Lycoming TIO-540-A1A, Operator'S Manual

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LYCOMING OPERATOR’S MANUAL SECTION 4
TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS PERIODIC INSPECTIONS
a. Ignition System –
(1) If fouling of spark plugs has been apparent, rotate bottom plugs to upper position.
(2) Examine spark plug leads of cable and ceramics for corrosion and deposits. This condition is
evidence of either leaking spark plugs, improper cleaning of the spark plug walls or connector
ends. Where this condition is found, clean the cable ends, spark plug walls and ceramics with a
dry, clean cloth or a clean cloth moistened with methyl-ethyl ketone. All parts should be clean
and dry before reassembly.
(3) Check ignition harness for security of mounting clamps and be sure connections are tight at spark
plug and magnetic terminals.
b. Fuel and Induction System –
Check the primer lines for leaks and security of the clamps. Remove and
clean the fuel inlet strainers. Check the mixture control and throttle linkage for travel, freedom of
movement, security of the clamps and lubricate if necessary. Check the air intake ducts for leaks,
security, filter damage; evidence of dust or other solid material in the ducts is indicative of inadequate
filter care or damaged filter. Check vent lines for evidence of fuel or oil seepage; if present, fuel pump
may require replacement.
c. Lubrication System –
(1) Check oil lines for leaks, particularly at connections; for security of anchorage and for wear due
to rubbing or vibration, for dents and cracks.
(2) Replace elements on external full flow oil filters. Before disposing of used element check interior
folds for traces of metal particles that might be evidence of internal engine damage. Drain and
renew lubricating oil on installations not employing replaceable full flow filters.
d. Exhaust System
– Check attaching flanges at exhaust ports on cylinders for evidence of leakage. If
they are loose, they must be removed and machined flat before they are reassembled and tightened.
Examine exhaust manifold for general condition.
e. Cooling System
– Check cowling and baffles for damage and secure anchorage. Any damaged or
missing part of the cooling system must be repaired or replaced before the aircraft resumes operation.
f. Cylinders
– Check rocker box covers for evidence of oil leaks. If found, replace gasket and tighten
screws to specified torque (50 in.-lbs.).
Check cylinders for evidence of excessive heat which is indicated by burned paint on the cylinder.
This condition is indicative of internal damage to the cylinder and, if found, its cause must be
determined and corrected before the aircraft resumes operation.
Heavy discoloration and appearance of seepage at cylinder head and barrel attachment area is
usually due to emission of thread lubricant used during assembly of the barrel at the factory, or by
slight gas leakage which stops after the cylinder has been in service for a while. This condition is
neither harmful nor detrimental to engine performance and operation. If it can be proven that leakage
exceeds these conditions, the cylinder should be replaced.
g. Turbocharger –
All fluid power lines and mounting brackets incorporated in turbocharger system
should be checked for leaks, tightness and any damage that may cause a restriction.
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