD TO A PROPELLER STRIKE SERIOUS INJURY OR DEATH 100 Hour or Annual Engine Inspection Checklist for TEO 540 C1A Engines Engi...

Page 55: ...the Service Table of Limits SSP 1776 Replace a damaged fuel injector rail assembly per the Fuel Injector Rail Assembly Replacement procedure in Chapter 73 10 Make sure fuel hoses are held securely in place using clamps with cushions If no clamps are attached to the fuel hose that was in service replace the fuel hose per instructions in Chapter 73 10 If cushions on clamps are deteriorated or missin...

Page 56: ... 20 Examine the engine ground straps for damage and security Refer to the aircraft manufacturer s instructions Power Examine the power box for physical damage Make sure it is securely attached Replace a damaged power box Refer to the section Power Box Removal and Power Box Installation in Chapter 72 70 Examine the alternator belt s Refer to the section Alternator Belt Inspection in Chapter 72 70 C...

Page 57: ...e Fault Code cause Refer to the Troubleshooting Guide in Appendix D of this manual to identify the fault and complete the Troubleshooting Steps Crankcase Complete the crankcase inspection Refer to the Exterior Crankcase Inspection procedure in Chapter 72 20 Engine Accessories Complete the accessory drive inspection Refer to the Accessory Drive Inspection procedure in Chapter 72 60 Engine Mounts Co...

Page 58: ...ual Engine Inspection Checklist for TEO 540 C1A Engines Cont Inspection Item Results Notes Done Cylinder Compression Check Complete the Cylinder Compression Check Procedure in Chapter 72 30 Record the results for each cylinder Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 Operational Test Complete an Operational Ground Check in Chapter 72 00 ...

Page 59: ...ER S ROTATIONAL ARC IF POWER IS ON A LOOSE OR BROKEN WIRE CAN CAUSE THE ENGINE TO START AND THE PROPELLER TO TURN WHICH CAN LEAD TO A PROPELLER STRIKE SERIOUS INJURY OR DEATH 250 Hour Engine Inspection Checklist for TEO 540 C1A Engines Engine Serial Number ____________________ Engine Time _________________________ Date Inspection Done _________________ Inspection done by _______________________ In...

Page 60: ...N WIRE CAN CAUSE THE ENGINE TO START AND THE PROPELLER TO TURN WHICH CAN LEAD TO A PROPELLER STRIKE SERIOUS INJURY OR DEATH 400 Hour Engine Inspection Checklist for TEO 540 C1A Engines Engine Serial Number ____________________Engine Time _____________________________ Date Inspection Done _____________________Inspection done by ________________________ Inspection Item Comments Results Notes Done Co...

Page 61: ...Engine Inspection Checklist for TEO 540 C1A Engines Cont Complete the Cylinder Borescope Inspection procedure in Chapter 72 30 Record the results below for each engine cylinder Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 Inspection Item Comments Results Notes Done Operational Test Complete an Operational Ground Check in Chapter 72 00 ...

Page 62: ...Y ENGINE INSPECTION OR SERVICE PROCEDURE MAKE SURE THE IGNITION SWITCH IS SET TO OFF AND THAT ALL POWER TO THE ENGINE IS DISCONNECTED ENSURE ALL OBJECTS PERSONNEL ARE CLEAR OF THE PROPELLER S ROTATIONAL ARC IF POWER IS ON A LOOSE OR BROKEN WIRE CAN CAUSE THE ENGINE TO START AND THE PROPELLER TO TURN WHICH CAN LEAD TO A PROPELLER STRIKE SERIOUS INJURY OR DEATH 1000 Hour Engine Inspection Checklist ...

Page 63: ...ist for TEO 540 C1A Engine Models Cont Exhaust Valve and Guide Inspection Cont Cylinder 4 Cylinder 5 Cylinder 6 Inspection Item Comments Results Notes Done Operational Test Complete an Operational Ground Check in Chapter 72 00 General Check for Fault Codes Refer to the Troubleshooting Guide in Appendix D of this manual to identify the fault and complete the Troubleshooting Steps ...

Page 64: ...TEO 540 C1A Engine Maintenance Manual 05 20 2018 Avco Corporation All Rights Reserved Page 34 November 2018 TEO 540 C1A Engine Maintenance Manual This page intentionally left blank ...

Page 65: ...UTIONS REMOVE THE FINISH ON ALUMINUM PARTS AND MAGNESIUM PARTS ALKALINE COMPOUNDS CAN GET INTO THE PORES OF THE METAL WHICH CAN CAUSE OIL FOAMING WHEN THE PART IS PUT BACK INTO SERVICE OBEY STANDARD SAFETY PRACTICES REGARDING THE HANDLING OF CLEANING MATERIALS AND THE USE OF PERSONAL PROTECTIVE EQUIPMENT NOTICE If you are not sure of the correct cleaning agent or whether the component contains alu...

Page 66: ...based solvent Refer to the Crankcase Cleaning procedure in this chapter Removal of silk thread and or gasket material from crankcase mating flanges Methyl Ethyl Ketone MEK Acetone Napsco SC 200 M 17 M 114 Removal of gasket material on vacuum pump housing or other surfaces MEK Acetone Naptha or equivalent Apply solvent to gasket material Use a wooden plastic or phenolic scraper to remove gasket mat...

Page 67: ... steel parts covered with light oil Oil based solvent mineral spirits or equivalent Refer to the Steel Aluminum or Magnesium Parts Cleaning procedure in this chapter Aluminum or magnesium parts Refer to the Steel Aluminum or Magnesium Parts Cleaning procedure in this chapter Oil sump Oil pump and oil pump housing Mineral spirits MIL PRF 680 or equivalent Oil suction screen Mineral spirits MIL PRF ...

Page 68: ...ngine exterior and components not contaminated with volcanic ash Use a brush or spray to apply degreaser hydrocarbon based solvent to parts to remove grease oil and dirt Refer to the manufacturer s instructions for usage safety data and disposal of all cleaning agents 2 Crankshaft Cleaning CAUTION DO NOT MAKE SCORES SCRATCHES OR ETCH MARKINGS OF ANY KIND ON THE CRANKSHAFT SINCE THEY CAN CAUSE THE ...

Page 69: ...ANKSHAFT AND REPLACE IT WITH A NEW CRANKSHAFT 2 Install the tap into the recessed counterbore on the crankshaft 3 Turn the tap as necessary to clean the threads 4 Remove the tap 5 Flush the crankshaft counterbore threads with mineral spirits MIL PRF 680 or equivalent or Stoddard Solvent or equivalent solvent to remove any debris 6 Dry the crankshaft counterbore threads with compressed air D Examin...

Page 70: ...ocedure in this chapter Make sure there is no dirt debris sludge paint or any other substance that could prevent reliable fluorescent penetrant inspection FPI or subsequent oil flow B Remove all plugs from oil passages in the crankcase NOTICE Clean the crankcase after all grit blasting is complete C Use a stiff bristle fiber not wire brush and clean petroleum solvent to clean and flush the oil pas...

Page 71: ...Operate the grit blast gun as per the manufacturer s instructions 3 Unless otherwise specified in the manufacturer s instructions use approximately 35 to 45 psi 241 to 310 kPa of air pressure during grit blasting 4 Use compressed air and the vacuum cleaner to remove any debris and residue 5 After all cleaning is complete a Rinse the part in a petroleum solvent b Dry the part with an air blast to r...

Page 72: ...n wire bristle brush wooden plastic or phenolic scraper or grit blasting per the section Grit Blasting in this chapter to physically remove the hard carbon E Remove any remaining hard carbon from the component with a lint free wipe F Apply a spray coating of preservative oil on the component to prevent corrosion G If the component is not to be installed immediately put the component in a sealed pl...

Page 73: ...ROUND OFF THE OUTER CORNER OF THE PISTON RING LANDS WHICH AFFECTS THE PISTON CONFIGURATION A Remove all oil or preservative oil accumulation from the piston by a soak or wash in a clean bath of mineral spirits Safety Solvent or equivalent degreasing solvent in compliance with MIL PRF 680 specifications B Remove any remaining deposits with a wooden scraper C Gently clean the piston pin bore with a ...

Page 74: ...h a lint free wipe D Apply a spray coating of preservative oil on the component to prevent corrosion E If the component is not be installed immediately put the component in a sealed plastic bag to prevent the oil from drying out 13 Spark Plug Cleaning A Remove the spark plug as per the Spark Plug Removal procedure in Chapter 74 20 B Refer to the spark plug manufacturer s cleaning instructions C Cl...

Page 75: ...Chapter 05 50 for further details E Refer to the aircraft manufacturer s instructions for additional information 16 Cleaning Guidelines for a Soaked Engine A Clean the engine especially all recessed areas where debris and silt can get trapped B When cleaning parts removed from an engine that was soaked especially ferrous iron metals do not use hot acidic cleaning agents or electrolytic cleaning me...

Page 76: ...tion Vapor degreasing Solvent degreasing Ultrasonic cleaning Chemical cleaning Aqueous based cleaning Mechanical cleaning such as grit blasting NOTICE Grit blasting without etching can be an acceptable cleaning method if it can be demonstrated that a sufficiently fine abrasive 150 grit or finer will not cause peening and can be removed by a detergent or alkaline cleaner Etching of the area s to be...

Page 77: ...tion and evaluation on whether an engine repair or overhaul is necessary OR Complete the following in the field in accordance with the applicable Lycoming Engines manual 1 Remove disassemble and clean the engine per Chapters 72 00 72 05 72 20 and 05 30 2 Examine the engine compartment in the aircraft the engine external surfaces internal parts for discoloration cracks and other indications of arci...

Page 78: ... 1 Overspeed Values for TEO 540 C1A Engines Overspeed Category rpm Corrective Action Engine overspeed less than 5 in excess of maximum rated rpm for more than 3 seconds 2576 to 2704 a Identify and correct the cause of the overspeed b In the engine logbook record the overspeed incident and any inspections and corrective action Engine overspeed between 5 and 10 in excess of maximum rated engine rpm ...

Page 79: ...uck or broken piston ring Refer to the Cylinder Borescope Inspection procedure in Chapter 72 30 4 Valve Train Overspeed Inspection a Either repeated moments or short periods of operation in the overspeed region increase the rate of wear at an accelerated pace in the parts that make up the valve train and consequently decrease engine reliability In addition to the checks completed on the engine dur...

Page 80: ...PRESSURE WHICH CAN DAMAGE THE ENGINE 2 Actual damage to the engine from incorrect fuel could be in a range from unnoticeable to severe damage or failure Primary damage to the engine caused by incorrect fuel occurs in the combustion chambers Tuliped intake valves and burnt pistons from excessive cylinder head and oil temperatures are evidence of primary damage If detonation has been severe enough f...

Page 81: ...N AN ENGINE HAS BEEN SOAKED IN WATER MOISTURE AND UNWANTED MATERIALS CAN CAUSE DAMAGE TO ALL SYSTEMS OF THE ENGINE DO NOT INSTALL OR OPERATE AN ENGINE THAT HAS BEEN SOAKED OR IMMERSED IN WATER OR OTHER FLUID UNTIL IT HAS BEEN DISASSEMBLED CLEANED EXAMINED AS NEEDED ASSEMBLED AND OPERATIONALLY TESTED TO ENSURE THE ENGINE CAN BE SAFELY PUT BACK INTO SERVICE NOTICE The composition of the substance th...

Page 82: ...engine per Chapter 72 10 9 Refer to the Airframe Maintenance Manual and make sure all airframe interface fuel and oil lines intake and exhaust and the oil cooler are clean and have no debris or silt to prevent re contamination of the engine after the engine is installed in the airframe and re connected to airframe interface components 10 Install the engine in the airframe per instructions in the T...

Page 83: ...to Chapter 72 20 to remove and examine the connecting rods c If all connecting rods are in compliance with the specified criteria in the latest revision of the Service Table of Limits SSP 1776 install the connecting rods d If any connecting rod is not in compliance with acceptance criteria disassemble the engine to examine the crankcase and crankshaft as per Chapters 72 05 and 72 20 H Volcanic Ash...

Page 84: ... filter as per the aircraft manufacturer s instructions to remove any internal contamination that can cause premature wear because of the highly abrasive effects from most solid particles Replace the intake air filter as a precaution to be sure there are no effects from particulate contamination Replace the intake air filter again after the next flight Examine the external condition of the engine ...

Page 85: ...0 hours of operation because of valve sticking complete the scheduled 1000 hour inspection after the next 1000 hours of engine operation from the time of this inspection unless valve sticking occurs again J Oil Starvation Sudden Loss of Oil Pressure 1 To operate correctly at various attitudes the engine must be supplied with a sufficient quantity of lubricating oil Unless there is an adequate quan...

Page 86: ...ndication system is operating correctly and there has been confirmation that oil pressure loss oil starvation has occurred contact Lycoming Engines Technical Support K Metal Contamination of the Lubrication System 1 If metallic particles residue metal shavings or metal flakes is found in the engine oil after oil servicing refer to the Identification of Metallic Solids After Oil Servicing section i...

Page 87: ...e engine is operating where repair of the propeller is necessary Any incident during engine operation where the propeller has impact on a solid object which causes a decrease in rpm and where a structural repair of the propeller is necessary This incident includes propeller strikes against the ground Although the propeller can continue to turn damage to the engine can occur possibly with progressi...

Page 88: ...the checklist and complete it NOTICE The agency that returns the aircraft to service is responsible for the decision to operate an engine that had a propeller strike Lycoming Engines does not take responsibility for the decision to return the engine to service after a propeller strike Refer to the latest revision of Service Bulletin No SB 533 Engine Inspection Checklist After Propeller Strike for ...

Page 89: ...d prevent reliable FPI or subsequent oil flow 8 Complete grit blast cleaning of the accessory housing with fine abrasive 150 grit or finer Make sure there is no dirt debris sludge paint or any other substance that could prevent reliable FPI or subsequent oil flow 9 Remove and discard the existing crankshaft gear bolt and lockplate Refer to the Crankshaft Disassembly procedure in Chapter 72 20 10 E...

Page 90: ...ervice Table of Limits SSP 1776 for crankshaft flange run out tolerance Record the crankshaft flange run out measurement Flange run out within acceptable limits use crankshaft Replace crankshaft 15 Measure the main bearing run out on the crankshaft Refer to the latest revision of Part I of the Service Table of Limits SSP 1776 for the main bearing run out tolerance Record the main bearing run out m...

Page 91: ...ss Measurement Connecting Rod 1 Connecting Rod 2 Connecting Rod 3 Connecting Rod 4 Connecting Rod 5 Connecting Rod 6 NOTICE The magnetic particle inspection must be done by a certified technician as per the latest revision of Service Instruction No 1285 20 Complete a magnetic particle inspection on the crankshaft Record test results Magnetic particle test results acceptable Replace crankshaft 21 C...

Page 92: ...oil sump 28 Complete the visual inspection and FPI on the engine mounts Record test results Use engine mounts Replace engine mounts 29 Complete the visual inspection and FPI on the accessory housing Record test results Use accessory housing Replace accessory housing 30 Complete the visual inspection and FPI on the oil pump impeller Record test results Use impeller Replace impeller 31 Examine the P...

Page 93: ... the documents of all engine mounted accessories including the propeller governor if installed etc for continued airworthiness instruction 38 Assemble and install the engine Install the propeller and test the engine Complete an Operational Ground Check of the engine In accordance with instructions in Chapters 72 00 and 72 10 39 Complete Field Run In if applicable and Engine Initiation Refer to the...

Page 94: ...ch can cause indications to be tightly closed and therefore missed during future inspections C Requirements for NDT Personnel Personnel who complete the Magnetic Particle and Fluorescent Penetrant Inspections on Lycoming engine components must be qualified and certified to a written procedure in accordance with NAS 410 Certification and Qualification of NDT personnel Also personnel who make the ac...

Page 95: ...OF THE TEO 540 C1A INSTALLATION AND OPERATION MANUAL IF THE ENGINE IS OPERATED WITH AN INSUFFICIENT OIL LEVEL ENGINE DAMAGE CAN OCCUR REFER TO THE SECTION OIL STARVATION SUDDEN LOSS OF OIL PRESSURE IN CHAPTER 05 50 A The oil in the engine must be kept at the correct level for the engine to operate correctly B Measure the oil level of an engine before every flight as follows 1 Pull out the oil leve...

Page 96: ...to the latest revision of Service Instruction No SI 1014 for additional details C The only type of oil approved for turbocharged engines is ashless dispersant oil because it can withstand wide variations of ambient temperature The ashless dispersant oil grades contain additives which have a viscosity stabilizing effect The additives in these oils extend operating temperature range improve cold eng...

Page 97: ...ocedure Add Oil to the Engine in this chapter 7 Oil Servicing Schedule NOTICE While compliance with the oil change schedule and inspections in Table 1 of this Service Bulletin is mandatory in special circumstances the oil change intervals in Table 1 can be extended by not more than 5 hours while on route to a place where the oil change can be done on engines using aviation fuel Table 1 Oil Servici...

Page 98: ...y a wear trend pattern Refer to the latest revision of Service Letter No L171 for spectrographic oil analysis CAUTION THE ENGINE OIL WILL BE VERY HOT AND CAN CAUSE BURNS HANDLE WITH CARE A Drain the oil from the oil sump as follows 1 Put an empty 15 quart 14 liter capacity container under the drain plugs of the oil sump 2 Remove the safety wire from the square drain plugs and discard the safety wi...

Page 99: ...ter H Safety cable wire the oil sump drain plugs Figure 2 suction screen plug Figure 3 and oil filter if applicable in accordance with the standard practices per the latest revision of AC43 13 1B or the latest revision of Service Instruction No SI 1566 I Dispose of the oil in the collection container in accordance with environmental safety laws J Clean up any oil spilled on the engine K After all ...

Page 100: ...R 10 TO 15 SECONDS LET THE STARTER COOL FOR 30 SECONDS AFTER EACH ENERGIZATION IF THE STARTER FAILS TO ENERGIZE AFTER TWO ATTEMPTS IDENTIFY AND CORRECT THE CAUSE PER THE AIRFRAME MANUFACTURER S MAINTENANCE MANUAL K Pre oil start cycle Energize the starter for 10 to 15 seconds and look for evidence of oil pressure of at least 20 psi 138 kPa within 10 to 15 seconds If there is no oil pressure within...

Page 101: ...or 1 Deformation or openings in the mesh 2 Metal particles shavings or flakes trapped in the oil suction screen Refer to the sections Identification of Metallic Solids After Oil Servicing and Visual Inspection of the Oil Filter Element and Oil Suction Screen in this chapter G Clean the oil suction screen with mineral spirits or equivalent solvent H Apply a light coat of Food Grade Anti Seize to th...

Page 102: ...rocedure after the next 25 hours of engine operation If oil consumption continues to be excessive identify and correct the cause and repeat the oil change and oil filter replacement after every 25 hours of engine operation until oil consumption stabilizes A Drain the oil from the oil sump per Oil Change Procedure in section 8 in this chapter B Remove the safety wire cable Figure 4 from the oil fil...

Page 103: ...ear or damage to engine components such as cylinders bushings piston pins etc Metallic particles herein include metal particulates and or chunks chips flake hair like strands shavings etc Identification of the metallic particles is a progressive approach that begins with a visual inspection that can be followed with basic chemical analysis or more in depth analysis or directly with component exami...

Page 104: ... compromise the integrity of this inspection Drain all fluid oil through a strainer cloth or paper to remove oil from the oil filter and oil suction screen as much as possible to enable better visibility of the metallic particles and prevent loss of metallic particles Since quantity matters try not to lose particles Loss of metallic particles can compromise the integrity of this inspection Scrape ...

Page 105: ...delines for Identification of Metal Particulates and Chips Corrective Action Metals Alloys Tests Characteristics Possible Source of Origin on Lycoming Engine Next Step Steel or cast iron Picked up by magnet or will move when a magnet is placed on the opposite surface of the filter element or strainer cloth which will prevent chips from sticking to the magnet Camshaft lobes Gears Tappets Push rods ...

Page 106: ...lead chips chunks or balls are found complete Corrective Action 4 in Table 4 Aluminum flakes When placed in 50 solution of nitric acid and muriatic acid approximately 30 hydrochloric acid and water or a sodium hydroxide solution the aluminum particles bubble and fizz and form a black residue Crankcase Accessory housing Oil pump body Cylinder head Pistons Piston pin plugs Oil sump baffle Turbocharg...

Page 107: ...orrective Action 3 Pieces of metal that are chunks greater than 3 16 in 4 8 mm or chips smaller than chunks NOTICE A mixture of magnetic and nonmagnetic material can indicate valve or ring and piston failure NOTICE Remove the bottom spark plugs to identify a non conforming cylinder Corrective Action 4 1 4 teaspoonful or more of nonmagnetic plating with or without a copper tint could vary in sizes ...

Page 108: ...st the oil filter Possibly only one engine cylinder is damaged or spark plug is worn or damaged Corrective Action 5 If the cause of the metal contamination cannot be identified speak with the Lycoming Engines Technical Support phone number at the front of this manual If there is unusual aluminum bronze or iron contamination in the oil make sure you have a full description of the engine model seria...

Page 109: ...and examine the oil filter d If the oil filter is clean install a new oil filter e Operate the engine in flight for 10 hours f Remove and examine the oil filter g If either the oil filter is clean resume the routine oil servicing schedule If chunks or more than 45 metallic particles are found ground the aircraft and proceed to Corrective Action 3 3 a Per sections in this chapter complete Oil Chang...

Page 110: ...ls that have a propeller governor can have a small screen molded within the propeller governor gasket Remove this gasket and look for particle contamination on the propeller gasket screen Replace with a new propeller governor gasket If less than 10 metallic particles are found on this screen If 10 or more metallic particles or flakes or slivers of metal are found on this screen A Replace the prope...

Page 111: ...RRECT EECS OPERATION DO NOT USE THE FST DURING FLIGHT A Additional Fault Isolation Guidelines 1 In addition to the FST the Fault Isolation Guide in Table 1 shows the specific problems causes and corrections Continue from the simplest to the most complex possible causes and corrections 2 Review maintenance logs to identify trends and possible causes 3 Discuss operational problems with the pilot to ...

Page 112: ...filters strainers lines or fuel valves AMM Water in fuel system Drain the fuel hoses AMM Cylinder compression problem 1 Complete the cylinder compression check 2 Complete the Cylinder Borescope Inspection of cylinder s to determine if further disassembly and repairs are necessary 72 30 Damaged spark plug Spark Plug Removal Ignition Lead Inspection Spark Plug Inspection Spark Plug Cleaning Spark Pl...

Page 113: ...edures Spark Plug Removal Ignition Lead Inspection Spark Plug Inspection 74 20 Spark Plug Cleaning 05 30 Spark Plug Gap Setting Spark Plug Rotation Spark Plug Installation 74 20 Low cylinder compression 1 Complete the Cylinder Compression Check Procedure 2 Complete a Cylinder Borescope Inspection procedure on low pressure cylinder s 72 30 Blocked fuel injector 1 Identify whether the cylinder with ...

Page 114: ...k of the vent return line for blockage Clean if necessary Cracked engine mounts or defective mount bushings Replace the engine mounts or bushings AMM Engine mount bushing incorrectly installed Check for damage and install the engine mount bushing correctly AMM Low fuel pressure 1 Look for a blocked fuel pump filter and inoperative NTO light 2 Replace fuel pump or fuel pressure regulator 73 10 Loos...

Page 115: ...g Rotation Spark Plug Installation 74 20 05 30 Uneven cylinder compression 1 Complete the cylinder compression check 2 Complete a borescope inspection of low pressure cylinder s 72 30 Engine to airframe ground strap not connected or broken Clean terminals Reconnect ground strap and preform a continuity check AMM Battery negative cable loose or faulty connection to airframe Ensure battery cables ar...

Page 116: ... fuel pump per the Fuel Pump Replacement procedure 73 10 Low fuel pressure in the fuel injector rails and fuel pump O ring is not installed and or intact All O rings on the fuel pressure regulator must be installed 73 10 Engine will not shut off Faulty power switches Replace the switches AMM Faulty wiring in a harness Replace the harness 72 70 Ignition switch faulty Complete a check for faults on ...

Page 117: ...egulator Refer to the Fuel Pressure Regulator Replacement procedure 73 10 Engine will not turn static rpm or will not develop rated rpm Decreased air flow in the air reduction system 1 Complete the Induction System Inspection and remove all blockages 2 Make sure that the air box is installed in accordance with the airframe manufacturer s specifications 72 80 AMM Propeller is out of adjustment not ...

Page 118: ... air filter Defective air filter 1 Put the aircraft in a dust free area 2 Remove the air filter 3 Operate the engine to full power control 4 If the engine operates at full rpm replace the air filter with a new air filter AMM Fouled spark plugs Spark Plug Removal Spark Plug Cleaning Spark Plug Fouling Spark Plug Gap Setting Spark Plug Rotation Spark Plug Installation 74 20 05 30 Incorrect fuel flow...

Page 119: ...ssive wear on the cylinders or damaged valve and valve seats 72 30 3 Complete a top overhaul replace all of the engine cylinders 72 30 Engine will not supply the rated power Blockage in manifold system Clear all ducting Blockage in compressor impeller or turbine Replace the turbocharger 72 40 Compressor is too dirty 1 Thoroughly clean the compressor assembly 2 Service the air cleaner and do a chec...

Page 120: ...y shaft for binding Turbocharger impeller binding frozen or fouling housing 1 Examine the shaft play and contact with housings for binding 2 If contact is present replace the turbocharger 72 40 Piston seal in actuator is leaking NOTICE Usually accompanied by oil leakage at drain line Remove and replace the actuator or disassemble and replace the packing Fuel injector clogged Replace the clogged fu...

Page 121: ...ocked Examine the breather for obstructions Remove all obstructions Faulty oil pump Replace the oil pump per the Oil Pump Removal and Oil Pump Installation procedures 72 25 Propeller blades are intermittently sticking in hub Remove and overhaul the propeller as per the propeller manufacturer s instructions Front main bearing has too much clearance Complete a Propeller Oil Control Leak Test 72 25 I...

Page 122: ...cess blow by 7 Blockage in air duct to the oil cooler AMM Pressure relief valve is out of adjustment Per the Oil Pressure Adjustment procedure turn the adjusting screw on the oil pressure relief valve to adjust oil pressure or change the spring as necessary in the oil pressure relief valve 72 50 Dirt or metal chips under the oil pressure relief valve 1 Remove disassemble and clean remove dirt or m...

Page 123: ...oo much bearing clearance Cracks in the oil galley area of the crankcase Air leak on suction side of the oil pump 1 Examine the conditions of these components Oil suction screen gasket 12 10 Oil sump gasket 72 50 Oil pump mating surface to accessory housing 2 Replace cracked or damaged parts 72 25 Relocated oil pressure take off Use only the approved oil pressure take off point NOTICE If the oil p...

Page 124: ...scope Inspection procedure to determine if further corrective action is necessary NOTICE Listen for a hissing sound at the breather entrance of the crankcase which is an indication of air leaks around the rings 72 30 3 Remove the cylinders replace the piston rings deglaze the cylinder barrels and re install the cylinders as per the following sections Cylinder Removal Piston Removal Piston Inspecti...

Page 125: ...ear breather hose blockage or restriction AMM Cam spacer not installed Borescope breather tube in accessory housing to ensure cam spacer is installed 72 20 High oil temperature Cooling baffles are missing broken or incorrectly installed Ensure that all baffles are installed correctly and none are broken Replace as necessary NOTICE Never modify relocate or eliminate any cooling baffles Oil level is...

Page 126: ...ge and operate the engine to compare gages 2 Replace the faulty gage if necessary AMM High manifold pressure at idle Air leak in induction system Complete the Induction System Inspection Identify and correct the cause of all leaks NOTICE If the induction system has leaks the engine will idle rough 72 80 AMM Incorrect tappets or hydraulic lifters were installed Send the engine to Lycoming Engines f...

Page 127: ...re take off point on the engine Use only the approved oil pressure take off point Oil temperature is too cold Before increasing the power control allow the oil temperature to increase Oil pressure incorrectly adjusted Decrease the oil pressure by turning the pressure adjustment on the oil pressure relief valve counterclockwise per the Oil Pressure Adjustment procedure 72 50 Incorrect weight of oil...

Page 128: ...eaking and cannot be serviced 1 Examine the actuator drain for leaks 2 Clean the cylinder and replace the piston seal Leak in exhaust system Identify and correct the cause of the leak Damaged compressor impeller blades Replace the turbocharger 72 40 High deck pressure Compressor discharge pressure Exhaust bypass valve is not opening correctly Examine the exhaust bypass valve to make sure that the ...

Page 129: ... 20 Clogged or restricted propeller governor oil passage Check propeller governor gasket screen for blockage or restriction 12 10 Propeller goes into feather during landing rollout with decreased power setting Propeller oil control leak Complete the Propeller Oil Control Leak Test Procedure 72 20 Clogged or restricted propeller governor oil passage Check propeller governor gasket screen for blocka...

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Page 131: ...craft manufacturer s instructions remove all cowling baffling and nacelle access panels to enable engine removal 5 Disconnect the ground terminal of the battery 6 Disconnect the positive terminal of the battery 7 Disconnect and examine the leads and wiring for damage or frayed wiring Replace damaged or frayed wiring per aircraft manufacturer s instructions 8 Remove all engine accessories aircraft ...

Page 132: ... IF ONE WIRE BREAKS ON THE WIRING HARNESS THE COMPLETE HARNESS WILL NEED TO BE REPLACED 7 Disconnect the airframe interface wiring harness from the ECU and power box Refer to the airframe manufacturer s wiring diagram 8 Disconnect the engine to firewall wiring harness from the airframe interface wiring harness at the four firewall connectors FW1 P1 FW1 P2 FW2 P1 FW2 P2 Matching connections are ide...

Page 133: ... ENGINE DO NOT ALLOW THE FRONT REAR SIDES OR BOTTOM OF THE ENGINE TO BUMP OR STRIKE ANY OBJECTS TO PREVENT DAMAGE TO THE ENGINE OR ITS COMPONENTS 19 Carefully lift the engine slowly out of the airframe 20 Put the engine on an engine stand transport dolly or engine shipping container base CAUTION DO NOT PUT TAPE OR INSERT PLUGS INSIDE OPEN LINES OR FITTINGS 3 Engine Installation Preparation Require...

Page 134: ...e replaced when removed Before installing a component complete a check of the shelf life of the part as per the latest revision of Service Letter No L247 After all inspections and maintenance tasks are complete install the engine per the TEO 540 C1A Engine Installation and Operation Manual During engine re installation A Refer to and follow the Maintenance Practices in Chapter 05 00 B Replace any ...

Page 135: ... tighten any loose hardware in accordance with the aircraft manufacturer s instructions B Examine the rubber engine mounts and mounting hardware for signs of deterioration or damage Replace worn or damaged engine mounts or hardware in accordance with the aircraft manufacturer s instructions C Examine the four engine mounting brackets for cracks damage or visible signs of wear Replace cracked damag...

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Page 137: ...Step Reference Step Reference Step 1 Sensor Replacement Procedures in Chapter 72 70 and Exhaust System Removal procedure in Chapter 78 00 and Turbocharger Removal in Chapter 72 40 Step 3 Procedures in Chapters 74 20 and 74 30 in this manual Figure 3 Ignition Leads Coil Box and Spark Plugs Disconnect the wiring harness from the EGT and TIT sensor leads and secure the sensor leads remove the exhaust...

Page 138: ...cedures in Chapters 73 10 and 73 20 Fuel Hose Removal Throttle Body Removal Fuel Injector Rail Assembly Removal Fuel Pump Removal Figure 8 Fuel System Components Remove the alternator belt alternator and alternator bracket Figure 5 Step 6 Remove the starter Figure 6 Starter Removal procedure in Chapter 72 70 Figure 6 Starter Step 9 Remove the intake pipes Figure 9 Intake Pipe Removal procedure in ...

Page 139: ...sassembly procedure in Chapter 72 20 Figure 14 Crankshaft Idler Gears Figure 11 Oil Cooler Bypass Valve and Oil Filter Step 12 Remove the accessories propeller governor if installed and accessory housing Figure 12 Procedures in Chapters 72 20 72 25 and airframe manufacturer s instructions Step 15 Remove the oil drain tubes from the engine cylinder heads and crankcase Figure 15 Oil Drain Tube Remov...

Page 140: ... shafts push rods and shroud tubes Figure 17 Remove the connecting rods Figure 20 Figure 17 Rockers Shroud Tubes and Push Rods Step 18 Cylinder Removal procedure in Chapter 72 30 Figure 18 Engine Cylinders Step 21 Oil Pressure Relief Valve Removal procedure in Chapter 72 50 Figure 21 Oil Pressure Relief Valve Remove the engine cylinders Figure 18 Remove the oil pressure relief valve Figure 21 Step...

Page 141: ...20 Figure 26 Piston Cooling Nozzles Remove the tappets main bearings and O rings Figure 23 Remove the piston cooling nozzle Figure 26 Figure 23 Tappets Main Bearings and O Rings Step 24 Remove the propeller governor drive Figure 24 Propeller Governor Drive Removal Disassembly in Chapter 72 20 Step 27 Disassemble the crankshaft Figure 27 Crankshaft Disassembly in Chapter 72 20 Figure 27 Crankshaft ...

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Page 143: ...o not get paint on any mating surfaces or under the cylinder hold down nuts There must be metal to metal contact to ensure proper torque Mask mating surfaces and the area where the nut will contact the component surface Table 2 includes paint stripping and painting guidelines for components All paint is to be sprayed however if it is necessary to use a brush use care to prevent an accumulation of ...

Page 144: ...m the cylinder Paint strippers are usually organic solvents like MEK or acetone or toluene etc and typically will not cause any damage to metals A vapor degreaser is best suited for this purpose NOTICE Masking tape corks plugs metal covers etc are acceptable for masking purposes 2 Mask off the following parts of the cylinder Rocker box section including the rocker box flange Both valve ports and f...

Page 145: ...k A Bearing Shell Surface Inspection 1 Examine all bearing saddle surfaces for damage scoring galling and wear If any of these conditions are found identify and correct the cause 2 Make sure that the clearance of each bearing agrees with the specification in the latest revision of the Service Table of Limits SSP 1776 If a bearing is not in the specified limits in the latest revision of the Service...

Page 146: ...aft trigger gear assembly fits correctly in the counterbore end of the crankshaft Figure 1 Crankshaft Trigger Gear Assembly Fit Verification procedure in Chapter 72 20 Figure 1 Crankshaft Trigger Gear Assembly Figure 4 Connecting Rods Step 6 Counterweight Installation procedure in Chapter 72 20 Figure 5 Counterweights Step 3 Install a new expansion plug on the crankshaft Figure 2 Expansion Plug In...

Page 147: ...ure in Chapter 72 20 Figure 10 Main Bearings and O Rings Figure 7 Oil Plugs Step 9 Install the oil pressure relief valve Figure 8 Oil Pressure Relief Valve Installation procedure in Chapter 72 50 Step 12 Install the propeller governor drive Figure 11 Propeller Governor Drive Installation in Chapter 72 20 Figure 11 Propeller Governor Drive Figure 8 Oil Pressure Relief Valve Step 10 Tappet Assembly ...

Page 148: ...r 72 20 Figure 13 Crankshaft Figure 16 Crankshaft Idler Gear Assemblies Step 15 Crankcase Assembly procedure in Chapter 72 20 Step 18 Oil Pump Installation procedure in Chapter 72 25 Assemble the crankcase halves Figure 14 Install the oil pump on the accessory housing Figure 17 Figure 14 Crankcase Halves Figure 17 Oil Pump Step 16 Complete installation of the crankshaft oil seal in the crankcase F...

Page 149: ... in Chapter 72 30 Figure 19 Propeller Governor Figure 22 Engine Cylinders Step 21 Install the oil sump on the crankcase Figure 20 Oil Sump Installation in Chapter 72 50 Figure 20 Oil Sump Step 24 Install the starter ring gear support on the engine Figure 23 Starter Ring Gear Support Installation procedures in Chapter 72 70 Figure 23 Starter Ring Gear Support Step 22 If removed install the piston i...

Page 150: ...Oil Drain Tube Installation procedure in Chapter 72 30 Step 30 Install the fuel pump fuel pressure regulator throttle body fuel injector rails and fuel hoses Figure 29 Procedures in Chapters 73 10 and 73 20 Fuel Pump Installation Fuel Pressure Regulator Throttle Body Installation Fuel Injector Rail Assembly Installation Fuel Hose Installation Attach six new oil drain tubes one on each engine cylin...

Page 151: ...nstallation procedure in Chapter 72 70 Figure 31 Alternator Bracket Alternator and Alternator Belt Figure 33 Sensors and Wiring Harness Step 33 Install the exhaust system and turbocharger Figure 32 Refer to Chapters 72 40 and 72 80 Figure 32 Exhaust System Step 35 Install the engine in the airframe Install the engine in the airframe per instructions Chapter 72 00 in this manual in the TEO 540 C1A ...

Page 152: ...he alignment dowel per the Alignment Dowel Installation procedure in the Crankshaft Assembly section in Chapter 72 20 CAUTION FOR CORRECT ENGINE OPERATION THE CRANKSHAFT TRIGGER GEAR ASSEMBLY MUST BE INSTALLED CORRECTLY WITH NO GAP IN THE MATING SURFACES BETWEEN THE COUNTERBORED END OF THE CRANKSHAFT AND THE CRANKSHAFT TRIGGER GEAR ASSEMBLY Complete the Crankshaft Trigger Gear Assembly Fit Verific...

Page 153: ...lete the Piston Cooling Nozzle Installation procedure in Chapter 72 20 If the oil plugs were removed complete the Oil Plug Installation procedure in Chapter 72 20 Complete the Oil Pressure Relief Valve Installation procedure in Chapter 72 50 Complete the Tappet Assembly Installation procedure on Chapter 72 20 Identify the types of tappets installed in the engine logbook Complete the Crankshaft Bea...

Page 154: ...ete the Crankshaft Installation procedure in Chapter 72 20 Measure the thrust face clearances between the crankshaft and crankcase per the Crankshaft Installation procedure in Chapter 72 20 Measurement Measure the slinger clearance per the Crankshaft Installation procedure in Chapter 72 20 Measurement Measure the crankshaft end play clearance per the Crankshaft Installation procedure in Chapter 72...

Page 155: ...ion procedure in Chapter 72 30 for all six pistons Make sure new piston rings and new piston pin plugs are installed on each piston Complete the Cylinder Installation procedure in Chapter 72 30 If necessary complete the Starter Ring Gear Replacement procedure in Chapter 72 70 Install the starter ring gear support per the Starter Ring Gear Support Installation procedure in accordance with the Start...

Page 156: ...the Starter Replacement section in Chapter 72 70 Complete the Alternator and Bracket Installation procedure in Chapter 72 70 Complete the Alternator Belt Installation procedure in accordance with the Alternator Belt Replacement section in Chapter 72 70 Install the sensors per the Sensor Replacement Procedures in Chapter 72 70 Complete the Engine to Firewall Wiring Harness Installation procedure in...

Page 157: ...ange Bushing Remove Install Tool ST 115 to remove each bushing from the propeller flange 2 Propeller Flange Bushing Installation CAUTION IF THE PROPELLER FLANGE BUSHING OF THE CORRECT PART NUMBER IS NOT INSTALLED IN THE SPECIFIED LOCATION THE PROPELLER WILL NOT BE INDEXED CORRECTLY EXCESSIVE PROPELLER BLADE STRESSES CAN OCCUR A Refer to Figure 1 or the latest revision of the TEO 540 C1A Illustrate...

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Page 159: ... is worn damaged or cracked replace both crankcase halves as a matched set C Examine the crankcase breather fitting for cracks dents and damage If cracks dents or damage are found replace the breather fitting CAUTION LOOSE CYLINDER BASE NUTS ON THE THRU STUDS ARE AN INDICATION THAT THERE IS NOT A UNIFORM LOAD ON THE MAIN BEARINGS IN THE CRANKCASE ENGINE DAMAGE CAN OCCUR DISASSEMBLE THE ENGINE PER ...

Page 160: ...throw position of the connecting rod for reference on assembly C Remove and discard the two connecting rod bearings Note excessive wear for repair Figure 1 Connecting Rod Parts 3 Crankcase Disassembly A Put the crankcase upright on a suitable work surface B Remove the high speed idler gear Figure 2 from the crankcase C Cut remove and discard the safety wire Figure 3 from the three screws in the fu...

Page 161: ...kcase Assembly H Cut remove and discard the safety wire on the six nuts on the bottom of the crankcase that were inside the oil sump I Remove the remaining bolts and nuts that attach the crankcase halves J Insert one used pushrod into each of the eight holes where the thru studs were removed to support the camshaft and crankshaft when the crankcase halves are separated K Separate the crankcase wit...

Page 162: ...to the code symbols the letters RN are stamped as a suffix to the serial number indicating that the crankshaft has been renitrided Figure 10 Crankshaft in V Block Type Fixture O Tappet Main Bearing and O Ring Removal 1 Remove the hydraulic tappet plungers using the Tappet Assembly Tool P N 64941 CAUTION IF A TAPPET ASSEMBLY TOOL IS NOT AVAILABLE REMOVE THE PUSH ROD SOCKETS BY HAND OR BY MAKING A L...

Page 163: ... a right angle in one end of a piece of wire and insert this end into the space between the plunger assembly and the tappet body Turn the wire 90º to engage a coil of the spring and draw out the hydraulic tappet plunger assembly Refer to Figure 12 Figure 11 Removing Push Rod Socket Figure 12 Removing Hydraulic Tappet Plunger Assembly 5 Remove and discard the crankshaft bearings crankshaft front be...

Page 164: ...d governor gasket Discard the governor gasket 3 Cut and remove the safety wire cable from the idler gear shaft plug Figure 14 4 Remove the idler gear shaft plug and gasket from the crankcase Discard the gasket 5 Remove and discard the set screw from the propeller governor idler gear shaft If the set screw was peened or staked in the hole remove any debris 6 Support the propeller governor idler gea...

Page 165: ...540 C1A Engine Maintenance Manual Q Remove the threaded oil NPT plugs from the accessory housing oil sump induction system and crankcase to facilitate cleaning Figures 15 16 and 17 Figure 15 Oil Plugs in the Accessory Housing Figure 16 Oil Plugs in the Oil Sump Induction System Figure 17 Oil Plugs in the Crankcase ...

Page 166: ...d with a new bolt for the applicable crankshaft trigger gear assembly The discarded bolt is not to be re installed on any engine Do not remove the alignment dowel Figure 19 from the end of the crankshaft unless it is damaged Replace a damaged alignment dowel per the Alignment Dowel Replacement procedure in this chapter Do not remove the propeller flange bushings unless they are loose or damaged Ch...

Page 167: ...HAFT WHEN REMOVING THE CRANKSHAFT OIL SEAL B Remove the crankshaft oil seal from the crankshaft If necessary cut the spring with wire cutters and cut the seal with side cutter pliers to remove a solid ring crankshaft oil seal C Counterweight Removal CAUTION WHEN HANDLING COUNTERWEIGHTS AND ROLLERS DO NOT MAKE SCORES SCRATCHES OR ETCH MARKINGS OF ANY KIND ON THE CRANKSHAFT AND ROLLERS A MARK IN ANY...

Page 168: ...g rings and washers regardless of condition Figure 20 Counterweight Rollers Counterweight Bushings and Lug Bushings Crankshaft Dynamic Counterweight Bushings CAUTION COUNTERWEIGHT BUSHINGS MUST ALWAYS BE REPLACED AS A SET WITH NEW COUNTERWEIGHT BUSHINGS WHENEVER THESE BUSHINGS ARE REMOVED DAMAGE OR WEAR ON THE CRANKSHAFT OR COUNTERWEIGHT BUSHINGS COULD CAUSE FAILURE OF THE COUNTERWEIGHT AND OR THE...

Page 169: ...e of the counterweight Discard the bushings Figure 21 Counterweight Bushing Removal Installation Using the Counterweight Fixture Assembly ST 93 and the Counterweight Bushing Driver ST 92 5 Interior Crankcase Inspection The interior crankcase inspection is done to identify cracks and mechanical damage within the crankcase WARNING REPLACE A DAMAGED OR CRACKED CRANKCASE DO NOT TRY TO WELD OR REPAIR A...

Page 170: ...bearings and camshaft bearing saddles Figure 13 formed by the crankcase halves are within allowable limits Complete the crankcase dimensional inspection as follows 1 Install new crankshaft bearings at all main bearing locations in the crankcase halves Figure 13 2 Assemble the crankcase halves and install thru studs Figure 4 3 Use washers and nuts on the thru studs to install the Torque Hold Down P...

Page 171: ...in bearing measurement _________ inches Crankshaft at 3 main bearing measurement _________ inches Crankshaft at 4 main bearing measurement _________ inches Measure the ID of the camshaft bearing saddles formed by the crankcase when assembled Camshaft bearing saddle 1 measurement ___________ inches Camshaft bearing saddle 2 measurement ___________ inches Camshaft bearing saddle 3 measurement ______...

Page 172: ...to inspection the crankshaft inner diameter must be clean dry and free of debris D Continue with the crankshaft inspection Do not make scores scratches or etch markings of any kind on the crankshaft A mark in any of these areas can cause the crankshaft to weaken and to possibly fail Crankshaft Inspection Checklist for TEO 540 C1A Engines Engine Serial Number _____________________Engine Time ______...

Page 173: ...ion Done Use a flashlight magnifying glass and angled inspection mirror to visually examine the hollow inner diameter bore of the crankshaft bore Figure 22 starting at the crankshaft flange end Replace a damaged or cracked crankshaft Replace the crankshaft if there is any raised metal on surfaces Replace the crankshaft if there is any scratch ding dent or pit that exceeds 0 050 in 1 27 mm depth Ac...

Page 174: ...mum permissible thickness If the crankshaft flange is bent replace the crankshaft Do NOT straighten or grind a bent crankshaft Refer to the latest revision of Service Bulletin No SB 201 for any additional details Crankshaft Flange Thickness Inches Millimeters Inches Millimeters 0 440 0 010 11 176 0 254 0 420 10 668 Measure the run out of the crankshaft flange with a dial indicator at the location ...

Page 175: ...d with a new bolt for the applicable crankshaft trigger gear assembly The discarded bolt is not to be re installed on any engine Do not remove the alignment dowel Figure 25 from the end of the crankshaft unless it is damaged Replace a damaged alignment dowel per the Alignment Dowel Replacement procedure in this chapter Figure 25 Crankshaft Trigger Gear Assembly and Crankshaft Gear Bolt Item Commen...

Page 176: ... trigger gear assembly for damage from galling or fretting If the pilot flange of the crankshaft trigger gear assembly is damaged replace the crankshaft trigger gear assembly Acceptable Replace If there is a hole slot or tang on the crankshaft trigger gear assembly examine the hole slot or tang for nicks or dents If nicks or dents are found on the hole slot or tang replace the crankshaft trigger g...

Page 177: ...terbore There must not be any clearance when the crankshaft trigger gear assembly is installed Crankshaft Counterbore Inspection CAUTION LYCOMING ENGINES NO LONGER ALLOWS REWORK OF THE COUNTERBORE DO NOT TRY TO REPAIR THE CRANKSHAFT COUNTERBORE THREADS IN THE FIELD IF THIS TYPE OF REPAIR IS NECESSARY IT IS RECOMMENDED THE CRANKSHAFT BE SENT TO THE FACTORY THROUGH AN AUTHORIZED LYCOMING DISTRIBUTOR...

Page 178: ...28 cannot be repaired It only can be replaced A counterweight roller cannot be repaired It only can be replaced as an identical paired set specific for each counterweight Examine the surface of the counterweight for scoring scratches punch marks or any other surface damage Make sure the counterweight surface is smooth Replace the counterweight if there is scoring scratches punch marks or any other...

Page 179: ...ace Outcome of Bushing Bore Inspection for Counterweight Position 2 Accept Replace a The bushing bore on the counterweight must be between 0 9369 and 0 9377 in 23 7973 and 23 8176 mm Bushing Bore Diameter Counterweight Position 1 Bushing Bore Diameter Counterweight Position 2 NOTICE If the bushing bore on the counterweight is not within the specified tolerances replace the counterweight Some count...

Page 180: ...found If corrosion is found or there is evidence of grinding to remove corrosion Crack s or pitting with crack s in the crankshaft inner bore Warped or bent crankshaft flange Do not try to repair or grind a warped or bent crankshaft flange If the mounting surface of the crankshaft counterbore is galled fretted or damaged Oversized inside diameter of the crankshaft greater than 2 126 in 54 000 mm I...

Page 181: ...test revision of Service Bulletin No SB 475 6 If the alignment dowel is out of tolerance or out of round replace the dowel with a new one per the Alignment Dowel Replacement procedure in this chapter 7 Crankshaft Bearing Surface Inspection A Examine all bearing surfaces for scoring galling gouges and wear If a bearing surface is scored galled or worn and polishing to either 0 003 in or 0 006 in un...

Page 182: ...logbook A Examine all bearing saddle surfaces for scoring galling gouges and wear If any of these conditions are found identify and correct the cause B Make sure that the clearance of each bearing agrees with the specification in the latest revision of the Service Table of Limits SSP 1776 C If a bearing does not conform to the specified limits in the latest revision of the Service Table of Limit S...

Page 183: ...Checklist for TEO 540 C1A Engines Item Comments Findings Corrective Action Done Camshaft Visual Inspection Visually examine all surfaces of the camshaft Figure 31 give particular attention to bearing surfaces and camshaft lobes If any of the following conditions are found during this visual inspection replace the camshaft cracks scoring galling corrosion pitting feathering at edge of camshaft lobe...

Page 184: ...eplace Acceptable Replace Examine the mating face of the connecting rod and its cap face for fretting Figure 32 If fretting is found replace the connecting rod assembly Acceptable Replace Acceptable Replace Acceptable Replace Acceptable Replace Acceptable Replace Acceptable Replace Use a 6 power magnifying glass minimum or bench microscope to examine the critical areas on the connecting rod identi...

Page 185: ...from the ID of the connecting rod bushing If the clearance is less than or equal to the Service Max clearance in the latest revision of the Service Table of Limits SSP 1776 the connecting rod bushing and piston pin are acceptable with regards to connecting rod bushing wear If the clearance is greater than the Service Max clearance in the latest revision of the Service Table of Limits SSP 1776 remo...

Page 186: ...ing Rods Parallelism Squareness Check in this chapter For the parallelism check measure the distance between arbors Figure 37 For exact parallelism or alignment the distances measured on both sides are to be the same For the squareness check use a feeler gage to measure the clearance at the four check points where the arbors rest on the parallel blocks Figure 38 Compare the clearance between each ...

Page 187: ... this checklist 4 Subtract the crankshaft diameter at the crank pin journal from the inside diameter of the bearings for each connecting rod to calculate the connecting rod bearing and crankshaft clearance Record the measurement in this checklist 5 Compare the connecting rod bearing and crankshaft clearance to the acceptable clearance measurement in the latest revision of the Service Table of Limi...

Page 188: ...rnished Flush to 0 010 in 0 254 mm Below Connecting Rod Surface E Make sure the split in the bushing is located so that it is toward the piston end of the connecting rod and 45 off the centerline Figure 34 and press the bushing into the connecting rod until the edge of the bushing is flush with the surface of the connecting rod F Use a suitable arbor press and the Connecting Rod Bushing Burnisher ...

Page 189: ... arm on the arbor as shown in Figure 37 E Turn the adjusting screw on the gage arm until it just touches the arbor F Use the wing nut to lock the adjusting screw G Make sure the adjusting screw just touches the arbor H Remove the gage arm and install it on the other end of the arbor I Measure the distance between arbors For exact parallelism or alignment the distances measured on both sides must b...

Page 190: ...ance replace the connecting rod and examine the crankshaft to make sure the crankshaft is not damaged 15 Tappet Inspection NOTICE Complete the Tappet Inspection Checklist to examine the hydraulic hyperbolic tappets Figure 39 Tappet Inspection Checklist for TEO 540 C1A Engine Models Figure 39 Hydraulic Hyperbolic Tappet Task Corrective Action Findings Examine the tappet body for part number identif...

Page 191: ...irregularity scuffing pitting or feathering at the edge of the lobe If any of these conditions are found on the camshaft lobe replace the camshaft Tappet body acceptable Replace tappet body New camshaft Replaced all tappet bodies NOTICE If a new camshaft is installed in the engine replace all of the tappet bodies New camshaft Replaced all tappet bodies Figure 41 Spalling on Tappet Face Figure 42 R...

Page 192: ...lder Figure 44 If wear feathering or a chipped edge is found replace with a new tappet body of the same part number Tappet body acceptable Replace tappet body Figure 44 Comparison Between Worn and New Tappet Body Refer to the latest revision of Service Instruction No SI 1011 for part numbers If an acceptable superseding tappet part number is installed replace all tappets with tappets of the same r...

Page 193: ...e acceptable non collapsed non cracked plunger with solvent back flush the plunger with solvent Look for a leaking check valve on the tappet plunger as follows A Dip the plunger in engine oil B Hold the hydraulic cylinder between the thumb and middle finger in a vertical position with one hand as shown in Figure 47 C Hold the plunger in position where it just enters the cylinder NOTICE Do not cove...

Page 194: ...Penetrant Inspection is recommended in lieu of magnetic particle inspection on these parts due to the original manufacturing techniques used to make these parts Results of FPI 16 Crankshaft Assembly A Alignment Dowel Replacement 1 Use a center punch to mark the center of the exposed surface of the installed alignment dowel Figure 48 2 Mark a 1 8 in drill bit to limit the depth of the drilled hole ...

Page 195: ...rankshaft Trigger Gear Assembly Fit Verification 1 Start with a clean crankshaft that passed the Crankshaft Inspection in this chapter 2 Make sure the mating surfaces of the crankshaft trigger gear assembly and crankshaft counter bored end are clean and dry and that there is no debris Refer to the procedures Crankshaft Cleaning Crankshaft Counterbore Cleaning and Crankshaft Trigger Gear Assembly C...

Page 196: ...bris or remaining gasket maker to ensure a good seal when the new bead of gasket maker is applied in the next step 2 Apply a bead of Loctite 2 Non Hardening Gasket Maker or equivalent to the perimeter of a new expansion plug 3 Seat the new expansion plug firmly on the shoulder in the bottom of the crankshaft bore with the convex side out Figure 51 Figure 51 Installed Expansion Plug NOTICE A driver...

Page 197: ...cedure later in this chapter Figure 52 Split Oil Seal Figure 53 Solid Ring Crankshaft Oil Seal NOTICE An oversize crankshaft oil seal could be necessary if the crankcase bore size was increased Part numbers for oversized parts include a P suffix such as P50 and are identified on the face of the seal Except for the revised outside diameter of the seals the oversize seals are identical in other aspe...

Page 198: ... ring crankshaft oil seal to prevent damage to the spring seal and potential injury Figures 54 and 55 Figure 54 Locating the Internal Spring Figure 55 Internal Spring Removed 5 Open the spring a Find the spring joining ends b Hold the spring tightly in your left hand so it cannot turn Figure 56 c Twist the spring and roll your fingers counter clockwise with your right hand about five turns to unth...

Page 199: ...re warm the seal to ease installation 7 Put a brass pin approximately 9 32 in diameter by 3 in 7 cm long through the crankshaft propeller flange bushing to hold both sides of the seal in place as shown in Figure 59 Figure 58 Pinion Cage Oil Retaining Housing Installed on the Crankshaft Propeller Flange as a Guard Figure 59 Crankshaft Propeller Flange Showing the Installation of the Solid Ring Oil ...

Page 200: ...e spring is not damaged and is seated completely in the internal groove of the solid ring crankshaft oil seal 11 Use ethyl alcohol and disposable wipes to clean the outer surface of the seal and the crankcase seal bore recess This oil seal installation procedure is completed after the crankcase halves are joined together Refer to the latest revision of Service Instruction No 1324 for any new detai...

Page 201: ...of the new connecting rod bolts Figure 60 Wipe away excess lubricant with a clean lint free cloth 7 Apply engine oil mixture to the crank pin journals 8 Install each connecting rod end cap with the bearings installed on their respective crank pins on the crankshaft where the numbers on the connecting rods and bearing locks point down toward the oil sump CAUTION CORRECT INSTALLATION OF THE NEW NUT ...

Page 202: ...3 2 Make sure the counterweights of the correct order and part number are to be installed on the crankshaft Refer to the latest revision of Service Instruction No SI 1012 CAUTION DO NOT INSTALL TWO DIFFERENT ROLLERS ON THE SAME COUNTERWEIGHT ALL MUST BE MATCHED PAIRS OF IDENTICAL PARTS 3 Measure the outside diameter of each roller to be installed to make sure it is in compliance with the dimension...

Page 203: ...A is the diameter of the gage Dimension B is the width of the gage 9 Make sure the circlip seating is correct Figure 64 as follows a Install one end of the counterweight Circlip Check Gage P N 64892 2 Figure 65 between the ends of the circlip Figure 67 Figure 65 Circlip Check Gage P N 64892 2 Figure 66 Circlip Installed Figure 67 Insertion of Circlip Check Gage b Make sure the gage is on the botto...

Page 204: ... in each crankcase half Figure 68 C Torque each piston cooling nozzle to 100 in lb 11 Nm 18 Oil Plug Installation if removed A Make sure the NPT oil plugs are acceptable not damaged or cracked Replace any worn damaged or cracked oil plug B Apply of coating of Loctite 564 or equivalent to all of the oil plugs C Install the NPT oil plugs in each crankcase half Figures 15 16 17 and 69 A B and C D Tor...

Page 205: ...DO NOT MIX HYDRAULIC TAPPET PLUNGER OR LIFTER ASSEMBLIES WITH DIFFERENT PART NUMBERS IN THE SAME ENGINE THE DIFFERENT LEAK DOWN RATES WILL CAUSE INCORRECT ENGINE OPERATION ALL PARTS OF EACH HYDRAULIC PLUNGER ASSEMBLY ARE SELECTIVELY FITTED AND ARE NOT INTERCHANGEABLE MATING PARTS MUST BE KEPT TOGETHER IF THERE IS ANY DOUBT AS TO WHETHER THE PARTS HAVE BECOME MIXED INSTALL NEW PLUNGER ASSEMBLIES NO...

Page 206: ...lic tappets have a bowed shape they will not have a snug fit after they are installed There will be some tappet movement or play which is acceptable Measure the outside diameter of hyperbolic tappets at the widest area approximately at the mid point of the length of the tappet body Replace all of the tappets as a complete set even if only one is found damaged Refer to the latest revision of Servic...

Page 207: ...Thrust Washer Thickness in mm 73249 0 0585 to 0 0595 1 4859 to 1 5113 73250 0 062 to 0 063 1 575 to 1 600 73251 0 0655 to 0 0665 1 6637 to 1 6891 73252 0 069 to 0 070 1 753 to 1 778 01L21418 0 055 to 0 056 1 397 to 1 422 A Governor Drive Gear Installation 1 Lubricate the shaft of the propeller governor drive gear with engine oil and install the propeller governor drive gear in the left half of the...

Page 208: ... is adequate material in the set screw hole to peen on top of the screw use a new set screw that is shorter than the one previously removed A smaller diameter center punch could be necessary Refer to Figure 79 1 Wear impermeable gloves and apply a light coat of Loctite 290 or equivalent to the new set screw Wipe away any excess Loctite 290 with a clean lint free cloth Figure 77 Shim Between Spacer...

Page 209: ... propeller governor drive gear NOTICE The governor drive cover or mask is to prevent FOD during engine assembly and will be removed when the propeller governor is installed F Install a governor drive cover or mask on the propeller governor mounting pad G Install four nuts on the studs in the crankcase to attach the governor drive cover or mask 22 Camshaft Assembly and Installation A Camshaft Assem...

Page 210: ...and complete a check of the camshaft end play clearance Acceptable end play clearance 0 002 to 0 015 in 0 051 to 0 381 mm Figure 83 Camshaft End Play Clearance Check NOTICE If the end play clearance values are not within the allowable limits examine the crankcase and or camshaft for wear or damage Replace a damaged or worn camshaft If one crankcase half is worn or damaged replace both crankcase ha...

Page 211: ...ing surfaces of each crankcase half Figure 84 Figure 84 Thrust Bearing Surfaces of Each Crankcase Half Figure 85 Lubrication to Roller Tappets and Camshaft Lobes 6 Install the camshaft in the left crankcase half 7 Tie a loop of soft wire around the camshaft and left crankcase half as shown in Figure 87 to hold the camshaft securely in place Figure 86 Lubricant Application to Camshaft Bearing Saddl...

Page 212: ... halves Figure 13 2 Install the front bearing halves where they touch butt together around the crankshaft 3 Lift the crankshaft assembly by the connecting rods Lower the crankshaft assembly into the crankcase half Figure 88 Let the connecting rods extend through the cylinder base openings in the crankcase half Figure 88 Crankshaft Installed in Crankcase Half 4 With the crankshaft assembly in the c...

Page 213: ... Chapter 05 30 in this manual If a crankcase stud is bent broken damaged loose rusted corroded or cannot be cleaned refer to the Stud Replacement procedure in Appendix A A Assemble the Crankcase Halves CAUTION THE CRANKCASE HALVES ARE A MATCHED SET IF ONE HALF IS CRACKED OR DAMAGED BOTH HALVES MUST BE REPLACED ONLY LYCOMING APPROVED SEALANTS ARE TO BE USED DURING CRANKCASE ASSEMBLY DO NOT USE ANY ...

Page 214: ... 90 AND THERE ARE NO BREAKS IN ANY OF THE THREADS BREAKS IN THE SILK THREAD CAN CAUSE THE CRANKCASE TO LEAK 3 Press two lengths of 00 silk threads in the gasket compound on the top and bottom flange sides of the crankcase half Figure 90 firmly in the gasket compound where both silk threads are oriented in the area between the bolt holes and the inside flange edge of the crankcase half approximatel...

Page 215: ... mated firmly all around and that there are no gaps between the mating flange surfaces Do not continue if the crankcase halves are not aligned Repeat the previous steps until the crankcase halves align 8 Apply a coat of 2 Permatex to the thru studs at the dowel section CAUTION BE SURE TO LUBRICATE THE CRANKCASE THRU STUDS TO ENSURE CORRECT FASTENING OF THE CRANKCASE HALVES 9 Install thru studs on ...

Page 216: ...MAIN BEARINGS IN THE CRANKCASE FOLLOW THE STEPS IN THE TORQUE SEQUENCE IN THE ORDER GIVEN IN FIGURE 96 14 Install a nut and spacer as required on each thru stud at the mating flanges on the crankcase halves in the sequence shown in Figure 96 to attach the crankcase halves securely Figure 96 Crankcase Tightening Sequence NOTICE To ensure uniform loading on the main bearings immediately torque the n...

Page 217: ...d at the rear camshaft bearing Figure 96 Torque the nut to 215 in lb 24 Nm Safety wire the nut as shown in Figure 97 23 Apply Loctite 564 or equivalent to the threads of the bolt Figure 98 to be installed behind the governor pad 24 Install the bolt behind the governor pad Torque the bolt per the torque values in Table 5 Figure 97 Nut on Stud at Rear Camshaft Bearing Figure 98 Bolt Behind Governor ...

Page 218: ...rter pad B Move the crankshaft to the rear of the engine as far as possible C Position the dial indicator gage on the face of the crankshaft flange Figure 100 and set the gage to read 0 D Slide the crankshaft forward as far as possible E Read the end play measurement indicated by the gage F Set the gage to read 0 with the crankshaft as far forward as possible G Move the crankshaft to the rear of t...

Page 219: ... rpm during cruise climb or descent Engine front main bearing has too much clearance Engine goes into feather during landing rollout with a decreased throttle setting 1 Remove the propeller governor from the engine per the airframe manufacturer s instructions NOTICE In the following steps to prevent an air leak use a propeller governor gasket P N 72053 with test plate P N ST 483 Figure 101 Refer t...

Page 220: ... circuit port and install a compression tester Chapter 72 30 at the propeller circuit fitting on the test plate NOTICE Allow 5 minutes after adjusting the first gauge to 40 psi 276 kPa for air pressure to stabilize before reading the pressure on the second gauge 6 Apply shop air to the differential pressure regulator and adjust it to 40 psi 276 kPa on the Gauge No 1 Figure 102 With the engine at o...

Page 221: ...RANKSHAFT OIL SEAL 3 Use ethyl alcohol and disposable wipes to clean the outer surface of the seal and the crankcase seal bore recess Make sure nothing comes in contact with the cleaned surfaces CAUTION USE A BRUSH AND BUTYL RUBBER GLOVES WHEN APPLYING SEALANT AND INSTALLING THE OIL SEAL FIGURES 103 TO 104 NOTICE In the next step do not allow any sealant to contact the crankshaft or the seal lip F...

Page 222: ...ess sealant smoothly over the oil seal and crankcase Figure 106 8 Do not allow any sealant to contact the crankshaft or the seal lip Wash the seal lip and crankshaft area with acetone and a cotton swab if contamination occurs Figure 104 9 Let the Dow Corning 737 Neutral Cure Sealant to cure for 24 hours NOTICE Refer to the latest revision of Service Instruction No SI 1324 for any additional detail...

Page 223: ...TION OF A NEW SPLIT OIL SEAL 5 Use ethyl alcohol and disposable wipes to clean the outer surface of the split oil seal and the crankcase seal bore recess Make sure nothing comes in contact with the cleaned surfaces CAUTION USE A BRUSH AND BUTYL RUBBER GLOVES WHEN APPLYING SEALANT AND INSTALLING THE OIL SEAL FIGURES 103 TO 106 NOTICE In the next step do not allow any sealant to contact the cranksha...

Page 224: ...ply a liberal amount of engine oil to the idler gear shafts and crankcase shaft bore before assembly The mark on one gear tooth of the left crankshaft idler gear Figure 109 must mesh with the space between the marked teeth on the camshaft gear The small etched circle on the crankshaft trigger gear assembly tooth must align with the involute between the two marked teeth of the left crankshaft idler...

Page 225: ...emble the left crankshaft idler gear right crankshaft idler gear and crankshaft trigger gear assembly with the timing marks on the crankshaft trigger gear assembly and left crankshaft idler gear aligned on the Idler Gear Assembly Aid ST 532 and install the gears on the crankcase Figure 110 Figure 110 Install the Left Crankshaft Idler Gear Right Crankshaft Idler Gear and Crankshaft Trigger Gear Ass...

Page 226: ...nd against the Torque Plate ST 222 as shown in Figure 112 The Crankshaft Locking Tool prevents the crankshaft from turning while the crankshaft gear bolt is torqued Figure 112 Insert Crankshaft Locking Tool ST 534 Through the Connecting Rod G Initially torque the crankshaft gear bolt Figure 111 to 125 in lb 14 12 Nm torque H With a hammer and brass drift tap lightly around the pilot flange of the ...

Page 227: ...nterbored end and the pilot flange of the crankshaft trigger gear assembly 2 If clearance is found remove the crankshaft gear bolt and crankshaft trigger gear assembly 3 Make sure the mating surfaces of the crankshaft trigger gear assembly and crankshaft counterbore are clean and dry and that there is no debris 4 Reinstall the crankshaft trigger gear assembly and crankshaft gear bolt Repeat the in...

Page 228: ...emove the drive shaft 2 Turn the drive shaft 120 3 Re install the drive shaft screws washers and torque to 100 in lb 11 Nm 4 Re check the drive shaft run out O Safety wire the screws in the crankshaft trigger gear assembly as shown in Figure 117 CAUTION FAILURE TO LUBRICATE THE SHAFT OF THE HIGH SPEED IDLER GEAR CAN CAUSE DAMAGE TO THE HIGH SPEED IDLER GEAR UPON INITIAL ENGINE START P Apply a libe...

Page 229: ...ylinder 2 as you rotate the crankshaft to move the piston just past TDC of Cylinder 1 H The crankshaft to camshaft timing is correct if the intake valve and the exhaust valve in Cylinder 2 just begins to close as the intake valve starts to open as the piston in Cylinder 1 goes over TDC on compression I If this simultaneous opening and closing of the intake and exhaust valves just past TDC does not...

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Page 231: ... instructions in Chapter 72 70 F Disconnect all wiring harness connections to accessories installed on the accessory housing G Disconnect all hoses connected to the accessory housing or any accessories installed on the accessory housing H Remove any other accessories on the accessory housing per airframe manufacturer s instructions NOTICE There are two different size bolts used on the accessory ho...

Page 232: ... the oil pump with a mixture of 15 pre lubricant and 85 SAE No 50 mineral base aviation grade lubricating oil B Install the impellers in their respective compartments in the oil pump body assembly Figure 4 C Install the oil pump body assembly over the mounting studs on the accessory housing D Install the oil pump drive gear assembly into the oil pump body assembly and through impeller Figure 4 E I...

Page 233: ...esh with the idler gear and the accessory housing will seat against the crankcase and align on the dowel pins Do not install the bolts if the accessory housing is not correctly seated against the crankcase F Fit the accessory housing into place on the rear of the crankcase G Install all bolts with plain washers and new lock washers Figure 2 Torque the hardware per the Standard Torque Tables in the...

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Page 235: ...ctions in this chapter B Look for loose damaged or leaking crankcase thru studs If loose damaged or leaking crankcase thru studs are found send the engine to Lycoming Engines C Look for loose or damaged cylinder hold down studs If loose or damaged cylinder hold down studs are found replace with appropriate oversize studs per Appendix A D Look for loose or damaged spark plug Heli Coil inserts If a ...

Page 236: ...of the engine cylinders This procedure compares the static leak rate of the cylinder with the leak rate through an orifice of a specified range B The Cylinder Compression Check on the engine cylinders must be done at the following times or if the engine has any of these conditions After every 100 hours of engine operation or annual inspection Loss of power or unsteady power Difficulty starting Inc...

Page 237: ...of the gages to be connected to the differential compression tester are calibrated in accordance with the differential compression tester manufacturer s specifications 3 Refer to the differential compression tester s manufacturer s instructions to ensure the tester operates correctly C Cylinder Compression Check Procedure NOTICE Make sure the differential compression tester has been calibrated and...

Page 238: ...ft by hand in the direction of propeller rotation to put the piston in a position as close to Top Dead Center TDC on the compression stroke as possible 6 Install the threaded end of an adapter with a coupling end in the spark plug hole of the cylinder to be tested 7 Make sure that the air valve on the differential compression tester is in the CLOSED position 8 Connect the differential compression ...

Page 239: ...ng motion to make sure that the piston rings are seated 16 Record the pressure reading on the engine cylinder pressure gage The difference between the engine cylinder pressure gage reading and the pressure shown on the air supply pressure gage reading is the amount of leakage through the cylinder 17 The minimum approved engine cylinder pressure reading is 60 psi 414 kPa Maximum approved leakage is...

Page 240: ...ses and complete the necessary corrective action Difference of 5 psi 34 kPa or less between engine cylinders Pressure readings for all engine cylinders must be nearly equal Satisfactory No corrective action necessary Difference of 6 to 15 psi 41 to 103 kPa between engine cylinders Repeat the Cylinder Compression Check after the next 10 hours of engine operation A valve can reseat itself and show s...

Page 241: ...er or send the engine cylinder to an authorized vendor to replace the valve seat 4 Intercylinder Baffle Inspection NOTICE This inspection can be done while the intercylinder baffles are installed on the engine A This inspection is done during the visual inspection to look for premature cylinder deterioration and make sure that intercylinder baffles are correctly fitted and installed The intercylin...

Page 242: ...Sticking section in this chapter 6 Worn piston rings or worn cylinder barrel 7 Insufficient combustion C Cylinder Borescope Inspection Procedure 1 Remove a top spark plug from each cylinder per the Spark Plug Removal procedure in Chapter 74 20 2 Put the piston at bottom dead center on the power stroke 3 Install the borescope through the vacant top spark plug hole on the engine cylinder and examine...

Page 243: ...e face Cracks or erosion on the intake valve face Replace the intake valve Examine the cylinder bore for scoring rubbing or corrosion Scoring or piston rub or corrosion on cylinder bore Remove and examine the engine cylinder Remove and examine the oil suction screen and the oil filter per instructions in Chapter 12 10 Look for excessive oil in the cylinder Excessive oil in the cylinder Remove and ...

Page 244: ...ar type valves on engine cylinders Although Gage ST 310 and a feeler gage can be used to measure valve stem movement a modified Gage ST 310 Figure 4 and a dial indicator are a faster and easier means to measure valve stem movement valve guide wear and carbon build up per this procedure Figure 4 Details for Modifying Tool P N ST 310 NOTICE Do not intermix valve and cylinder components between cylin...

Page 245: ...CAUTION DO NOT MIX PLUNGER ASSEMBLIES WITH DIFFERENT PART NUMBERS IN THE SAME ENGINE DIFFERENT PLUNGERS HAVE VARYING LEAK DOWN RATES WHICH CAN CAUSE INCORRECT ENGINE OPERATION Figure 5 TEO 540 C1A Engine Valve Components 8 Remove all of the push rods shroud tubes hydraulic tappets plunger assemblies sleeve springs washers and seals from the engine cylinder 9 Use a cloth dampened with mineral spiri...

Page 246: ... Adapter ST 310 9 over the top of the valve stem Figure 7 Make sure it is tight NOTICE If you can move the Gage Adapter ST 310 9 on the valve stem with your hand it is incorrectly installed 15 Push the valve stem and Gage Adapter ST 310 9 against the upper spring retainer as far as they will go 16 Put the blade of a screwdriver in the area between the exhaust valve spring and Gage ST 310 Figure 7 ...

Page 247: ... per instructions in the latest revision of Service Instruction No SI 1425 22 Move the piston to near its top end of travel 23 Remove the Gage Adapter ST 310 9 from the valve stem 24 Loosen each cap screw in the Gage ST 310 Figure 6 in small equal increments to decrease pressure on the valve spring slowly and equally 25 Remove the Gage ST 310 from the cylinder 26 Repeat this exhaust valve and guid...

Page 248: ... Complete the Operational Ground Check in Chapter 72 00 Figure 10 Exhaust Valve Stem Cap 7 Cylinder Removal A Disable all power to the engine and disconnect the engine wiring harness from the airframe per instructions in the Engine to Firewall Wiring Harness Removal section in Chapter 72 70 B If not already done Remove airframe components to enable cylinder removal Airframe Maintenance Manual Drai...

Page 249: ...l drain tube in case the drain tube is to be replaced Refer to the TEO 540 C1A Illustrated Parts Catalog for the correct part number for the oil drain tube 1 Remove the hose clamps Figure 13 from hose attached to the oil drain tube assembly 2 Disconnect the hose from the nipple 3 Disconnect the drain tube fitting from the engine cylinder 4 Remove and discard the hose Figure 13 5 Remove the drain t...

Page 250: ...NOTICE During cylinder removal identify and label the cylinder piston and other parts by location i e cylinder number as they are removed for reference on assembly to ensure that each serviceable part is installed in the same location from which it was removed D Intercylinder Baffle Removal 1 Turn the baffle retainer hook to disengage the retainer on the intercylinder baffle Figure 15 2 Remove the...

Page 251: ...D IF ANY OF THESE ITEMS ARE DAMAGED THEY MUST BE REPLACED E Disconnect and remove the Knock Sensor Figure 16 and Cylinder Head Temperature Sensor Figure 17 from the engine cylinder Refer to the Sensor Replacement Procedures in Chapter 72 70 Figure 16 Knock Sensor on the Engine Cylinder Figure 17 Cylinder Head Temperature Sensor on the Engine Cylinder F Remove the screws from the rocker box cover F...

Page 252: ... turn each shroud tube 90º in either direction to release the tube from the spring N Remove the shroud tubes by first releasing them from the seal seats in the cylinder head and withdrawing the tubes O Remove the seals from the ends of the shroud tubes Discard the seals P Remove the seals from the crankcase Discard the seals Q Remove the valve stem keys valve spring seats and valve springs CAUTION...

Page 253: ...port the connecting rod one of two ways to prevent damage to the connecting rods and crankcase 1 Install Torque Hold Down Plates ST 222 as shown in Figure 21 OR 2 Make a loop around the cylinder base studs and connecting rod using a rubber band or the cylinder base oil seal ring removed during cylinder removal as shown in Figure 22 Figure 21 Torque Hold Down Plates ST 222 Figure 22 Loop Cylinder B...

Page 254: ...g seats Corrective Action Replace any broken or worn parts Figure 18 Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 Examine the intake and exhaust valve seats for looseness scoring pitting damage or non conformities Look for cracked or eroded valve seat bores Corrective Action If a valve seat is loose scored pitted defective or damaged either replace the cylinder or send the eng...

Page 255: ...s Look for blistered paint on the cylinder barrel Corrective Action Replace the cylinder if the cylinder barrel bores are scored or if the paint is discolored burnt blistered Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 Examine the threads in all threaded holes in the cylinder for debris or damage Corrective Action Use the correct size bottoming tap to clean the threads If thr...

Page 256: ...e cylinder head Measure the diameter of the cylinder head to check for out of roundness Corrective Action Replace any cylinder that has a crack in the cylinder head or if the cylinder head is out of round as specified in the latest revision of the Service Table of Limits SSP 1776 Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 Measure the diameter of the cylinder to find the Aver...

Page 257: ...r 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 Look for scratches in the honed surface of the cylinder wall or cylinder bore Corrective Action Hone the cylinder to remove the scratches then measure the cylinder for Average Cylinder Diameter Refer to the Piston Specifications Table in Section II of the latest revision of the Service Table of Limits SSP 1776 for measurement instructions ...

Page 258: ...nder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 Examine the sealing surface of the rocker box covers for nicks scoring or dents that would prevent complete sealing of the rocker box cover Corrective Action Replace the cylinder if the mounting pad for the rocker box cover is nicked scored or dented or leaking and not sealing correctly Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylind...

Page 259: ...the cylinder head for looseness or damage Corrective Action Replace all loose or damaged studs with the next higher applicable oversize studs Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 Measure the inside diameter of the rocker shaft bushings Refer to the latest revision of the Service Table of Limits SSP 1776 for dimensions Corrective Action Replace the rocker shaft bushings...

Page 260: ... the piston Piston ring lands and grooves Piston pin holes Piston pin hole bosses Look for deposits or damage Complete the Piston Cleaning procedure in Chapter 05 30 NOTICE Surface distortion can be an indication of detonation or pre ignition Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 After Cleaning Look for cracks on the piston head or skirt Replace the piston if a crack is...

Page 261: ...ing land of the piston between the top and second compression ring grooves at a right angle to the piston pin hole Figure 24 Actual Measurement SSP 1776 Measure the diameter approximately 1 8 in 3 18 mm above the bottom of the piston skirt at a right angle to the piston pin hole Figure 24 Actual Measurement SSP 1776 Subtract the diameter approximately 1 8 in above the bottom of the piston skirt fr...

Page 262: ...eler gauge and straight edge Figure 25 Top piston compression ring Actual Measurement SSP 1776 Second piston compression ring Actual Measurement SSP 1776 Piston oil ring Actual Measurement SSP 1776 Measure the piston ring gap with feeler gauges Complete the Piston Ring End Gap Check in this chapter Top piston compression ring Actual Measurement SSP 1776 Second piston compression ring Actual Measur...

Page 263: ...SE CARE NOT TO SCRATCH OR SCORE THE PISTON OR CYLINDER BORE 1 Lubricate the piston ring piston and cylinder bore with a light coating of a mixture of 15 pre lubricant STP or equivalent and 85 SAE 50 mineral base aviation grade lubricating oil unless otherwise directed per the latest revision of Service Instruction No SI 1059 2 Put one of the piston rings in the cylinder in which it will be used 3 ...

Page 264: ...ston rings For new piston rings refer to the TEO 540 C1A Illustrated Parts Catalog to identify the correct new piston rings to be installed on the piston New piston rings are shipped from Lycoming with the piston oil ring and the inner expander ring assembled The inner expander ring must be separated from the piston oil ring before installing them on the piston B Apply a generous coating of a mixt...

Page 265: ...er of the piston pin hole CAUTION DO NOT ATTEMPT TO TURN THE CRANKSHAFT UNLESS THE CONNECTING RODS ARE SUPPORTED C Turn the crankshaft so that when the Number 1 piston is inserted it will be at TDC of its firing stroke with both tappets on the base circle of the camshaft lobes D Remove the Torque Hold Down Plates ST 222 rubber bands or cylinder base oil seal rings from the crankcase E Install the ...

Page 266: ... the inside of the cylinder barrel when removing the intake valve 5 Remove the intake valve from the valve guide through the cylinder barrel B Intake Valve Installation NOTICE Use care not to scratch the inside of the cylinder barrel when installing the intake valve 1 Apply lubricant identified in the latest revision of Service Instruction No SI 1059 to the intake valve stem 2 Install a serviceabl...

Page 267: ...e exhaust valve in the valve guide Figure 27 through the cylinder barrel 3 Install the valve spring seats and valve springs 4 Use a Valve Spring Compressor Tool ST 25 to compress the exhaust valve spring and install the valve stem key 5 Install the rotator valve stem cap on the exhaust valve 6 Install the cylinder on the engine per the Cylinder Installation procedure in this chapter 15 Cylinder In...

Page 268: ... the Piston Ring Compressor ST 485 to install the cylinders Figure 30 as follows 1 Assemble the Piston Ring Compressor ST 485 over the top piston rings and install the cylinder over the piston pushing the piston ring compressor ahead with the cylinder barrel Figure 31 Figure 30 Piston Ring Compressor ST 485 Figure 31 Install the Cylinder 2 As the cylinder barrel approaches the crankcase catch the ...

Page 269: ...he same time at the all locations Make sure all thru studs have at least 1 1 2 threads above attaching nuts at both ends 6 Make sure all cylinder base hold down nuts are torqued Complete a torque check of all nuts on the cylinder base using the torque wrench to apply the appropriate torque on each nut for 5 seconds If the nut does not turn it is correctly torqued 7 Apply torque seal to all cylinde...

Page 270: ... each shroud tube where the detent notches in the spring are 90 removed from the tangs on the shroud tubes as shown in Figure 35 6 Install each shroud tube through the shroud tube oil seal in the crankcase 7 Hold both shroud tubes with the detent at the inner end at the unlocked position and insert the outer end of the tubes in the rocker box of the cylinder head 8 Make sure that all shroud tube o...

Page 271: ...R ASSEMBLY IS INSTALLED ON THE EXHAUST VALVE SIDE OF THE CYLINDER K Install the rockers with the cupped end on the push rod Figure 18 L Align each valve rocker assembly with the rocker shaft M Slide the valve rocker shafts through each valve rocker assembly and washer to seat the valve rocker in place for both the intake and exhaust valves N Make sure the valve rocker assemblies are in the correct...

Page 272: ...rocker assembly and the valve stem cap If it cannot be inserted remove the current push rod and use a shorter pushrod b Try to insert the 0 080 end of the Valve Clearance Gage ST 23 between the valve rocker assembly and the valve stem cap If it can be inserted remove the current push rod and use a longer pushrod 3 The distance must be between 0 028 and 0 080 in 0 711 to 2 032 mm NOTICE If the clea...

Page 273: ...Refer to the Sensor Replacement Procedures in Chapter 72 70 NOTICE After replacing one or more cylinder you must complete the Break In Flight Test 50 Hour Operation procedure the Engine Initiation chapter of the TEO 540 C1A Engine Installation and Operation Manual and per any details in the latest revision of Service Instruction No SI 1427 X Intercylinder Baffle Installation 1 Engage the S Type re...

Page 274: ...pter 73 10 Z Install the exhaust tube Figure 11 and a new gasket with the two washers and two nuts AA Install the applicable intake pipe on the cylinder per the Intake Pipe Installation procedure in Chapter 72 80 AB Oil Drain Tube Installation NOTICE Since there are different oil drain tube assemblies for the engine cylinders refer to the TEO 540 C1A Illustrated Parts Catalog for the correct part ...

Page 275: ...cking occurs again Sticking between the valve stem and guide on intake and exhaust valves can substantially change valve opening and closing If the valve cannot open or close correctly incomplete combustion will occur which can cause formation of more deposits and increased valve sticking Because a correctly timed sequence of valve opening and closing is essential to efficient and reliable engine ...

Page 276: ...rough the exhaust port or through spark plug hole using an angled mirror 2 Clean the valve guide per the Hard Carbon Removal procedure in Chapter 05 30 for additional cleaning details 3 Measure the inner diameter of the valve guide using the correct plug gage 4 Examine the reamed hole to see if the reamer has cut all the way to the exhaust port end of the guide If it has not and the exhaust port e...

Page 277: ...hone F Wipe as much of the abrasive build up from the cylinder walls and recesses as possible especially the recesses formed by the top of the cylinder barrel and the bottom of the cylinder head G Make a hooked tool from soft wire and rub the tool back and forth in the recess to loosen any built up abrasive Complete this task each time the cylinder is flushed There must not be any abraded material...

Page 278: ...e a standard sized Heli Coil insert Never replace a standard sized Heli Coil insert with another standard sized Heli Coil insert The oversize Heli Coil inserts are identified by three marks on the tang of the Heli Coil insert as shown Figure 50 Figure 50 Heli Coil Inserts for Long Reach Spark Plugs 1 Disable all power to the engine to prevent propeller rotation and engine start Disconnect ignition...

Page 279: ...e new 0 010 in oversized Heli Coil insert 10 Remove all chips and shavings to prevent contamination from foreign object debris 11 Remove the rope from the spark plug hole Figure 52 0 010 Inch Bottoming Tap 64596 1 Figure 53 Inserting Tool P N 64594 12 Install the new 0 010 in oversized Heli Coil insert into the spark plug hole as follows a Use the T shaped Inserting Tool P N 64594 Figure 53 and wi...

Page 280: ...to turn the mandrel clockwise until the insert is no longer visible above the boss k When the top of the insert is approximately a half turn from the face of the boss remove the Inserting Tool P N 64594 l Use the Expanding and Staking Tool P N 64593 Figure 54 to stake the new installed 0 010 in oversized Heli Coil insert securely in the spark plug hole as follows 1 Fix the stop nut adjusting screw...

Page 281: ...e air inlet housing Figure 1 The exhaust gas is discharged through exhaust outlet pipe attached to the turbocharger Figure 1 Exhaust Crossover Pipes and Transition Assembly B An exhaust bypass valve Figure 1 at the exhaust transition at the rear of the engine controls the amount of exhaust gas flow This valve is controlled by an actuator The actuator is activated by a solenoid C The EECS controls ...

Page 282: ...and examine it for cracks or distortions Re use or replace the clamp as necessary Before installing the V band coupling on the engine carefully clean the coupling area of the exhaust transition and mating flange on the turbine side of the turbocharger C Repeat the previous step for the V band couplings that attach the exhaust bypass valve Figure 1 D Examine all flexible hoses in the induction syst...

Page 283: ... mounting bracket agree with the Standard Torque Tables in the latest revision of the Service Table of Limits SSP 1776 NOTICE The clearance at the turbine blade tip measured as shown in Figure 3 identifies the general condition of the turbocharger F Remove the exhaust pipe from the turbine discharge port and measure the clearance between the turbine blades and housing G Use a feeler gage to measur...

Page 284: ...th deposits Look for deposits in the turbine Remove the deposits per the turbocharger manufacturer s instructions identify and correct the cause H Install the turbocharger as per instructions in the Turbocharger Installation section in this chapter 5 Turbocharger Removal CAUTION PRIOR TO TURBOCHARGER REMOVAL LET THE ENGINE AND THE EXHAUST SYSTEM COOL FOR 1 HOUR OR LONGER AFTER ENGINE SHUTDOWN TO P...

Page 285: ...scard the lock washers I Remove the oil adapter and gasket Discard the gasket J Remove the two bolts washers and lock washers from the oil drain tube assembly Figure 5 at the bottom of the turbocharger Discard the lock washers K Remove the oil drain tube assembly and gasket Discard the gasket L Remove the cotter pin from the bolt through the support clamp bracket top right support rod top support ...

Page 286: ...ons and remove any carbon deposits B Apply a thin coat of C5 A copper based anti seize lubricant to the inside diameter of the four lock nuts Figure 6 that attach the turbocharger and exhaust transition Figure 1 C Hold the turbocharger in place with the exhaust side mating flange against the exhaust transition Figure 7 Install the four bolts Figure 6 through the turbocharger mating flange in the e...

Page 287: ...ass hose from the exhaust bypass valve Figure 8 2 Disconnect the wastegate control hose from the exhaust bypass valve Figure 8 Exhaust Bypass Valve 3 Remove the V band coupling and gasket Figure 6 that attaches the exhaust bypass valve to the exhaust transition Discard the gasket 4 Remove the exhaust bypass valve B Exhaust Bypass Valve Installation 1 Attach the exhaust bypass valve to the exhaust ...

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Page 289: ...its Figure 1 Adjustment Screw on the Oil Pressure Relief Valve NOTICE If the oil pressure cannot be adjusted to within specified limits by turning the adjustment screw refer to the Oil Pressure Relief Valve Removal Oil Pressure Relief Valve Inspection and Oil Pressure Relief Valve Installation sections in this chapter 2 Oil System Inspection A Look for leaks around the oil sump and crankcase flang...

Page 290: ... no sharp bends or kinks in the oil line routing E Torque the fitting connections on the oil hose ends in accordance with the torque values in the Standard Torque Tables in the latest revision of the Service Table of Limits SSP 1776 and aircraft manufacturer s instructions 5 Oil Filler Extension and Oil Level Gage Assembly Removal A Remove and discard the safety wire cable Figure 2 from the oil fi...

Page 291: ...ANY DEBRIS OR CONTAMINATION E Install the oil level gage assembly into the oil filler extension F Safety wire cable the oil filler extension as shown in Figure 2 Refer to the latest revision of Service Instruction No SI 1566 7 Oil Pressure Relief Valve Removal A Remove and discard the safety wire cable from the oil pressure relief valve Figure 4 B Remove the oil pressure relief valve spring ball a...

Page 292: ...to 300 in lb 34 Nm F Safety wire cable the oil pressure relief valve as shown in Figure 4 Refer to the latest revision of Service Instruction No SI 1566 10 Oil Cooler Bypass Valve Removal A Remove and discard the safety wire cable from the oil cooler bypass valve B Remove the oil cooler bypass valve Figure 7 from the oil accessory housing Discard the gasket Figure 7 Oil Cooler Bypass Valve 11 Oil ...

Page 293: ...erent length bolts installed on the oil sump keep bolts nuts and washers removed in each of the following steps separate from bolts nut and washers removed in other steps Draw a sketch or refer to the TEO 540 C1A Illustrated Parts Catalog to identify the location of different length bolts installed on the oil sump D Remove the six bolts six nuts six lock washers 12 washers and six nuts Figure 8 fr...

Page 294: ...t and debris from getting in the oil sump 14 Oil Sump Inspection A Examine the oil sump for any raised metal on surfaces and for any scratch ding dent or pit that exceeds 0 050 in 1 27 mm depth B Replace the oil sump if there is any raised metal on surfaces or if a scratch ding dent or pit that exceeds 0 050 in 1 27 mm depth is found on the sump C Examine the oil sump baffle for cracks or distorti...

Page 295: ... the Oil Sump F Install a new oil sump gasket in the oil sump groove Figure 8 G Align the oil sump flange with the bottom of the mated crankcase halves CAUTION ALL OF THE OIL SUMP FASTENERS STUDS BOLTS AND NUTS MUST BE INTACT TO ENSURE CORRECT AND SECURE TIGHTENING TO PREVENT OIL LEAKAGE AT THE OIL SUMP MATING FLANGE WITH THE CRANKCASE NO OIL IS TO LEAK OUT OF THE OIL SUMP H Examine all of the oil...

Page 296: ...ision of the Service Table of Limits SSP 1776 CAUTION MAKE SURE THAT THE OIL SUMP DRAIN PLUGS ARE INSTALLED TIGHTLY IF THE DRAIN PLUGS ARE NOT TIGHTLY INSTALLED AND LEAK ENGINE FAILURE CAN OCCUR N Safety cable wire the oil sump drain plug and oil suction screen if not already done in accordance with the standard practices per the latest revision of AC43 13 1B or the latest revision of Service Inst...

Page 297: ...re 1 from the accessory drive housing in accordance with the aircraft manufacturer s instructions B Vacuum Pump Installation Install the vacuum pump Figure 1 on the accessory drive housing in accordance with the aircraft manufacturer s instructions 3 Vacuum Pump Driven Gear Replacement if installed A Vacuum Pump Driven Gear Removal 1 Remove the four nuts lock washers and washers from the vacuum pu...

Page 298: ... Driven Gear Installation 1 Apply engine oil mixture to the vacuum pump driven gear 2 Install a new pin in the vacuum pump adapter 3 Install the vacuum pump driven gear with the thrust button already installed inside the geared end and drive gear washer in the vacuum pump adapter Figure 2 4 Install a new accessory adapter gasket on the vacuum pump adapter in the correct orientation as shown in Fig...

Page 299: ...e wiring and connectors that came in contact with the chemicals and fluids 1 Hydraulic fluid 5 Cleaning agents 2 Battery electrolytes 6 De icing fluid 3 Fuel corrosion inhibiting compounds 7 Paint 4 Waste system chemicals D Replace the harness if any of the following conditions are found on the harness 1 Broken frayed chafed worn degraded or damaged wire 4 Vibration damage or chafing 5 Cracked or ...

Page 300: ...nsion check 1 Immediately after the alternator belt is replaced and then after 25 hours of operation after installation 2 During each 100 hour service inspection thereafter B Use either of the following methods to complete an alternator belt tension check Deflection Method Belt Tension Gage Method 1 Deflection Method a Attach the hook of a small spring scale to the alternator belt at the approxima...

Page 301: ...ion Gage ST 131 and read the indicated belt tension on the dial Figure 3 d Repeat the previous steps several times to ensure an accurate reading e If the tension reading on the alternator belt is out of tolerance adjust the belt tension per the Alternator Belt Tension Adjustment procedure for the respective alternator in this chapter to get the appropriate reading on the Belt Tension Gage ST 131 F...

Page 302: ... two cotter pins two bolts two slotted nuts shims and three washers from the alternator bracket strut and alternator Figure 5 Discard the cotter pins 6 Remove the alternator and alternator belt B To remove the alternator bracket 1 Remove the two bolts and lockplate from the alternator bracket Figure 5 Discard the lockplate 2 Remove the two bolts and washers from the strut and alternator bracket 3 ...

Page 303: ...torque the top terminal nut per the top nut torque value shown in Table 1 Figure 6 Alternator Terminals Table 1 Alternator Terminal Stud Nut Torque Values Terminal Bottom Nut Torque Value Top Nut Torque Value Output Terminal 70 to 85 in lb 7 9 to 9 6 Nm 70 to 85 in lb 7 9 to 9 6 Nm Field Terminal 12 to 15 in lb 1 4 to 1 7 Nm 6 to 8 in lb 0 7 to 0 9 Nm GND Terminal 25 to 30 in lb 2 8 to 3 4 Nm 25 t...

Page 304: ...ion of Service Instruction No SI 1566 7 Power Box and PMA A The power box does not have regularly scheduled maintenance procedures The power box is not field repairable It only can be replaced B The Permanent Magnet Alternator PMA does not have regularly scheduled maintenance procedures The PMA is not field repairable 8 The Electrical System Includes Three Wiring Harnesses Figure 7 Engine to firew...

Page 305: ...ER USE A KNIFE BLADE OR SCREWDRIVER TO LIFT A LOCKING TAB IF NECESSARY USE A THIN PIECE OF WOOD OR PLASTIC TO LIFT THE LOCKING TAB ANY TIME AN ELECTRICAL CONNECTOR IS DISCONNECTED INSTALL A CAP ON THE CONNECTOR TO PREVENT DAMAGE OR CONTAMINATION FROM FOD CHEMICALS OR FLUIDS NOTICE Petrolatum or DC 4 lubricant or equivalent can be applied as necessary to the mating surfaces of connectors Table 2 Wi...

Page 306: ...ss connector from the sensor Figure 12 Connect 1 Insert the wiring harness connector into the sensor and press firmly until you hear the hinged locking tab click in place Fuel Pump Pressure Sensor FPP Figure 13 Oil Pressure Sensor Figure 14 Wiring Harness Connector Removed from the Sensor Fuel Rail Pressure Sensor FUEL P Induction Delta Pressure Sensor DPS Pressure sensor connectors have a single ...

Page 307: ...ect 1 Connect the wiring harness side of the connector to the sensor side of the connector 2 Install the cap screw through the connector to hold the connector securely Exhaust Gas Temperature Sensor EGT Turbine Inlet Temperature Sensor TIT Figure 17 TIT Connector Figure 18 TIT Connector Separated The Turbine Inlet Temperature Sensor connector Figure 37 is the same type of connector as the Cylinder...

Page 308: ...king tab click in place Primary Induction Air Deck Pressure Sensor DECK P P Figure 22 Primary and Secondary Induction Deck Pressure Sensors Figure 23 Wiring Harness Connector Removed from Induction Deck Pressure Sensor Secondary Induction Air Deck Pressure Sensor DECK P S Primary Compressor Inlet Pressure Sensor CIP P Pressure sensor connectors have a single locking tab on the wiring harness conne...

Page 309: ...perature Sensor Figure 35 is located on the left side of the induction system Disconnect 1 Pull or pry up on the front of the locking tab on the wiring harness side of the connector Figure 24 to release it from the locking feature on the sensor side of the connector and pull the two parts of the connector apart Figure 25 Connect 1 Press the two parts of the connector together firmly until you hear...

Page 310: ...rness connector up to remove it from the fuel injector Figure 29 Connect 1 Install the wiring harness connector onto the sensor and press firmly until you hear the locking tab click in place 2 Move the green locking slide feature Figure 27 down until you hear it click into place Prop Governor if an electronic prop governor is installed Figure 30 Prop Governor Connector Figure 31 Wiring Harness Con...

Page 311: ...s connector to release them from the locking features on the wastegate solenoid and pull the wiring harness connector from the wastegate solenoid Connect 1 Insert the wiring harness connector into the wastegate solenoid connection and press firmly until you hear the locking tabs click in place Permanent Magnet Alternator Figure 33 Permanent Magnet Alternator Harness Plug Figure 34 Wiring Harness P...

Page 312: ...er a band clamp type or bayonet type which are installed with a quarter turn rotation lock Make sure the correct wiring harness connector is reconnected to the sensor any time the wiring harness has been disconnected Table 3 Sensor Replacement Procedures Sensor Name Abbr ID Qty Location Replacement Instructions Crankshaft Speed Sensor CRANK A003 1 Mounted on the accessory housing Figure 35 1 Disco...

Page 313: ...nstall the new sensor Torque hardware to 84 to 120 in lb 9 5 to 13 Nm 4 Connect the harness connector to the sensor per instruction in the Wiring Harness Connectors section in this chapter 5 Complete an operational ground check Manifold Pressure Sensor MAP A040 1 Mounted on the crankcase Figure 35 1 Disconnect the wiring harness from the sensor per instruction in the Wiring Harness Connectors sect...

Page 314: ...in the Wiring Harness Connectors section in this chapter 6 Complete an operational ground check Primary Induction Air Manifold Temperature Sensor MAT P A035 1 Figure 35 1 Disconnect the harness connector from the sensor per instruction in the Wiring Harness Connectors section in this chapter 2 Remove and discard tie wraps from the fire shield on the sensor lead 3 Remove the fire sleeve from the se...

Page 315: ...les in the latest revision of the Service Table of Limits SSP 1776 for torque values 7 Complete an operational ground check CHT 2 A088 CHT 3 A089 CHT 4 A090 CHT 5 A091 CHT 6 A092 Exhaust Gas Temperature EGT Sensor EGT 1 A080 6 Mounted in the exhaust port of each cylinder Figure 38 NOTICE Be sure to install the correct EGT sensor in the applicable numbered cylinder 1 Remove the cap screw holding th...

Page 316: ...ter 6 Complete an operational ground check Oil Pressure Sensor OIL P A025 1 Remote mounted at top of accessory housing Figure 35 1 Disconnect the harness connector from the sensor per instruction in the Wiring Harness Connectors section in this chapter 2 Disconnect the hose assembly fitting from the elbow 3 Loosen the clamp and remove the sensor from the clamp 4 Install the new sensor with the cla...

Page 317: ... Wiring Harness Connectors section in this chapter 6 Complete an operational ground check Fuel Rail Pressure Sensor FUEL P A013 1 Mounted on the fuel manifold immediately before the fuel pressure regulator NOTICE Fuel manifold is mounted behind the coil box on top of the engine crankcase Figure 39 1 Ensure the fuel hoses are depressurized by loosening the cap on the fuel pressure regulator bleed p...

Page 318: ...in lb 9 5 to 13 Nm 7 Connect the harness connector to the sensor per instruction in the Wiring Harness Connectors section in this chapter 8 Complete an operational ground check Primary Induction Air Deck Pressure Sensor DECK P P A045 1 Mounted on the pipe attached to the inlet of the throttle body Figure 38 1 Disconnect the harness connector from the sensor per instruction in the Wiring Harness Co...

Page 319: ...nsor in the correct numbered cylinder 1 Disconnect the harness connector from the sensor per instruction in the Wiring Harness Connectors section in this chapter 2 Remove the bolt lock washer and washers securing the sensor to the cylinder and remove the sensor Discard the lock washers 3 Install the new sensor with a bolt new lock washer and washer 4 Torque the bolt to 120 in lb 13 Nm 5 Connect th...

Page 320: ...ne Maintenance Manual 72 70 2018 Avco Corporation All Rights Reserved Page 290 November 2018 TEO 540 C1A Engine Maintenance Manual Figure 35 Sensor Locations Accessory Housing View Figure 36 Sensor Locations Rear View ...

Page 321: ... 540 C1A Engine Maintenance Manual 2018 Avco Corporation All Rights Reserved 72 70 November 2018 Page 291 TEO 540 C1A Engine Maintenance Manual Figure 37 Knock Sensor Figure 38 Sensors Locations Left View ...

Page 322: ...ce Manual 72 70 2018 Avco Corporation All Rights Reserved Page 292 November 2018 TEO 540 C1A Engine Maintenance Manual Figure 39 Fuel Injector Rail Pressure Sensor and Fuel Temperature Sensor Figure 40 Sensors on the Throttle Body ...

Page 323: ... to disconnect power to the EECS ECU CAUTION USE CAUTION AROUND THE WIRING HARNESS SENSORS AND ACTUATORS THEY CAN BE EASILY DAMAGED AND CANNOT BE REPAIRED IF ANY OF THESE ITEMS ARE DAMAGED THEY MUST BE REPLACED IF ONE WIRE BREAKS ON THE WIRING HARNESS THE COMPLETE HARNESS WILL NEED TO BE REPLACED C For reference on assembly identify by label each of the sensors on the engine D Disconnect the engin...

Page 324: ...e each engine to firewall wiring harness connector from its sensor actuator and coil I Remove the fasteners from the left and right side harness brackets Remove the brackets CAUTION THE HARNESS HAS DIFFERENT DIAMETERS AT VARIOUS LOCATIONS CLAMPS ARE SIZED SPECIFICALLY FOR EACH AREA ON THE HARNESS KEEP THE CLAMPS ON THE HARNESS TO BE REMOVED J Remove the harness from left and right side harness bra...

Page 325: ...IS TO BE INSTALLED REFER TO THE LOCATION OF EACH CLAMP ON THE OLD HARNESS FOR INSTALLATION ON THE NEW HARNESS ALL OF THE CLAMPS MUST BE INSTALLED IN THE CORRECT LOCATION ONE AT A TIME D If a new harness is being installed remove the screws lock nuts bolts and screws and labeled clamps from the old wiring harness one at a time Discard the lock nuts E Install the left and right side harness brackets...

Page 326: ...00 pin receptacle identified as PRI D Disconnect harness plug A001 P3 from the ECU small 37 pin receptacle identified as PRI E Disconnect harness plug A001 P2 from the ECU large 100 pin receptacle identified as SEC F Disconnect harness plug A001 P4 from the ECU small 37 pin receptacle identified as SEC G Disconnect harness plug A002 P1 from the power box receptacle identified as PRI H Disconnect h...

Page 327: ...AUTION THE HARNESS HAS DIFFERENT DIAMETERS AT VARIOUS LOCATIONS CLAMPS ARE SIZED SPECIFICALLY FOR EACH AREA ON THE HARNESS IF A NEW HARNESS IS TO BE INSTALLED REFER TO THE LOCATION OF EACH CLAMP ON THE OLD HARNESS FOR INSTALLATION ON THE NEW HARNESS ALL OF THE CLAMPS MUST BE INSTALLED IN THE CORRECT LOCATION ONE AT A TIME D If a new fuselage harness is to be installed remove each clamp and attachi...

Page 328: ...eptacle identified as SEC F Disconnect the airframe interface harness plug from the ECU small 37 pin receptacle identified as SEC G Remove the ECU in accordance with instructions in the airframe maintenance manual 16 ECU Installation CAUTION THE ECU HAS A SPECIFIC CONFIGURATION FOR EACH ENGINE AND THE AIRFRAME THE ECU AND ENGINE HAVE FACTORY DESIGNATED SERIAL NUMBERS THAT GO TOGETHER MAKE SURE THE...

Page 329: ...frame maintenance manual B Connect the appropriate airframe interface harness plug A002 P1 to the power box receptacle identified as PRI Refer to Appendix B in this manual C Connect the appropriate airframe interface harness plug A002 P2 to the power box receptacle identified as SEC D Reconnect the battery and reset the EECS ECU circuit breaker E Complete the operational ground check in Chapter 72...

Page 330: ...f the PMA mating surface 7 Align the holes in the PMA flange with the three studs in the accessory housing as shown in Figure 42 8 Install the PMA by meshing the PMA gear with the idler gear in the accessory housing 9 Attach the PMA to the accessory housing with the three nuts new lock washers and washers Figure 43 10 Torque the nuts in incremental steps to a final torque of 96 in lb 11 Nm 20 Star...

Page 331: ...rframe manufacturer s manual 6 Connect the battery 7 Complete the operational ground check in Chapter 72 00 to make sure the starter operates correctly 21 Starter Ring Gear Support Replacement A Starter Ring Gear Support Removal 1 If not already done release the tension on the alternator belt Figure 48 Starter Ring Gear Support Assembly 2 Remove the alternator belt from the starter ring gear suppo...

Page 332: ...support A Starter Ring Gear Removal 1 Make sure that none of the propeller bolt holes in the starter ring gear support are worn or out of round 2 If you find defective holes replace the entire starter ring gear assembly CAUTION DO NOT GRIND INTO THE STARTER RING GEAR SUPPORT IFYOU GRIND INTO THE STARTER RING GEAR SUPPORT IT MUST BE REPLACED 3 If the propeller bolt holes are satisfactory grind thro...

Page 333: ... 4 Use a 0 0015 in 0 0381 mm feeler gage to measure the clearance between the starter ring gear and support at both locations where the ring gear and support surfaces make contact Measure around the entire circumference The clearance measurements must be the same to ensure correct seating of the starter ring gear against the starter ring gear support face Different clearance measurements are an in...

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Page 335: ...g as required D Examine for loose flange bolts Replace the flange gasket and lock washers Torque the bolt in accordance with the Standard Torque Tables in the latest revision of the Service Table of Limits SSP 1776 Figure 1 Intake Pipes and Attaching Parts 2 Intake Pipe Replacement NOTICE Each engine cylinder has a corresponding intake pipe of a different part number Be sure to replace the intake ...

Page 336: ... Remove the intake pipe and seal ring at the oil sump connection Discard the seal ring Figure 2 Intake Pipes and Attaching Parts B Intake Pipe Installation NOTICE Since there is a corresponding intake pipe for each engine cylinder make sure the correct intake pipe is installed for the respective engine cylinder Refer to the TEO 540 C1A Illustrated Parts Catalog for the part number and installation...

Page 337: ...duction Housing B Examine the fuel drain valve adapter for damage C Make sure the fuel drain valve adapter is operating correctly 1 The valve is operating correctly if it is open with no air pressure applied 2 The valve is operating correctly if it closes when 0 75 to 1 0 psi 5 2 to 6 9 kPa of air pressure is applied to the inboard side of the fuel drain valve adapter assembly then repeated with t...

Page 338: ...housing per the Standard Torque Tables in the latest revision of the Service Table of Limits SSP 1776 5 Air Inlet Housing Replacement A Air Inlet Housing Removal 1 Remove the six bolts and washers from the air inlet housing Figure 2 2 Remove the air inlet housing and gasket from the induction housing Discard the gasket B Air Inlet Housing Installation 1 Install the air inlet housing Figure 2 with ...

Page 339: ...injector rail per the Fuel Injector Rail Assembly Replacement section in this chapter D Examine the weld joints at the end of both fuel injector rails for cracks Replace the fuel injector rail if the weld joint is cracked E Examine the fuel injector and fire sleeves Figures 1 and 9 for damage leaks and loose fittings or connections If the fuel injector fire sleeves are damaged replace them Tighten...

Page 340: ...40 C1A Engine Maintenance Manual 73 10 2018 Avco Corporation All Rights Reserved Page 310 November 2018 TEO 540 C1A Engine Maintenance Manual Figure 1 Fuel System Components Figure 2 Fuel Distribution System ...

Page 341: ...inked or loose fuel hose A loose fuel hose could have been subjected to vibrational forces and be weakened Cracks can develop at kinks in fuel hoses CAUTION TO SUPPORT FUEL SYSTEM PERFORMANCE ALL WORN DAMAGED CHAFED BRITTLE KINKED OR LOOSE FUEL HOSES MUST BE REPLACED NOT REPAIRED MAKE SURE EACH FUEL HOSE IS INSTALLED WITH SERVICEABLE CUSHIONED CLAMPS TO KEEP THE FUEL HOSES SECURELY IN PLACE TO PRE...

Page 342: ...ur engine could have a different configuration WARNING DO NOT ROUTE FUEL HOSES CLOSE TO HEAT SOURCES HEAT CAN CAUSE FUEL VAPORIZATION IN THE FUEL HOSES OR CAN DAMAGE THE FUEL HOSE AND CAUSE A FUEL LEAK WHICH COULD LEAD TO ENGINE STOPPAGE OR A FIRE CAUTION DO NOT RETURN THE ENGINE TO SERVICE UNLESS THE ENGINE IS OPERATING CORRECTLY AND DOES NOT HAVE ANY LEAKS E Make sure no fuel hoses touch the eng...

Page 343: ... from vibration Deteriorated cushion on clamp missing cushion or cushion does not completely cover the fuel hose diameter Examine fuel hoses in areas adjacent to the clamp Replace any fuel hose that has missing or deteriorated cushions on clamps Problem with fuel injector clamp installation caused by obstructive baffling Install the fuel injector clamps to enable clearance 3 Fuel Injector Leak Che...

Page 344: ...r 1 Apply power to the aircraft 2 Start the engine and operate it for 3 minutes 3 Shut down engine and look for fuel leaks wet spots or pooled fuel around the fuel injector inlet fuel injector rail assembly Figure 1 and injector adapter in the cylinder Replace any fuel injector rail or adapter that leaks per procedures in this chapter CAUTION DO NOT RETURN THE ENGINE TO SERVICE UNLESS THE ENGINE I...

Page 345: ... 5 Cyl 6 NOTICE Fuel hoses are identified as A B C D and E in Figure 7 Examine fuel hose fittings for damage or leaks Unless otherwise stated make sure all fuel hose fittings and connections are secure and correctly torqued If tightening does not correct a fuel leak replace the fitting A B C D E Examine each fuel hose for damage leaks nicks dents pits nicks kinks stains from fuel leaks cracks brit...

Page 346: ...se replace the fuel hose Install new clamps that attach the hose securely A B C D E Examine the cushion on clamps for deterioration If cushions are deteriorated or missing replace the fuel hose and the clamp with a new clamp with the cushion intact A B C D E Examine solder joints as necessary at the end of each fuel hose for cracks Replace the fuel hose if a crack is found at a solder joint Operat...

Page 347: ...hose Keep the fuel fittings if they are not part of the fuel hose NOTICE If no clamps were attached to the fuel hose replace the fuel hose and install serviceable cushioned clamps to dampen vibration B Fuel Hose Installation WARNING DO NOT ROUTE FUEL HOSES CLOSE TO HEAT SOURCES HEAT CAN DAMAGE THE FUEL HOSE AND CAUSE A FUEL LEAK WHICH COULD LEAD TO CATASTROPHIC ENGINE FAILURE NOTICE Refer to the T...

Page 348: ...are deteriorated or missing replace the clamp with a new clamp with the cushion intact c Refer to Figures 5 and 6 which show how the fasteners are to be installed on P clamps and L shaped clamps Figure 5 P Clamp Figure 6 L Shape Clamp d Make sure the clamps are securely attached to support the fuel hose and to prevent movement from vibration or motion frequencies e Torque the fuel hose connections...

Page 349: ...each side of the engine If this fuel injector rail assembly replacement procedure is completed with the engine installed in the airframe refer to the airframe manufacturer s instructions for shutting off the fuel and grounding the aircraft A Fuel Injector Rail Assembly Removal 1 Remove the harness connector from all three fuel injectors on the affected fuel injector rail assembly 2 Remove the scre...

Page 350: ... fire sleeve on the fuel injector Figure 9 9 Move the locking clip to unlock each fuel injector from the fuel injector rail 10 Remove the fuel injector rail from the fuel injectors 11 Remove the three fuel injectors from the fuel injector adapters 12 Remove the fuel collection container and dispose of the fuel in accordance with environmental regulations Figure 9 Fuel Injector B Fuel Injector Rail...

Page 351: ...s in the latest revision of the Service Table of Limits SSP 1776 12 Install and tighten the bleed cap on the fuel pressure regulator bleed port CAUTION DO NOT RETURN THE ENGINE TO SERVICE UNLESS THE ENGINE IS OPERATING CORRECTLY AND DOES NOT HAVE ANY LEAKS THERE MUST NOT BE ANY FUEL LEAKS A FUEL LEAK CAN CAUSE A FIRE 13 Look for any fuel leaks Identify and correct the cause of any fuel leaks There...

Page 352: ...PARKS CAN CAUSE FUEL IGNITION WHICH CAN CAUSE SERIOUS BURNS INJURY OR DEATH NOTICE If this fuel injector adapter replacement procedure is completed with the engine installed in the airframe refer to the airframe manufacturer s instructions for shutting off the fuel and grounding the aircraft A Removal of Adapter from Fuel Injector 1 Remove the fuel injector rail per instructions in the Fuel Inject...

Page 353: ...the adapter 5 Remove and discard the O ring from the fuel pump filter 6 Clean the fuel pump filter per Chapter 05 30 7 Remove the fuel collection container and dispose of the fuel in accordance with environmental regulations Figure 10 Fuel Pump B Fuel Pump Filter Inspection 1 Complete the Fuel Pump Filter Removal procedure in this chapter 2 Examine the fuel pump filter Figure 10 for dents damage d...

Page 354: ...o make sure it is operating correctly and there is no leak anywhere 10 Fuel Pump Replacement WARNING DO NOT SMOKE OR HAVE AN OPEN FIRE FLAME OR USE ANY DEVICE THAT CAN MAKE SPARKS FLAMES OR SPARKS CAN CAUSE FUEL IGNITION WHICH CAN CAUSE SERIOUS BURNS INJURY OR DEATH NOTICE If this fuel pump replacement procedure is completed with the engine installed in the airframe refer to the airframe manufactu...

Page 355: ...test revision of the Service Table of Limits SSP 1776 7 Connect the fuel pump inlet supply hose to the 90º elbow on the fuel pump Figure 10 8 Connect the fuel pump outlet hose to the fuel pump filter 9 Attach the harness connector to the Fuel Pump Pressure Sensor on the fuel pump outlet 10 Install and tighten the bleed cap on the fuel pressure regulator bleed port CAUTION DO NOT RETURN THE ENGINE ...

Page 356: ...e the fuel collection container and dispose of the fuel in accordance with environmental regulations Figure 11 Fuel Pressure Regulator and Manifold B Fuel Pressure Regulator Installation CAUTION DO NOT DAMAGE THE O RING DURING INSTALLATION OF THE FUEL PRESSURE REGULATOR LOSS OF FUEL SYSTEM PRESSURE AND FUEL LEAKS COULD OCCUR CREATING A POTENTIAL FIRE HAZARD 1 Install a new O ring on the adapter Fi...

Page 357: ...UNLESS THE ENGINE IS OPERATING CORRECTLY AND DOES NOT HAVE ANY LEAKS 8 Look for any fuel leak Identify and correct the cause of any fuel leak There must not be any leak All fuel connections must be secure and torqued in accordance with the Standard Torque Tables in the latest revision of the Service Table of Limits SSP 1776 9 If a leak or malfunction was found and corrected operate the engine agai...

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Page 359: ...he harness connections from the Throttle Position Sensor Figure 1 and Delta Pressure Sensor 3 Remove the throttle cable from throttle input lever 4 Remove the two bolts washers and lock washers from the top aft end of the throttle body Refer to Figure 1 Discard the lock washers Figure 1 Electronic Throttle Body 5 Loosen the two bolts washers and lock washers from the top forward end closest to the...

Page 360: ...tall on each end of the throttle body 2 Install the correct new gasket on each respective end of the throttle body Install the lower bolts thick washers with the washers on the non mating face of the throttle body flanges with a new lock washer to hold each gasket in place 3 Install the throttle body with the throttle input lever on the left side looking forward onto the installed four bolts do no...

Page 361: ...ECTED FROM THE ENGINE NOTICE As shown in Figure 1 there are two spark plug leads ignition leads in each cylinder head The 12 ignition leads Figure 2 are identified in Table 1 A Open the coil box Refer to the procedure Coil Box Access in Chapter 74 30 NOTICE Ignition leads can have different part numbers Refer to the TEO 540 C1A Parts Catalog to identify the correct part number for an ignition lead...

Page 362: ...on lead Remove the harness connector from the coil assembly if necessary NOTICE The Spark Plug Wire Nut Special Socket ST 535 Figure 3 is used by placing tool with the ignition lead through the open side of the socket so the socket end of the tool can engage on the ignition lead nut Figure 4 Use care not to kink or damage the ignition lead when turning the ignition lead nut with the ST 535 F Use t...

Page 363: ...on lead CAUTION HOLD FERRULES WHILE LOOSENING THE SPARK PLUG COUPLING NUT TO PREVENT TWISTING THE CONDUIT OR CABLE C Use the applicable sized socket on top of the spark plug and turn the socket to remove the spark plug from the engine cylinder head Figure 2 D Identify by tag or label each spark plug as it is removed according to cylinder number and top or bottom position E Remove and discard the g...

Page 364: ...Findings Condition of Fine Wire Ground Electrode on Spark Plug Condition of Center Electrode on Spark plug What to do Acceptable Spark Plugs Insulator tip gray tan or light brown No ash deposits Electrodes intact not burnt or eroded Clean set the spark plug gap and install the spark plug per applicable sections in this chapter and in Chapter 05 30 Partially Worn Spark Plugs Ash deposits Electrode ...

Page 365: ...Operate the engine at the specified operating temperature to prevent low temperature operation Use oil cooler baffles to keep the oil temperature from decreasing during winter flight Avoid rapid power reduction in flight to prevent sudden engine cooling Do not stop the engine immediately after landing to prevent rapid engine cooling Before engine shutdown operate the engine between 1000 and 1200 r...

Page 366: ...ion or annually whichever occurs first or when there is evidence of spark plug fouling A Remove all of the spark plugs Refer to the Spark Plug Removal procedure in this chapter B Examine each spark plug and ignition lead Refer to the Spark Plug Inspection and Ignition Lead Inspection procedures in this chapter C Complete the Spark Plug Cleaning procedure in Chapter 05 30 CAUTION USE CARE TO PREVEN...

Page 367: ...r s recommendations D Torque the spark plug to 420 in lb or 35 ft lb 47 5 Nm or per the spark plug manufacturer s instructions E Connect the spark plug to the applicable ignition lead per the Ignition Lead Installation procedure in this chapter F Torque the spark plug lead nut to 110 to 120 in lb 12 to 13 6 Nm or per the spark plug manufacturer s instructions 12 Ignition Lead Installation WARNING ...

Page 368: ...torque the nut on the coil box end of the ignition lead Figure 4 to 60 in lb 6 8 Nm I Install the coil box lid as per instructions in the Coil Box Access section in Chapter 74 30 J Route the ignition leads to the appropriate spark plug position as indicated by the alpha numeric markings on the coil box lid adjacent to each ignition lead K Attach the spark plug connector end of the ignition lead to...

Page 369: ...0 COIL ASSEMBLY AND COIL BOX MAINTENANCE 1 Coil Box Access WARNING MAKE SURE THE BATTERY HAS BEEN DISCONNECTED FROM THE ENGINE A To Open the Coil Box 1 Remove the 15 screws washers and lock washers Figure 1 from the coil box lid Discard the lock washers 2 Remove the two nuts and washers from the coil box lid 3 Remove the coil box lid Figure 1 Coil Box ...

Page 370: ...w lock washer 2 Torque the screws and nuts to the specified torque limits in the Standard Torque Tables in the latest revision of the Service Table of Limits SSP 1776 2 Coil Assembly Replacement A Coil Assembly Removal WARNING MAKE SURE THE BATTERY HAS BEEN DISCONNECTED FROM THE ENGINE 1 Remove coil box lid per instructions in the Coil Box Access section in this chapter 2 Remove the harness connec...

Page 371: ...lose the Coil Box section in this chapter 6 Connect the battery 7 Complete the operational test in Chapter 72 00 3 Coil Box Removal WARNING MAKE SURE THE BATTERY HAS BEEN DISCONNECTED FROM THE ENGINE A Remove coil box lid per instructions in the Open the Coil Box section in this chapter B Release the clamps Figure 1 that hold the spark plug wires C Disconnect the ignition lead spark plug connector...

Page 372: ...assemblies CAUTION IN THE NEXT STEP DO NOT PUT THE HARNESS DIRECTLY ON THE SCREW IN THE COIL BOX HARNESS CLIP ATTACH THE HARNESS SECURELY TO ONE LOOP ON THE CLAMP BASE E Use ignition lead tie wraps to attach the harness to the clamp bases on the coil box base F Make sure the ignition leads are not kinked cracked damaged or frayed G Route the ignition leads to the corresponding spark plugs per inst...

Page 373: ...e the hose clamps to release the inner heat shield Figure 1 Removal of Heat Shield CAUTION DO NOT MARK THE EXHAUST PIPE WITH A GRAPHITE LEAD PENCIL OR SCRIBE A CHEMICAL REACTION WILL OCCUR BETWEEN THE GRAPHITE LEAD AND THE STAINLESS STEEL USE A NON GRAPHITE MARKER SUCH AS COLORBRITE NOS 2127 4127 OR MARKS A LOT NOTICE During the 250 Hour Exhaust System Inspection in this chapter or anytime the exh...

Page 374: ... accordance with the Standard Torque Tables in the latest revision of the Service Table of Limits SSP 1776 Complete a check if this tightening stopped the leak E Look for loose heat shields Tighten fasteners on loose heat shields F Examine the exhaust manifolds for visible damage such as bulging cracks dents residue and overall general condition Identify and correct all of the causes in accordance...

Page 375: ...0 C1A Engine Maintenance Manual D Examine the underside of bends for signs of rubbing and or wear E Examine the slip joint Figure 4 components for distortion cracks separation gas leaks and make sure it is correctly aligned Figure 3 Exhaust System Figure 4 Right Crossover Exhaust Pipe and Left Crossover Exhaust Pipe ...

Page 376: ...tance from the mark made earlier Figure 5 to the end of the right exhaust pipe If this measurement is less than 0 75 in 1 95 cm replace the pipe G Measure from the mark to the end of the intermediate exhaust pipe Figure 5 If this measurement is less than 0 75 in 1 95 cm replace the pipe Figure 5 Measuring Engagement of Slip Joints H Examine the flange face and the area inside the flange mouth at t...

Page 377: ...orque Requirements Tables in Part 1 Section V in the latest revision of the Service Table of Limits SSP 1776 C Attach the outer heat shield to the inner heat shield with the five screws and five washers three on top and two on bottom Torque the screws per the Standard Torque Tables in the latest revision of the Service Table of Limits SSP 1776 6 Exhaust System Removal CAUTION PRIOR TO EXHAUST SYST...

Page 378: ... 2 4 6 even numbered cylinder side of the engine two people lower and remove the exhaust pipes and put them on a clean work surface Discard the self locking nuts and gasket from each exhaust pipe flange at the cylinder head I Repeat the previous step for the three exhaust pipes on the 1 3 5 odd numbered cylinder side of the engine Figure 3 7 Exhaust System Installation CAUTION CRACKS AS WELL AS IN...

Page 379: ...ection and at all slip joints to minimize binding H Refer to the photo or sketch done before disassembly to ensure correct assembly and installation of the exhaust pipes CAUTION WHEN INSTALLING EXHAUST SYSTEM COMPONENTS INITIALLY TIGHTEN HARDWARE FASTENERS FINGER TIGHT DO NOT TIGHTEN ANY PART OF THE EXHAUST SYSTEM BEFORE PROCEEDING TO ANOTHER PART ON THE SAME SIDE OF THE ENGINE I Install exhaust s...

Page 380: ...t all of the pipes so the slip joints are engaged at the same distance for each joint 4 With the pipe transition attached assemble the V band coupling over both pipes and the gasket 5 Press the V band coupling on the flanges 6 Engage the T bolt 7 Use a torque indicator wrench to tighten the different types of coupling nuts approximately 70 of the specified torque values identified below a Split ty...

Page 381: ...gure A 2 Refer to the tool manufacturer s instructions B If you cannot use a Stud Removal Tool or if the stud is broken beneath the surface 1 Drill a small hole in the stud 2 Use a pilot bushing to guide the drill into the center of the stud 3 Drill again to adjust the size of the hole to the necessary extractor 4 Remove the stud with the extractor C After stud removal examine the size and conditi...

Page 382: ...n Stabilizer Installation NOTICE Two different widths of fin stabilizers 0 63 in 16 00 mm and 0 31 in 7 87 mm are to be installed on each engine cylinder in the locations shown in Figure A 3 1 Clean the fin stabilizers and cylinder fin areas with mineral spirits or equivalent to remove all grease dirt and other unwanted materials 2 Use compressed air to dry the stabilizers and fins 3 Apply Dow Cor...

Page 383: ...070 Coil 5 Bottom A006 Fuel Injector Cylinder 2 A069 Coil 5 Top A007 Fuel Injector Cylinder 3 A075 Coil 6 Bottom A008 Fuel Injector Cylinder 4 A076 Coil 6 Top A009 Fuel Injector Cylinder 5 A004 Camshaft Speed A010 Fuel Injector Cylinder 6 A087 Cylinder Head Temperature 1 A016 Knock Cylinder 1 A088 Cylinder Head Temperature 2 A015 Knock Cylinder 2 A089 Cylinder Head Temperature 3 A018 Knock Cylinde...

Page 384: ...r I D Description Wiring Harness Connector I D Description A080 Exhaust Gas Temperature Cyl 1 A085 Exhaust Gas Temperature Cyl 6 A081 Exhaust Gas Temperature Cyl 2 A025 Oil Pressure A026 Oil Temperature A082 Exhaust Gas Temperature Cyl 3 A110 Permanent Magnet Alternator A083 Exhaust Gas Temperature Cyl 4 A050 Prop Governor A093 Turbine Inlet Temperature A084 Exhaust Gas Temperature Cyl 5 A043 Thro...

Page 385: ... 2018 Avco Corporation All Rights Reserved Appendix B November 2018 Page 355 TEO 540 C1A Engine Maintenance Manual Figure B 1 Airframe Wiring Interface ...

Page 386: ...Appendix B 2018 Avco Corporation All Rights Reserved Page 356 November 2018 TEO 540 C1A Engine Maintenance Manual Figure B 2 Communications Buses and 28 Volt Power Wiring ...

Page 387: ... 2018 Avco Corporation All Rights Reserved Appendix B November 2018 Page 357 TEO 540 C1A Engine Maintenance Manual Figure B 3 System Block Diagram ...

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Page 389: ... 2018 Avco Corporation All Rights Reserved Appendix B November 2018 Page 359 TEO 540 C1A Engine Maintenance Manual Figure B 4 Schematic T 11327 Y Sheet 1 ...

Page 390: ...Appendix B 2018 Avco Corporation All Rights Reserved Page 360 November 2018 TEO 540 C1A Engine Maintenance Manual TEO 540 C1A Engine Maintenance Manual Figure B 5 Schematic T 11327 Y Sheet 2 ...

Page 391: ... 2018 Avco Corporation All Rights Reserved Appendix B November 2018 Page 361 TEO 540 C1A Engine Maintenance Manual Figure B 6 Schematic T 11327 Y Sheet 3 ...

Page 392: ...Appendix B 2018 Avco Corporation All Rights Reserved Page 362 November 2018 TEO 540 C1A Engine Maintenance Manual TEO 540 C1A Engine Maintenance Manual Figure B 7 Schematic T 11327 Y Sheet 4 ...

Page 393: ... 2018 Avco Corporation All Rights Reserved Appendix B November 2018 Page 363 TEO 540 C1A Engine Maintenance Manual Figure B 8A Schematic T 11327 Y Sheet 5 ...

Page 394: ...Appendix B 2018 Avco Corporation All Rights Reserved Page 364 November 2018 TEO 540 C1A Engine Maintenance Manual TEO 540 C1A Engine Maintenance Manual Figure B 8B Schematic T 11327 Y Sheet 5 ...

Page 395: ... 2018 Avco Corporation All Rights Reserved Appendix B November 2018 Page 365 TEO 540 C1A Engine Maintenance Manual Figure B 9A Schematic T 11327 Y Sheet 6 ...

Page 396: ...Appendix B 2018 Avco Corporation All Rights Reserved Page 366 November 2018 TEO 540 C1A Engine Maintenance Manual TEO 540 C1A Engine Maintenance Manual Figure B 9B Schematic T 11327 Y Sheet 6 ...

Page 397: ...id for display to the pilot Engine Oil Temperature EOT Requested Power or Throttle Position POR Engine Oil Pressure EOP Lamp Status Engine Speed rpm ECU Supply Volts Manifold Pressure MAP ECU Voltage Source Manifold Air Temperature MAT Active Fault Count Deck Air Pressure Deck P TLO Time Remaining Deck Air Temperature Deck T Trip Time Fuel Rail Pressure Fuel P Engine Hours Tach Time Fuel Rail Temp...

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Page 399: ...k CTC Cylinder Temperature Control D DC Direct Current DLU Data Logger Unit E ECU Engine Control Unit physical box consisting of a primary and a secondary channel EECS Electronic Engine Control System EGT Exhaust Gas Temperature EPA Environmental Protection Agency ETC Electronic Throttle Control F FAA Federal Aviation Administration FAR Federal Aviation Regulations FAR Fuel Air Ratio FFL Fault Fou...

Page 400: ...ake Off P PFT Pre Flight Test PSSA Preliminary System Safety Assessment R RAM Random Access Memory ROC Rate of Change ROM Read Only Memory RTCA Radio Technical Commission for Aeronautics RTD Resistance Temperature Detector S SAE Society of Automotive Engineers SPF Single Point Failure T TBD To Be Decided TBO Time Between Overhaul TLO Time Limited Operation TIT Turbine Inlet Temperature TPS Throttl...

Page 401: ...e the Field Service Tool FST A laptop using Windows 7 8 1 or 10 operating system with an internet connection iE2 Service Cable ST 528 Figure C 1 iE2 Field Service Tool CAN Interface ST 530 Figure C 2 NOTICE ST 528 and ST 530 are available from an Authorized Lycoming Engines Distributor Figure C 1 iE2 Service Cable ST 528 Figure C 2 iE2 Field Service Tool CAN Interface ST 530 ...

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Page 403: ...and connected to the internet navigate to the Lycoming Engines Home Page www lycoming com 2 Click on the iE2 Portal tab in the ribbon at the top of the page Figure C 3 Figure C 3 iE2 Portal on the Lycoming com Website 3 If you are not already registered click on REGISTER Figure C 4 and enter your email address and name Figure C 5 on the First Time Registration Page Figure C 4 Lycoming iE2 Software...

Page 404: ...to the Password Entry Page to create and confirm a password Figure C 6 5 After you have successfully registered you will receive a confirmation email from Lycoming Figure C 6 Password Entry Page 6 If you are already registered click on LOGIN Figure C 7 and go directly to the Log In page Figure C 8 to enter your username and password Figure C 7 Lycoming iE2 Software Portal Figure C 8 Log In Page ...

Page 405: ...tenance Manual 7 After log in navigate to the Shared Folders page Figure C 9 and double click on the iE2 Software Download Figure C 9 Shared Folders Page 8 You will be transferred to the iE2 Software Download page Figure C 10 Double click on the iE2 Software icon Figure C 10 iE2 Software Download Page ...

Page 406: ... to the left of the iE2 Field Service Tool SW icon then click on the Download button Figure C 11 Figure C 11 File Download Page 10 Click Save As from the pop up window at the bottom of the page Figure C 12 and choose a file folder location for the download from the Save As dialog window then click Save Figure C 12 File Save Page ...

Page 407: ...e Manual 11 From the file folder where the download was saved double click the iE2 Field Service Tool SW icon Figure C 13 to open the Destination Directory Figure C 13 Saved File Folder 12 Click the Setup button on the WinZip Self Extractor dialog box Figure C 14 Figure C 14 WinZip Self Extractor Dialog Box ...

Page 408: ... Destination Directory Dialog Box 14 Read the Lycoming Software License Agreement then choose the I accept the License Agreement button Click Next on the License Agreement page Figure C 16 15 Read the National Instruments Software License Agreement then choose the I accept the License Agreement button Click Next on the License Agreement page Figure C 17 Figure C 16 Lycoming Software License Agreem...

Page 409: ...arate folder for each engine ECU serial number for storing Service History Faults each time a new engine ECU serial number is entered A separate folder for each engine ECU serial number for storing TBO Fault History each time a new engine ECU serial number is entered A separate folder for each engine ECU serial number for storing data from the Data Logger each time a new engine ECU serial number i...

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Page 411: ...ere the FST is installed 1 Connect the USB plug end of the iE2 Field Service Tool CAN Interface ST 530 to the USB port on the laptop 2 Connect the CAN Interface plug end of the iE2 Service Cable ST 528 to the CAN Interface 3 Connect the RCA plug end of the iE2 Service Cable ST 528 to the airframe supplied RCA jack in the cockpit Figure C 20 Laptop Connected to the ECU ...

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Page 413: ...Click the Start button 5 Click All Programs 6 Find the FST Folder in the menu and double click on Field Service Tool Figure C 21 NOTICE The program will open and display the Home screen Figure C 22 If the program does not open refer to the Field Service Tool Software Problems chapter in this manual Figure C 21 Field Service Tool Folder NOTICE Each Tab is an independent function and do not have to ...

Page 414: ...cable per the ECU to FST Connection Chapter in this manual D Close the FST program per the Close the FST Program section in this chapter then start to FST program per the Start the FST Program previously in this chapter 4 If the engine serial number displayed by the FST is not the same as the serial number on the engine data tag A Click the Edit S N Figure C 24 button on the Engine Serial Number p...

Page 415: ... Active Data screen Figure C 25 to display active faults data from the ECU NOTICE If the Active Faults panel is blank there is no active fault data in the ECU 4 Click the Stop button Figure C 26 to stop reading active data from the ECU NOTICE Must be streaming active data to record 5 Click the Start Recording button Figure C 26 to record the broadcast active data in a file on the laptop NOTICE Aft...

Page 416: ...anual Uploading Fault History 1 Open the FST program per the Start the FST Program procedure 2 Click on the Retrieve Clear Faults tab Figure C 27 Figure C 27 Retrieve Clear Faults Tab NOTICE The destination file for saved data is identified as the Log File Name on the Info Tab Figure C 28 Figure C 28 Info Tab ...

Page 417: ... Faults drop down menu Figure C 30 select one of the following options Clear TLO Clear Service History Faults 2 Click the OK Button on the Clear ECU Faults drop down menu to clear the selected faults from the ECU Figure C 29 Retrieve DLU Data Figure C 30 Clear ECU Faults NOTICE The data from the Data logger unit will be logged in a folder in the FST folder on the laptop hard drive Retrieving Data ...

Page 418: ...CU and correct the problem If the problem persists contact Lycoming Figure C 32 Data Logger Unit Not Detected 3 From the Retrieve DLU Data drop down menu Figure C 33 select the following option Run Time Data Trip Time Data Life Time Data 4 Click the OK button to start to retrieve the selected data The Data Table will show streaming data from the ECU Figure C 33 Retrieve DLU Data Drop Down Menu NOT...

Page 419: ...right of the screen 1 Close the FST program by clicking on the Exit button at the bottom of the screen Figure C 34 Figure C 34 Exit Button Disconnect the ECU and FST 1 Turn power to the ECU OFF per instructions in the applicable aircraft manual 2 Disconnect the CAN adapter from the airframe supplied RCA jack in the cockpit 3 Disconnect the NI 8473 CAN adapter Figure C 20 from the USB port on the l...

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Page 421: ... the internet navigate to the Lycoming Engines Home Page www lycoming com 2 Open Lycoming s iE2 Portal Figure C 35 and click on SHARE DATA Figure C 35 Lycoming iE2 Software Portal 3 Enter your email name and company in the designated areas on the left hand side of the page Figure C 36 4 Click on the icon for all the data files you want to share with Lycoming Technical Support then drag and drop th...

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Page 423: ...stalled Replace the laptop if necessary Laptop will not interface with the ECU Aircraft power is off Turn the aircraft power on Cable is not connected Check all cable connections make sure all plugs are correctly installed Cable is damaged or broken Contact Lycoming for a replacement iE2 Service Cable ST 528 CAN Adapter is not operating correctly Contact Lycoming for a replacement iE2 Field Servic...

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Page 425: ...ROPELLER TO PREVENT PERSONNEL INJURY OR DEATH CAUTION DO NOT REMOVE POWER FROM THE ENGINE WHILE DOWNLOADING SERVICE OR TBO HISTORY OR CLEARING SERVICE FAULTS DAMAGE TO THE ECU MEMORY CAN OCCUR NOTICE If a satisfactory outcome is not achieved using this troubleshooting guide contact Lycoming Engines product support TROUBLESHOOTING GUIDE ABBREVIATIONS AND ACRONYMS A ACJ Auto Cold Junction C CAN Cont...

Page 426: ...gital Converter R RPRA Reset Persistent RAM RTC Real Time Clock S SPE Signal Processing Engine SPI Serial Peripheral Interface T TLB Translation Lookaside Buffer TLO Time Limited Operation TPU Time Processing Unit V VDC Volts Direct Current NOTICE If the Troubleshooting Steps in this guide reference a procedure in another manual the chapter and manual name will be specified For example Appendix A ...

Page 427: ...O FAULTS PRESENT All faults in this TLO category must be corrected within 20 hours of operation 1 TLO Fault s which are present for 20 hours of operation will result in a NTO Fault 2 If multiple TLO Faults are present the first TLO fault to reach 20 hours of operation will trigger a NTO Fault After which all TLO Faults must be corrected before the NTO Fault can be cleared and the NTO Annunciator e...

Page 428: ...LL clock reset Fault Lamp None Root Cause This fault indicates a failure of the FMPLL feature on the processor Troubleshooting Steps 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 2 If yes replace the ECU 2 Clear Service faults using the FST by following the steps outlined in the Access the Field...

Page 429: ...sing the FST by following the steps outlined in the Access the Field Service Tool section in Appendix C or the latest revision of SSP 118 3 If fault repeats replace the ECU Fault ID 6 Fault Group 1 Fault Name FAULT Software Reset Fault Description Software Reset Fault Lamp None Root Cause This fault indicates the software requested a system reset Troubleshooting Steps 1 With Ignition switch in OFF...

Page 430: ...indicates a possibility of either failed unit calibration block CRC check OR corrupted failed memory This fault may also indicate a broken hardware memory Troubleshooting Steps 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 3 If yes go to step 2 2 Contact Lycoming Personnel to reprogram the ECU I...

Page 431: ... issue Troubleshooting Steps 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 3 If yes go to step 2 2 Contact Lycoming Personnel to have the ECU reprogrammed Is fault active or reprogram unsuccessful If no go to step 3 If yes replace the ECU 3 Clear Service faults using the FST by following the ste...

Page 432: ...aster configuration block Troubleshooting Steps 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 3 If yes go to step 2 2 Contact Lycoming Personnel to have the ECU reprogrammed Is fault active or reprogram unsuccessful If no go to step 3 If yes replace the ECU 3 Clear Service faults using the FST b...

Page 433: ...e issue Troubleshooting Steps 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 3 If yes go to step 2 2 Contact Lycoming Personnel to have the ECU reprogrammed Is fault active or reprogram unsuccessful If no go to step 3 If yes replace the ECU 3 Clear Service faults using the FST by following the st...

Page 434: ...n ECU hardware issue Troubleshooting Steps 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 3 If yes go to step 2 2 Contact Lycoming Personnel to have the ECU reprogrammed Is fault active or reprogram unsuccessful If no go to step 3 If yes replace the ECU 3 Clear Service faults using the FST by fol...

Page 435: ...F position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 3 If yes go to step 2 2 Contact Lycoming Personnel to have the ECU reprogrammed Is fault active or reprogram unsuccessful If no go to step 3 If yes replace the ECU 3 Clear Service faults using the FST by following the steps outlined in the Access the Field Service Tool section ...

Page 436: ...id data possibly due to an ECU hardware issue Troubleshooting Steps 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 3 If yes go to step 2 2 Contact Lycoming Personnel to have the ECU reprogrammed Is fault active or reprogram unsuccessful If no go to step 3 If yes replace the ECU 3 Clear Service fa...

Page 437: ... boot and application code OR a possible ECU hardware issue Troubleshooting Steps 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 3 If yes go to step 2 2 Contact Lycoming Personnel to have the ECU reprogrammed Is fault active or reprogram unsuccessful If no go to step 3 If yes replace the ECU 3 Cl...

Page 438: ... Clear Service faults using the FST by following the steps outlined in the Access the Field Service Tool section in Appendix C or the latest revision of SSP 118 3 If fault repeats replace the ECU Fault ID 34 Fault Group 5 Fault Name FAULT 1ms task overrun Fault Description Application 1ms task overrun Fault Lamp None Root Cause The fault indicates a delay in execution completion of a 1ms periodic ...

Page 439: ... 118 3 If fault repeats replace the ECU Fault ID 37 Fault Group 5 Fault Name FAULT task scheduler overrun Fault Description Application task scheduler overrun Fault Lamp None Root Cause The fault indicates a delay in execution completion of a scheduler task before the request scheduling of the next scheduler task due to possible hardware interrupts Troubleshooting Steps 1 With Ignition switch in O...

Page 440: ...perative cylinder detected Fault Description Cylinder 8 detected as inoperative Fault Lamp NTO Root Cause The fault indicates EGT1 and CHT1 has been below the minimum threshold The fault will become inactive if the cylinder starts operating as expected again CHT 1 OR EGT 1 above the minimum threshold level Troubleshooting Steps for Faults 40 thru 47 1 Run the engine in accordance with the engine a...

Page 441: ...ot move with the coil perform a continuity test of the harness from the harness coil connector to the ECU and APU connectors using the engine system schematic If continuity check fails isolate to affected harness by disconnecting the firewall connection then contact Lycoming Engines If continuity check passes but 14 VDC is not present contact Lycoming Engines for replacement of the APU If all chec...

Page 442: ...plete steps 5 and 6 If faults are found for step 3b complete step 7 4 Swap detonation sensor with another cylinder If fault does not move with sensor complete a continuity check of harness from knock sensor connector to ECU connector using the engine system schematic If the continuity check fails isolate to affected harness by disconnecting firewall harness and repeating the continuity check then ...

Page 443: ...ame baffles to ensure that there are no leaks If no defects or leaks found go to step 3 3 Using the FST download active and service fault logs 4 Review logs to determine if there are any faults for the following sub systems in the active or service fault logs and go to the step that corresponds to the fault a CHT b Induction System MAP CIP Deck Pressure c Fuel d Injector If faults are found for st...

Page 444: ... 9 Fault Name FAULT Cylinder 3 ignition output failure Fault Description Cylinder 3 Ignition output failure Fault Lamp TLO Fault ID 67 Fault Group 9 Fault Name FAULT Cylinder 4 ignition output failure Fault Description Cylinder 4 Ignition output failure Fault Lamp TLO Fault ID 68 Fault Group 9 Fault Name FAULT Cylinder 5 ignition output failure Fault Description Cylinder 5 Ignition output failure ...

Page 445: ... coil connectors Group 1 2 3 or 4 apply power to the aircraft turn on the ignition and check for 14VDC on pin A of each coil connector Is 14 VDC present on one or all malfunctioning coils If 14 VDC is present on at least one but not three complete a continuity test of the harness from each of the harness coil connectors to the ECU and Power Box connectors using the engine system schematic If the c...

Page 446: ... the fault active If yes or no continue Does the behavior of the engine correspond to the fault missing If yes continue If no go to step 3 Are there active faults for other cylinders or other cylinders behaving the same as the affected cylinder If yes go to step 5 If no go to step 2 2 Are there faults on both primary and secondary channels for the same injector If yes replace the injector If no go...

Page 447: ...LO Fault ID 86 Fault Group 11 Fault Name FAULT Cylinder 7 detonation sensor Fault Description Cylinder 7 detonation sensor circuit fault Fault Lamp TLO Fault ID 87 Fault Group 11 Fault Name FAULT Cylinder 8 detonation sensor Fault Description Cylinder 8 detonation sensor circuit fault Fault Lamp TLO Root Cause This fault indicates that the cylinder detonation voltage is consistently outside the mi...

Page 448: ...ycoming If the continuity check passes replace the ECU NOTE If all steps are unsuccessful contact Lycoming Fault ID 88 Fault Group 12 Fault Name FAULT cam sensor Fault Description Cam sensor fault Fault Lamp NTO Root Cause This fault indicates that a cam synchronization has failed due to an incorrect number of teeth detection or no teeth detection This fault also indicates an issue with the cam se...

Page 449: ...driver fault Fault Lamp NTO Root Cause This fault occurs to indicate inability to actuate the Wastegate as desired due to a circuit fault The circuit fault may be internal to the ECU drive stage or external to the ECU load or harness The fault is set under any one of the following conditions The actuator or the drive stage is Open circuit The actuator is short circuited Low Side Drive LSD is short...

Page 450: ...ep 5 If no go to step 6 3 Using the FST download active and service fault logs Go to step 4 4 Review logs to determine which fault was set and if there are more than one fault If there are no active faults but fault s keep reoccurring go to step 5 5 If faults are found on both channels inspect harness for damage eg burned broken or frayed wires cracked or broken connectors If damage found contact ...

Page 451: ...ils isolate to affected harness by disconnecting the airframe interface connection AF P1 If problem is isolated to engine airframe harness contact Lycoming Engines If problem is found from switch to AF J1 repair in accordance with aircraft maintenance manual If the continuity check is good replace the ECU Fault ID 97 Fault Group 13 Fault Name FAULT local takeoff reserve switch noise Fault Descript...

Page 452: ...t Description Take off reserve switch discrepancy fault Fault Lamp FFL Root Cause This fault indicates the primary and secondary channel s take off reserve switch position differ possibility due to a switch hardware issue The fault will become inactive if one of both switch change position and agree with each other Troubleshooting Steps 1 Disconnect wires from switch Does fault go inactive If yes ...

Page 453: ...harness by disconnecting the airframe interface connection AF P1 If problem is isolated to engine airframe harness contact Lycoming Engines If problem is found from switch to AF J1 repair in accordance with aircraft maintenance manual If the continuity check is good replace the ECU Fault ID 105 Fault Group 14 Fault Name FAULT local pre flight test switch stuck Fault Description Local pre flight te...

Page 454: ...condary channel s pre flight test switch differ possibly due to a hardware switch issue The fault will become inactive if both test switches change and agree with each other Troubleshooting Steps 1 Disconnect wires from switch Does fault go inactive If yes replace the switch If no go to step 2 2 Complete a continuity and short circuit test of the harness from the switch connector s to ECU connecto...

Page 455: ...esetting 2 Apply power to ECU Is fault still active If yes replace the ECU If no go to step 3 3 Using the FST download active and service fault logs then clear fault logs and monitor engine operation for the fault to repeat Fault ID 114 Fault Group 15 Fault Name FAULT CAN 3 Initialization Failure Fault Description CAN 3 initialization fault Fault Lamp None Root Cause This fault indicates that comm...

Page 456: ... 117 Fault Group 15 Fault Name FAULT CAN3 Error Fault Description CAN 3 error fault Fault Lamp None Root Cause This fault indicates a hardware error detected in CAN 3 device Troubleshooting Steps 1 Is the fault intermittent If yes see note If no go to step 2 2 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault still active If...

Page 457: ...NOTE This fault can be caused by too much data being requested from the ECU than the controller can provide through CAN 2 and CAN 3 This fault doesn t cause any operational or performance issues and is considered low risk Fault ID 119 Fault Group 15 Fault Name Reserved Fault Description Fault Lamp Root Cause Troubleshooting Steps Fault ID 120 Fault Group 16 Fault Name FAULT channel ID discrepancy ...

Page 458: ...ot Cause This fault indicates Unit Factory Calibration area is corrupt OR the unit serial number in the Unit Factory Calibration area has maxed out on the greatest number possible due to a possible hardware issue The fault may be inactive upon reprogramming the unit Troubleshooting Steps 1 Contact Lycoming Personnel to have the ECU reprogrammed 2 Clear service fault codes Start the engine Is the f...

Page 459: ...te Fault Description Cylinder head temperature 7 slew rate fault Fault Lamp None Fault ID 135 Fault Group 17 Fault Name FAULT cylinder head temperature cyl 8 slew rate Fault Description Cylinder head temperature 8 slew rate fault Fault Lamp None Root Cause This fault indicates the temperature sensor slew rate is greater than the calibrated maximum Troubleshooting Steps for Faults 128 thru 135 1 Ru...

Page 460: ... Fault Description Exhaust Gas Temperature cyl 7 slew rate fault Fault Lamp None Fault ID 143 Fault Group 18 Fault Name FAULT exhaust gas temperature cyl 8 slew rate Fault Description Exhaust Gas Temperature cyl 8 slew rate fault Fault Lamp None Root Cause This fault indicates the temperature sensor slew rate is greater than the calibrated maximum Troubleshooting Steps for Faults 136 thru 143 1 Ru...

Page 461: ...uity check fails isolate to affected harness by disconnecting the firewall connection then contact Lycoming Engines If the continuity checks good replace the sensor If fault persists replace the ECU NOTE This fault could be caused by another TIT fault If there are any other active TIT faults go to troubleshooting steps for the corresponding TIT fault Fault ID 146 Fault Group 19 Fault Name FAULT lo...

Page 462: ...by another deck temperature fault If there are any other active deck temperature faults go to troubleshooting steps for the corresponding deck temperature fault Fault ID 148 Fault Group 19 Fault Name FAULT fuel rail temperature slew rate Fault Description Fuel rail temperature slew rate fault Fault Lamp None Root Cause This fault indicates the temperature sensor slew rate is greater than the calib...

Page 463: ... for the corresponding oil temperature fault Fault ID 150 Fault Group 19 Fault Name FAULT venturi pressure slew rate Fault Description Venturi Pressure slew rate fault Fault Lamp None Root Cause This fault indicates the pressure sensor slew rate is greater than the calibrated maximum Troubleshooting Steps 1 Run the engine in accordance with the engine and aircraft maintenance manuals Is the fault ...

Page 464: ...sure faults go to troubleshooting steps for the corresponding manifold pressure fault Fault ID 152 Fault Group 20 Fault Name FAULT local deck pressure slew rate Fault Description Local Deck Pressure slew rate fault Fault Lamp None Root Cause This fault indicates the pressure sensor slew rate is greater than the calibrated maximum Troubleshooting Steps 1 Run the engine in accordance with the engine...

Page 465: ...e sensor If fault persists replace the ECU NOTE This fault could be caused by another compressor inlet air pressure fault If there are any other active compressor inlet air pressure faults go to troubleshooting steps for the corresponding compressor inlet air pressure fault Fault ID 154 Fault Group 20 Fault Name FAULT engine oil pressure slew rate Fault Description Engine Oil pressure slew rate fa...

Page 466: ...on Fuel rail pressure slew rate fault Fault Lamp None Root Cause This fault indicates the pressure sensor slew rate is greater than the calibrated maximum Troubleshooting Steps 1 Run the engine in accordance with the engine and aircraft maintenance manuals Is the fault active If yes go to step 3 If no go to step 2 2 Using the FST download active and service fault logs then clear fault logs and mon...

Page 467: ...aused by another fuel pump pressure fault If there are any other active fuel pump pressure faults go to troubleshooting steps for the corresponding fuel pressure fault Fault ID 158 Fault Group 20 Fault Name FAULT local throttle position slew rate Fault Description Local throttle position slew rate fault Fault Lamp None Root Cause This fault indicates the throttle position sensor slew rate is great...

Page 468: ...he engine system schematic If the continuity check fails isolate to affected harness by disconnecting the airframe interface connection AF P1 If the continuity fails between switch and AF J1 repair cable in accordance with aircraft maintenance manual If the continuity fails between AF P1 and ECU contact Lycoming Engines If the continuity checks good replace the ECU Fault ID 160 Fault Group 21 Faul...

Page 469: ...ordance with the engine and aircraft maintenance manuals Vary the throttle setting to allow the EGT CHT and TIT to increase and decrease with engine operation Is the fault active If yes go to step 3 If no go to step 2 2 Using the FST download active and service fault logs then clear fault logs and monitor engine operation for the fault to repeat 3 If the fault is active and no other associated fau...

Page 470: ...eserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 167 Fault Group 21 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 168 Fault Group 22 Fault Name FAULT ACJ temperature slew rate Fault Description ACJ temperature voltage slew rate Fault Lamp None Root Cause This fault indicates ACJ Auto Cold Junction temperature slew...

Page 471: ... the fault to repeat If fault repeats go to step 2 2 Check area surrounding ECU and Power Box to ensure there is nothing that could be causing a rapid temperature change If something is found correct discrepancy If nothing is found go to step 3 3 If fault is still active or repetitive but is not affecting engine operation contact Lycoming for further assistance If fault affects engine operation ie...

Page 472: ...ault Group 22 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 174 Fault Group 22 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 175 Fault Group 22 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps ...

Page 473: ...xpected window defined by the calibratable Highest and Lowest Valid Raw voltage values This does not distinguish between Open and Short Circuit Faults as any of the following failures would result in the Raw voltage outside the expected voltage window Open Circuit Short to GND Troubleshooting Steps 1 Run the engine in accordance with the engine and aircraft maintenance manuals Is the fault active ...

Page 474: ...bove are for troubleshooting a single fault event If there are faults on multiple thermocouples check to see if there are any active faults for ECU ACJ offset or internal power supply If there are any other active faults as those just mentioned proceed to the troubleshooting of those faults Fault ID 185 Fault Group 24 Fault Name FAULT AN16 circuit Fault Description Primary MAT Manifold Air Tempera...

Page 475: ...nuity check fails isolate to affected harness by disconnecting the firewall connection then contact Lycoming Engines If the continuity checks good replace the ECU Fault ID 187 Fault Group 24 Fault Name FAULT AN18 circuit Fault Description Primary FRT Fuel Rail Temp Circuit Fault Secondary reserved Fault Lamp TLO Root Cause This fault occurs if the Raw voltage observed on the input is outside the e...

Page 476: ...solate to affected harness by disconnecting the firewall connection then contact Lycoming Engines If the continuity checks good replace the ECU Fault ID 189 Fault Group 24 Fault Name FAULT AN20 circuit Fault Description Primary Venturi Pressure Circuit Fault Secondary Manifold Pressure Circuit Fault Fault Lamp TLO Root Cause This fault occurs if the Raw voltage observed on the input is outside the...

Page 477: ... the firewall connection then contact Lycoming Engines If the continuity checks good replace the ECU 6 If the above steps are unsuccessful contact Lycoming Fault ID 191 Fault Group 24 Fault Name FAULT AN22 circuit Fault Description Primary CIP Compressor Inlet Pressure Circuit Fault Secondary CIP Circuit Fault Fault Lamp TLO Root Cause This fault occurs if the Raw voltage observed on the input is ...

Page 478: ...ts replace the ECU NOTE If the secondary fault is active go to troubleshooting procedures for Fault ID 256 Fault ID 193 Fault Group 25 Fault Name FAULT AN24 circuit Fault Description Primary FRP Fuel Rail Pressure Circuit Fault Secondary FPP Fuel Pump Pressure Circuit Fault Fault Lamp TLO Root Cause This fault occurs if the Raw voltage observed on the input is outside the expected window defined b...

Page 479: ...s the fault move with the sensor If yes replace the sensor If no go to step 6 6 Complete a continuity test of the harness from the harness sensor connector to the ECU connector using the engine system schematic If the continuity check fails isolate to affected harness by disconnecting the firewall connection then contact Lycoming Engines If the continuity checks good replace the sensor If fault pe...

Page 480: ...on remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault still active or repetitive If yes replace the ECU Fault ID 197 Fault Group 25 Fault Name FAULT AN32 circuit Fault Description Primary Secondary 5V Sensor Supply 2 Circuit Fault Fault Lamp TLO Root Cause This fault occurs if the Raw voltage observed on the input is outside the expected window defined by the ca...

Page 481: ...age Circuit Fault Fault Lamp TLO Root Cause This fault occurs if the Raw voltage observed on the input is outside the expected window defined by the calibratable Highest and Lowest Valid Raw voltage values This does not distinguish between Open and Short Circuit Faults as any of the following failures would result in the Raw voltage outside the expected voltage window Open Circuit Short to VPwr Sh...

Page 482: ... Highest and Lowest Valid Raw voltage values This does not distinguish between Open and Short Circuit Faults as any of the following failures would result in the Raw voltage outside the expected voltage window Open Circuit Short to VPwr Short to 5V Short to GND Troubleshooting Steps 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting...

Page 483: ...ge Fault Fault Lamp None Fault ID 213 Fault Group 27 Fault Name FAULT exhaust gas temperature cyl 3 range Fault Description Primary reserved Secondary EGT3 Sensor Range Fault Fault Lamp None Fault ID 214 Fault Group 27 Fault Name FAULT exhaust gas temperature cyl 5 range Fault Description Primary reserved Secondary EGT5 Sensor Range Fault Fault Lamp None Fault ID 215 Fault Group 27 Fault Name FAUL...

Page 484: ...y Fault Fault Description Primary EGT2 External Reference Fault Secondary reserved Fault Lamp None Fault ID 218 Fault Group 28 Fault Name FAULT EGT 6 External Supply Fault Fault Description Primary EGT2 External Reference Fault Secondary reserved Fault Lamp None Fault ID 219 Fault Group 28 Fault Name FAULT EGT 8 External Supply Fault Fault Description Primary EGT2 External Reference Fault Secondar...

Page 485: ...Fault Lamp TLO Root Cause This fault occurs if the Engineering value of the measured parameter is outside the expected window defined by the calibratable Highest and Lowest Valid Engineering Values The Highest and Lowest possible engineering values define the range of values that can be expected for the entire engine operating envelope Any value observed outside this envelope is flagged as a senso...

Page 486: ...y Fault Fault Description Primary reserved Secondary CHT2 External Reference Fault Fault Lamp None Fault ID 237 Fault Group 30 Fault Name FAULT CHT 4 External Supply Fault Fault Description Primary reserved Secondary CHT4 External Reference Fault Fault Lamp None Fault ID 238 Fault Group 30 Fault Name FAULT CHT 6 External Supply Fault Fault Description Primary reserved Secondary CHT6 External Refer...

Page 487: ...ate to affected harness by disconnecting the firewall connection then contact Lycoming Engines If the continuity checks good replace the ECU 6 If the above steps are unsuccessful contact Lycoming Fault ID 241 Fault Group 31 Fault Name FAULT local manifold temperature range Fault Description Primary MAT Sensor Range Fault Secondary MAT Sensor Range Fault Fault Lamp TLO Root Cause This fault occurs ...

Page 488: ...e firewall connection then contact Lycoming Engines If the continuity checks good replace the ECU 6 If the above steps are unsuccessful contact Lycoming Fault ID 243 Fault Group 31 Fault Name FAULT fuel rail temperature range Fault Description Primary FRT Fuel Rail Temperature Sensor Range Fault Secondary reserved Fault Lamp TLO Root Cause This fault occurs if the Engineering value of the measured...

Page 489: ...o go to step 2 2 Using the FST download active and service fault logs then clear fault logs and monitor engine operation for the fault to repeat 3 Inspect the sensor sensor lead and connector If there is damage found replace the sensor per the Sensor Replacement Procedure in Chapter 72 70 If there is no damage go to step 4 4 Inspect engine harness for visible signs of damage If damage is found con...

Page 490: ...the fault active If yes go to step 3 If no go to step 2 2 Using the FST download active and service fault logs then clear fault logs and monitor engine operation for the fault to repeat 3 Inspect the sensor sensor lead and connector If there is damage found replace the sensor per the Sensor Replacement Procedure in Chapter 72 70 If there is no damage go to step 4 4 Inspect engine harness for visib...

Page 491: ...assembly hence replacing the sensor is not possible and requires replacement of the entire throttle body assembly Fault ID 249 Fault Group 32 Fault Name FAULT local deck pressure range Fault Description Primary Deck Pressure Sensor Range Fault Secondary Deck Pressure Sensor Range Fault Fault Lamp TLO Root Cause This fault occurs if the Engineering value of the measured parameter is outside the exp...

Page 492: ...sing the engine system schematic If the continuity check fails isolate to affected harness by disconnecting the firewall connection then contact Lycoming Engines If the continuity checks good replace the ECU 6 If the above steps are unsuccessful contact Lycoming Fault ID 251 Fault Group 32 Fault Name FAULT engine oil pressure range Fault Description Primary EOP Sensor Range Fault Secondary reserve...

Page 493: ...ffected harness by disconnecting the firewall connection then contact Lycoming Engines If the continuity checks good replace the sensor If fault persists replace the ECU Fault ID 253 Fault Group 32 Fault Name FAULT local throttle position range Fault Description Primary TPS Sensor Range Fault Secondary TPS Sensor Range Fault Fault Lamp TLO Root Cause This fault occurs if the Engineering value of t...

Page 494: ...contact Lycoming Engines If the continuity checks good and if fault persists replace the ECU Fault ID 255 Fault Group 32 Fault Name FAULT fuel pump pressure range Fault Description Primary reserved Secondary FPP Sensor Range Fault Fault Lamp TLO Root Cause This fault occurs if the Engineering value of the measured parameter is outside the expected window defined by the calibratable Highest and Low...

Page 495: ...NOTE By default this configurable parameter has been disabled hence this fault should only occur if this is enabled in the calibration for an engine specific installation Fault ID 257 Fault Group 33 Fault Name FAULT analogue pilot operating mode range Fault Description Primary reserved Secondary Op Mode Selector Sensor Range Fault Fault Lamp TLO Root Cause This fault occurs if the Engineering valu...

Page 496: ...ircuit breaker Wait 10s before resetting Is fault still active or repetitive If yes go to step 2 If no monitor engine operation for the fault to repeat If fault repeats go to step 2 2 Check area surrounding ECU and Power Box to ensure there is nothing that could be causing an out of limit temperature change If something is found correct discrepancy If nothing is found go to step 3 3 If fault is st...

Page 497: ...using the FST by following the steps outlined in the Access the Field Service Tool section in Appendix C or the latest revision of SSP 118 Fault ID 261 Fault Group 33 Fault Name FAULT APU 100 temperature range Fault Description Primary Power Box Temperature Sensor Range Fault Secondary Power Box Temperature Sensor Range Fault Fault Lamp TLO Root Cause This fault occurs if the Engineering value of ...

Page 498: ...perating envelope Any value observed outside this envelope is flagged as a sensor range fault Troubleshooting Steps for Faults 264 and 265 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active or intermittent If active and won t clear replace the ECU If intermittent go to step 2 If not active or intermittent monitor eng...

Page 499: ...an intermittent range fault by altering the 5V supply voltage to 0 001 volts below its monitored range This does not affect system operation but if the frequency is not removed can produce an ongoing nuisance fault Fault ID 267 Fault Group 34 Fault Name FAULT ECU supply voltage range Fault Description Primary ECU Supply Voltage Range Fault Secondary ECU Supply Voltage Range Fault Fault Lamp TLO Ro...

Page 500: ...velope Any value observed outside this envelope is flagged as a sensor range fault Troubleshooting Steps 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 2 If yes replace the Power Box 2 Clear Service faults using the FST by following the steps outlined in the Access the Field Service Tool section ...

Page 501: ...arness by disconnecting the firewall connection then contact Lycoming Engines If the continuity checks good replace the ECU Fault ID 273 Fault Group 35 Fault Name FAULT local deck pressure external Fault Description Primary Deck Pressure External Sensor Supply Fault Secondary Deck Pressure External Sensor Supply Fault Fault Lamp TLO Root Cause This fault implies that the 5V sensor supply that is c...

Page 502: ...ine system schematic If the continuity check fails isolate to affected harness by disconnecting the firewall connection then contact Lycoming Engines If the continuity checks good replace the ECU Fault ID 275 Fault Group 35 Fault Name FAULT engine oil pressure external Fault Description Primary EOP External Sensor Supply Fault Secondary reserved Fault Lamp TLO Root Cause This fault implies that th...

Page 503: ...ing the firewall connection then contact Lycoming Engines If continuity checks good replace the ECU Fault ID 277 Fault Group 35 Fault Name FAULT local throttle position external Fault Description Primary TPS External Sensor Supply Fault Secondary TPS External Sensor Supply Fault Fault Lamp TLO Root Cause This fault implies that the 5V sensor supply that is connected to the sensor is deemed INVALID...

Page 504: ... check fails isolate to affected harness by disconnecting the firewall connection then contact Lycoming Engines If the continuity checks good replace the ECU Fault ID 279 Fault Group 35 Fault Name FAULT fuel pump pressure external Fault Description Primary reserved Secondary FPP External Sensor Supply Fault Fault Lamp TLO Root Cause This fault implies that the 5V sensor supply that is connected to...

Page 505: ...ontinuity or correct resistance exist If yes reconnect A001 J2 and go to step 4 If no contact Lycoming Engines 4 Clear Service fault history and turn ignition switch on If the fault is still active replace the ECU NOTE By default this configurable parameter has been disabled hence this fault should only occur if this is enabled in the calibration for an engine specific installation Fault ID 281 Fa...

Page 506: ...P1 and ECU contact Lycoming Engines If the continuity checks good replace the ECU Fault ID 282 Fault Group 36 Fault Name FAULT turbine inlet temperature 1 external Fault Description Primary TIT1 External Sensor Supply Fault Secondary reserved Fault Lamp None Root Cause This fault implies that the Thermocouple offset voltage is deemed INVALID Troubleshooting Steps 1 Run the engine in accordance wit...

Page 507: ...ion Primary reserved Secondary Operating Mode Selector Invalid Value Fault Lamp None Root Cause This fault indicates an invalid interpolation of the analogue pilot mode input Troubleshooting Steps 1 Is there an active fault s that correspond to the fault numbers listed in the Root Cause box items 1 and 2 If yes go to troubleshooting procedure for the active fault s If no go to step 2 2 Inspect wir...

Page 508: ... 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 2 If yes replace the ECU 2 Clear Service faults using the FST by following the steps outlined in the Access the Field Service Tool section in Appendix C or the latest revision of SSP 118 3 If fault repeats replace the ECU Fault ID 286 Fault Group 36...

Page 509: ... for the active fault If no go to step 2 2 Contact Lycoming Engines Fault ID 291 Fault Group 37 Fault Name FAULT engine load airflow speed throttle vs speed density discrepancy Fault Description Engine Load airflow ST Vs SD fault Fault Lamp FFL Root Cause This fault indicates ST airflow tertiary airflow measurement and speed density secondary airflow measurement differ by more than calibrated thre...

Page 510: ...Are there any active CIP sensor slew rate circuit or range faults If yes refer to troubleshooting section for the active fault If no go to step 2 2 Contact Lycoming Engines Fault ID 295 Fault Group 37 Fault Name FAULT throttle position discrepancy Fault Description TPS discrepancy fault Fault Lamp FFL Root Cause This fault indicates primary channel and secondary channel TPS values differ by more t...

Page 511: ...nsor slew rate circuit or range faults If yes refer to troubleshooting section for the active fault If no go to step 2 2 Contact Lycoming Engines Fault ID 299 Fault Group 38 Fault Name FAULT manifold pressure cross check Fault Description Manifold Pressure crosscheck fault Fault Lamp FFL Root Cause This fault indicates the combined and inferred manifold pressure from throttle position differ by mo...

Page 512: ...2 Contact Lycoming Engines Fault ID 303 Fault Group 38 Fault Name FAULT throttle position cross check Fault Description Throttle position crosscheck fault Fault Lamp FFL Root Cause This fault indicates the arbitrated and inferred throttle position differ by more than a calibrated maximum threshold The fault will become inactive if the arbitrated and inferred values converge Troubleshooting Steps 1...

Page 513: ...memory corruption or one channel being down while the other was running Troubleshooting Steps 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 2 If yes go to step 3 2 Clear Service faults using the FST by following the steps outlined in the Access the Field Service Tool section in Appendix C or the...

Page 514: ...o go to step 4 If yes go to step 5 3 Inspect data logger and cabling for damage If damage is noted repair damage in accordance with aircraft maintenance manual If data logger is damaged replace 4 Clear Service faults using the FST by following the steps outlined in the Access the Field Service Tool section in Appendix C or the latest revision of SSP 118 5 Set ignition switch to on do not start eng...

Page 515: ...upt Record Fault Description TBO clear corrupt fault Fault Lamp None Root Cause This fault indicates one or more corrupt records were found in the TBO fault clearing history block Troubleshooting Steps 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 2 If yes go to step 3 2 Clear Service faults usi...

Page 516: ... switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 2 If yes go to step 3 2 Clear Service faults using the FST by following the steps outlined in the Access the Field Service Tool section in Appendix C or the latest revision of SSP 118 3 Set ignition switch to on do not start engine complete step 2 Is fault still ac...

Page 517: ...U Fault ID 318 Fault Group 40 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 319 Fault Group 40 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 320 Fault Group 41 Fault Name FAULT SH Priority 1 Corrupt Record Fault Description SH priority 1 corrupt record fault Fault Lamp None Root Cause This fault ind...

Page 518: ...roubleshooting Steps 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault active If no go to step 2 If yes go to step 3 2 Clear Service faults using the FST by following the steps outlined in the Access the Field Service Tool section in Appendix C or the latest revision of SSP 118 3 Set ignition switch to on do not start engi...

Page 519: ... Lamp None Root Cause Troubleshooting Steps Fault ID 325 Fault Group 41 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 326 Fault Group 41 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 327 Fault Group 41 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps ...

Page 520: ... reset the TLO timer by following the steps outlined in the Access the Field Service Tool section in Appendix C or the latest revision of SSP 118 2 Set ignition switch to on do not start engine then Clear Service faults using the FST by following the steps outlined in the Access the Field Service Tool section in Appendix C or the latest revision of SSP 118 Is fault still active If no sequence comp...

Page 521: ...ault Group 42 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 333 Fault Group 42 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 334 Fault Group 42 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 335 Fault Group 42 Fault Name Reserved Fault Description Fau...

Page 522: ... yes go to step 3 If no complete the following for the finding PMA not secure o Remove PMA per the PMA Removal section in Chapter 73 10 and inspect PMA shaft and gear for damage If damage is found replace the PMA and inspect accessory gear drive for damage If no damage is found on either the PMA or accessory gear drive reinstall PMA per the PMA Installation section in Chapter 73 10 PMA damaged Rep...

Page 523: ...ge If no damage is found on either the PMA or accessory gear drive reinstall PMA per the PMA Installation section in Chapter 73 10 PMA damaged Replace the PMA per the Permanent Magnet Alternator PMA Replacement section in Chapter 73 10 Engine harness damaged Contact Lycoming Engines 2 Complete a continuity and short circuit test of the engine and engine airframe harnesses from PMA connector to the...

Page 524: ...t Lamp NTO Root Cause Troubleshooting Steps Fault ID 341 Fault Group 43 Fault Name Reserved Fault Description Fault Lamp NTO Root Cause Troubleshooting Steps Fault ID 342 Fault Group 43 Fault Name Reserved Fault Description Fault Lamp NTO Root Cause Troubleshooting Steps Fault ID 343 Fault Group 43 Fault Name Reserved Fault Description Fault Lamp NTO Root Cause Troubleshooting Steps ...

Page 525: ...go to step 2 2 Are there any active or logged fuel injector detonation fuel filter in the fault history that match the EEC hours for the TIT fault If yes go to troubleshooting procedure for that fault s If no go to step 3 3 Remove TIT sensor and inspect for physical damage to probe eg burnt end connector or lead Is there any damage to sensor If yes replace the sensor If fault becomes inactive go t...

Page 526: ...Fault Group 44 Fault Name Reserved Fault Description Fault Lamp TLO Root Cause Troubleshooting Steps Fault ID 349 Fault Group 44 Fault Name Reserved Fault Description Fault Lamp TLO Root Cause Troubleshooting Steps Fault ID 350 Fault Group 44 Fault Name Reserved Fault Description Fault Lamp TLO Root Cause Troubleshooting Steps Fault ID 351 Fault Group 44 Fault Name Reserved Fault Description Fault...

Page 527: ...nuity checks good replace the ECU Fault ID 353 Fault Group 45 Fault Name FAULT ignition switch discrepancy Fault Description Local Ignition Switch Discrepancy Fault Fault Lamp FFL Root Cause This fault indicates the ignition switch differs between primary and secondary channels possibly due to a hardware issue Troubleshooting Steps 1 Is the fault active or are there any active or logged ignition s...

Page 528: ...Fault Group 45 Fault Name Reserved Fault Description Fault Lamp FFL Root Cause Troubleshooting Steps Fault ID 357 Fault Group 45 Fault Name Reserved Fault Description Fault Lamp FFL Root Cause Troubleshooting Steps Fault ID 358 Fault Group 45 Fault Name Reserved Fault Description Fault Lamp FFL Root Cause Troubleshooting Steps Fault ID 359 Fault Group 45 Fault Name Reserved Fault Description Fault...

Page 529: ...e fault Fault Lamp None Root Cause This fault indicates the power down diagnostic pin is noisy Troubleshooting Steps 1 Is the fault active If no go to step 2 If yes are there any other active or logged Power Box APU faults If yes replace the Power Box If no go to step 3 2 Clear Service faults using the FST by following the steps outlined in the Access the Field Service Tool section in Appendix C o...

Page 530: ...Lamp None Root Cause Troubleshooting Steps Fault ID 365 Fault Group 46 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 366 Fault Group 46 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 367 Fault Group 46 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps ...

Page 531: ...ault indicates the placard condition time is invalid on both primary and secondary channel possibly due to a non volatile memory issue Fault ID 370 Fault Group 47 Fault Name FAULT placard condition active Fault Description Placard condition time invalid fault Fault Lamp TLO Root Cause This fault indicates the engine has been operating outside of safe limits for more than the consecutive allowable ...

Page 532: ...Fault Group 47 Fault Name Reserved Fault Description Fault Lamp TLO Root Cause Troubleshooting Steps Fault ID 374 Fault Group 47 Fault Name Reserved Fault Description Fault Lamp TLO Root Cause Troubleshooting Steps Fault ID 375 Fault Group 47 Fault Name Reserved Fault Description Fault Lamp TLO Root Cause Troubleshooting Steps ...

Page 533: ...8 Fault Group 48 Fault Name FAULT EEPROM rolling buffer failure Fault Description EEPROM rolling buffer fault Fault Lamp None Root Cause This fault indicates a failure to read from the EEPROM The fault will become inactive if an EEPROM read is successful Troubleshooting Steps for Faults 376 thru 378 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s...

Page 534: ...t mode Fault ID 385 Fault Group 49 Fault Name FAULT BOOT COMMS TIMEOUT Fault Description Boot mode service tool timeout Fault Lamp None Root Cause This fault indicates a loss of communication with service tool while in boot mode Fault ID 386 Fault Group 49 Fault Name FAULT BOOT PROG ERROR Fault Description Boot mode programming error Fault Lamp None Root Cause This fault indicates a failure to pro...

Page 535: ...is fault indicates a failure to erase the flash memory potentially due to flash memory corruption Fault ID 390 Fault Group 49 Fault Name FAULT Flash SPI read Fail Fault Description Flash SPI read fail fault Fault Lamp None Root Cause This fault indicates a failure to read the flash memory potentially due to flash memory corruption Fault ID 391 Fault Group 49 Fault Name FAULT Flash SPI write Fail F...

Page 536: ...at duty cycle fault Fault Lamp NTO Root Cause This fault indicates remote PWM heartbeat has an invalid duty cycle possibly due to an unexpected response from standby channel Fault ID 395 Fault Group 50 Fault Name FAULT control priority PWM frequency invalid Fault Description Control Priority PWM invalid frequency Fault Lamp NTO Root Cause This fault indicates remote PWM heartbeat has an invalid fr...

Page 537: ...lly initializes on subsequent attempts Fault ID 402 Fault Group 51 Fault Name FAULT QADC scan overrun Fault Description QADC scan overrun fault Fault Lamp None Root Cause This fault indicates QADC has failed to sample the analogue channels every 1ms potentially due to a hardware failure in the converter The fault will become inactive if the converter returns to normal function Fault ID 403 Fault G...

Page 538: ...Lamp None Root Cause Troubleshooting Steps Fault ID 405 Fault Group 51 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 406 Fault Group 51 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 407 Fault Group 51 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps ...

Page 539: ... files and reflash the ADL Is fault still active If no go to step 3 If yes replace ADL 3 Clear Service faults using the FST by following the steps outlined in the Access the Field Service Tool section in Appendix C or the latest revision of SSP 118 Fault ID 410 Fault Group 52 Fault Name FAULT ADL_STATE_RTC reception failure Fault Description Data logger state RTC message reception failure fault Fa...

Page 540: ...ault Group 52 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 413 Fault Group 52 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 414 Fault Group 52 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 415 Fault Group 52 Fault Name Reserved Fault Description Fau...

Page 541: ...ine Is the fault active If yes swap the new sensor in the crank position with the cam sensor reinstall the original crank sensor and run the engine Is the fault active If yes go to step 7 If no go to step 8 7 Complete a continuity test of the harness from the engine harness crank and cam sensor connectors to the ECU connector using the engine system schematic If the continuity check fails isolate ...

Page 542: ... to step 2 2 Contact Lycoming Engines to correct the calibration files and reflash the ECU Is fault still active If no go to step 3 If yes replace ECU 3 Clear Service faults using the FST by following the steps outlined in the Access the Field Service Tool section in Appendix C or the latest revision of SSP 118 Fault ID 419 Fault Group 53 Fault Name Reserved Fault Description Fault Lamp TLO Root C...

Page 543: ...l section in Appendix C or the latest revision of SSP 118 Fault ID 425 Fault Group 54 Fault Name FAULT high fuel injector pressure delta Fault Description High fuel injector pressure delta fault Fault Lamp FFL Root Cause This fault indicates the fuel injector pressure delta is consistently above the maximum allowable threshold Troubleshooting Steps 1 Run the engine in accordance with the engine an...

Page 544: ...within limits contact Lycoming Engines 6 Clear Service faults using the FST by following the steps outlined in the Access the Field Service Tool section in Appendix C or the latest revision of SSP 118 Fault ID 427 Fault Group 54 Fault Name FAULT Low fuel pressure with aux pump active Fault Description Low fuel pressure with Aux Pump active Fault Lamp FFL Root Cause This fault indicates the fuel pu...

Page 545: ...lt Lamp FFL Root Cause Troubleshooting Steps Fault ID 429 Fault Group 54 Fault Name Reserved Fault Description Fault Lamp FFL Root Cause Troubleshooting Steps Fault ID 430 Fault Group 54 Fault Name Reserved Fault Description Fault Lamp FFL Root Cause Troubleshooting Steps Fault ID 431 Fault Group 54 Fault Name Reserved Fault Description Fault Lamp FFL Root Cause Troubleshooting Steps ...

Page 546: ...s Is the fault active If yes replace the filter If no go to step 4 4 Clear Service faults using the FST by following the steps outlined in the Access the Field Service Tool section in Appendix C or the latest revision of SSP 118 Fault ID 433 Fault Group 55 Fault Name FAULT TLO time expired Fault Description TLO timer expired Fault Lamp NTO Root Cause This fault indicates the time limited operation...

Page 547: ... Fault Group 55 Fault Name Reserved Fault Description Fault Lamp NTO Root Cause Troubleshooting Steps Fault ID 437 Fault Group 55 Fault Name Reserved Fault Description Fault Lamp NTO Root Cause Troubleshooting Steps Fault ID 438 Fault Group 55 Fault Name Reserved Fault Description Fault Lamp NTO Root Cause Troubleshooting Steps Fault ID 439 Fault Group 55 Fault Name Reserved Fault Description Faul...

Page 548: ... in Appendix B and airframe wiring manual If the continuity check fails between the relay connector and the ECU isolate to affected harness by disconnecting the airframe interface connection AF P1 If the continuity fails between the relay connector and AF J1 repair cable in accordance with aircraft maintenance manual If the continuity fails between AF P1 and ECU contact Lycoming Engines If the con...

Page 549: ... the Access the Field Service Tool section in Appendix C or the latest revision of SSP 118 4 Remove connector wires from annunciator Complete continuity short circuit test on annunciator assembly using a multi meter and aircraft wiring manual If annunciator is defective replace If annunciator passes tests go to step 5 5 Complete a continuity test of the harness from the annunciator to the ECU conn...

Page 550: ...ort circuit test on annunciator assembly using a multi meter and aircraft wiring manual If annunciator is defective replace If annunciator passes tests go to step 5 5 Complete a continuity test of the harness from the annunciator to the ECU connector using the engine system schematic in Appendix B and aircraft wiring diagram manual If the continuity check fails isolate to affected harness by disco...

Page 551: ... power and ground to the appropriate contacts on cowl flap actuator connector for the direction it needs to move Does the cowl flap actuator operate If yes go to step 2 If no replace the actuator Then go to step 4 2 Complete a continuity and short circuit test on the cowl flap actuator limit switch Did tests pass If no replace switch If yes go to step 3 3 Complete a continuity and short circuit te...

Page 552: ...ault Group 57 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 452 Fault Group 57 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 453 Fault Group 57 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 454 Fault Group 57 Fault Name Reserved Fault Description Fau...

Page 553: ...n failure fault Fault Lamp None Root Cause This fault indicates a failure transmitting data via the SPI B This fault will become inactive if successful data transmission resumes on the SPI B Fault ID 459 Fault Group 58 Fault Name FAULT SPI D transmission failure Fault Description SPI D transmission failure fault Fault Lamp None Ro ot Cause This fault indicates a failure transmitting data via the S...

Page 554: ...65 1 Is fault active or logged If yes go to step 2 If no go to step 5 2 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault still active If yes go to step 3 If no go to step 5 3 Inspect the data logger and cabling for damage If damage is noted repair damage in accordance with the aircraft maintenance manual If data logger is d...

Page 555: ... Lamp None Root Cause Troubleshooting Steps Fault ID 468 Fault Group 59 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 469 Fault Group 59 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 470 Fault Group 59 Fault Name Reserved Fault Description Fault Lamp None Root Cause Troubleshooting Steps Fault ID 47...

Page 556: ...ult ID 473 Fault Group 60 Fault Name FAULT instrumentation message watchdog Fault Description Instrumentation message watchdog fault Fault Lamp None Root Cause This fault indicates a failure with CAN messages on the instrumentation interface Troubleshooting Steps 1 With Ignition switch in OFF position remove ECU power by pulling the ECU circuit breaker Wait 10s before resetting Is fault still acti...

Page 557: ...ccess the Field Service Tool section in Appendix C or the latest revision of SSP 118 Fault ID 476 Fault Group 60 Fault Name FAULT receive inter channel message watchdog Fault Description Receive inter channel message watchdog fault Fault Lamp None Root Cause This fault indicates a failure to receive inter channel CAN messages Troubleshooting Steps 1 With Ignition switch in OFF position remove ECU ...

Page 558: ...nfigurable values exceed their upper or lower limits Fault ID 482 Fault Group 61 Fault Name FAULT Excessive Programming Time Fault Description Excessive programming time fault Fault Lamp None Root Cause This fault indicates programming did not complete within the timeout limit Troubleshooting Steps for Faults 480 thru 482 1 With Ignition switch in OFF position remove ECU power by pulling the ECU c...

Page 559: ...mp SPI Diag Fault Description SPI lamp diagnostic fault Fault Lamp None Root Cause This fault indicates a failure of the processors SPI hardware Fault ID 489 Fault Group 62 Fault Name FAULT Lamp SPI Fault Description SPI lamp fault Fault Lamp None Root Cause This fault indicates a failure of the processors SPI hardware Fault ID 490 Fault Group 62 Fault Name FAULT Consistency EMM EEPROM Fault Descr...

Page 560: ...Description Airflow load 1 consistency fault Fault Lamp None Root Cause Memory corruption affecting airflow load Fault ID 497 Fault Group 63 Fault Name FAULT Consistency AIRFLOWLOAD 2 Fault Description Airflow load 2 consistency fault Fault Lamp None Root Cause Memory corruption affecting airflow load Fault ID 498 Fault Group 63 Fault Name FAULT Consistency CP 1 Fault Description Configuration pro...

Page 561: ...use Memory corruption affecting Non Volatile parameter processing Fault ID 507 Fault Group 64 Fault Name FAULT Consistency FUEL Fault Description Fuel consistency fault Fault Lamp None Root Cause Memory corruption affecting Fueling Fault ID 508 Fault Group 64 Fault Name FAULT Consistency SYNC DATA Fault Description Sync Data consistency fault Fault Lamp None Root Cause Memory corruption affecting ...

Page 562: ...corruption affecting cowl flap control Fault ID 518 Fault Group 65 Fault Name FAULT Consistency DETSENS Fault Description Detonation sensor consistency fault Fault Lamp None Root Cause Memory corruption affecting detonation sensors Fault ID 519 Fault Group 65 Fault Name FAULT Consistency DETCTL Fault Description Detonation control consistency fault Fault Lamp None Root Cause Memory corruption affe...

Page 563: ...sistency fault Fault Lamp None Root Cause Memory corruption affecting inoperative cylinder detection Fault ID 529 Fault Group 67 Fault Name FAULT Consistency ADAPT Fault Description Adapt fuel consistency fault Fault Lamp None Root Cause Memory corruption affecting adaptive fueling Fault ID 530 Fault Group 67 Fault Name FAULT Consistency AUX FUEL Fault Description Aux fuel consistency fault Fault ...

Page 564: ...stency MIOS 2 Fault Description MIOS 2 consistency fault Fault Lamp None Root Cause Memory corruption affecting enhanced Modular Input output subsystem Fault ID 541 Fault Group 68 Fault Name FAULT Consistency FAULT_INTERNAL_MAJORFAULT Fault Description Internal fault consistency fault Fault Lamp None Root Cause Memory corruption affecting internal faults Fault ID 542 Fault Group 68 Fault Name FAUL...

Page 565: ...ause Troubleshooting Steps Fault ID 549 Fault Group 69 Fault Name FAULT Consistency INSTR Fault Description Instrumentation consistency fault Fault Lamp None Root Cause Memory corruption affecting the instrumentation interface Fault ID 550 Fault Group 69 Fault Name FAULT Consistency TPU Fault Description TPU consistency fault Fault Lamp None Root Cause Memory corruption affecting the instrumentati...

Page 566: ... 70 Fault Name FAULT CHT cyl 5 coss check Fault Description CHT cyl 5 cross check fault Fault Lamp FFL Root Cause This fault indicates the cross check of cylinder head temperature which means a cross check between local cylinder head temperature and inferred cylinder head temperature has consistently exceeded its calibrated maximum threshold Fault ID 557 Fault Group 70 Fault Name FAULT CHT cyl 6 c...

Page 567: ...he channel giving the fault with another sensor in a different cylinder and run the engine Did the fault move with the sensor If yes replace the sensor per the Sensor Replacement Procedure in Chapter 72 70 If no complete a continuity test of the harness from the harness sensor connector to the ECU connector using the engine system schematic If the continuity check fails isolate to affected harness...

Page 568: ...Appendix D 2018 Avco Corporation All Rights Reserved Page 538 November 2018 TEO 540 C1A Engine Maintenance Manual This page intentionally left blank ...

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