Lycoming TEO-540-C1A Manuals

Manuals and User Guides for Lycoming TEO-540-C1A. We have 1 Lycoming TEO-540-C1A manual available for free PDF download: Maintenance Manual

Lycoming TEO-540-C1A Maintenance Manual (568 pages)

Brand: Lycoming | Category: Engine | Size: 8.75 MB

Record of Revisions

3
Service Document List

5
- Table of Contents
  9
Table of Contents

10
Abbreviations and Acronyms

19
Introduction

23
Airworthiness Limitations

29
Required Maintenance

31
- General
  
  31
- List of Tools for Service and Maintenance
  
  31
Time Limits / Inspections

37
- Engine Inspection Schedule for TEO-540-C1A Engines
  
  37
Required Engine Inspections for TEO-540-C1A Engines

39
Cleaning

65
- Cleaning Guidelines
  65
- Crankshaft Cleaning
  68
- Crankshaft Counterbore Cleaning
  68
- Crankshaft Trigger Gear Assembly Cleaning
  69
- Tappet Cleaning
  70
- Crankcase Cleaning
  70
- Grit-Blasting
  70
- Soft Carbon Removal
  71
- Hard Carbon Removal
  72
- Cylinder Cleaning
  72
- Piston Cleaning
  73
- Steel, Aluminum, or Magnesium Parts Cleaning
  73
- Spark Plug Cleaning
  74
- Lead Deposit Removal
  74
- Volcanic Ash Removal
  75
- Cleaning Guidelines for a Soaked Engine
  75
- Cleaning Methods for Non-Destructive Testing
  76
Subject

65
Unscheduled Corrective Maintenance

77
Subject

95
Servicing - Replenishing

95
- Refueling
  95
- Oil Level Check
  95
- Oil Consumption
  96
- Oil Type and Viscosity
  96
- Add Oil to the Engine
  96
- Oil Leak Check
  97
- Oil Servicing Schedule
  97
- Oil Change Procedure
  98
- Engine Pre-Oil Procedure
  99
- Oil Suction Screen Removal/Inspection/Cleaning/Installation
  101
Subject

102
- Oil Filter Replacement
  102
Crankcase Maintenance (Cont.)

102
Fault Isolation

111
- Recommended Approach to Fault Isolation
  111
Engine Removal and Return to Service

131
- Engine Removal Prerequisites
  131
- Engine Removal Procedure
  131
- Engine Installation Preparation Requirements
  133
- Operational Ground Check
  134
- Engine Mount Inspection
  135
- Return to Service Procedure
  135
Subject

137
Engine Disassembly

137
- Engine Disassembly Procedure
  137
Engine Assembly

143
- Corrosion Prevention
  143
- Painting the Engine and Engine Components
  143
- Limits and Clearances
  145
- Inspections
  145
  - Engine Assembly Procedure
    146
  - Engine Assembly Checklist
    152
Propeller Flange Bushing Replacement

157
- Propeller Flange Bushing Removal
  157
- Propeller Flange Bushing Installation
  157
Crankcase Maintenance

159
- Exterior Crankcase Inspection
  159
- Connecting Rod Removal
  160
- Crankcase Disassembly
  160
- Crankshaft Disassembly
  166
- Interior Crankcase Inspection
  169
- Crankshaft Inspection
  172
- Crankshaft Bearing Surface Inspection
  181
- Bearing Shell Surface Inspection
  182
- Gear Inspection
  182
- Screwed Fitting Inspection
  182
- Camshaft Disassembly and Inspection
  183
- Connecting Rod Inspection
  184
- Connecting Rod Bushing Replacement
  188
- Connecting Rod Parallelism / Squareness Check
  189
- Tappet Inspection
  190
- Crankshaft Assembly
  194
- Piston Cooling Nozzle Installation (if Removed)
  204
- Oil Plug Installation (if Removed)
  204
- Tappet Assembly Installation
  205
- Crankshaft Bearing and O-Ring Installation
  206
- Propeller Governor Drive Installation
  207
- Camshaft Assembly and Installation
  209
- Crankshaft Installation
  212
- Crankcase Assembly
  213
- Crankshaft End Play Clearance Check
  218
- Propeller Oil Control Leak Test
  219
- Crankshaft Oil Seal Installation
  221
- Crankshaft Trigger Gear Assembly and Crankshaft Idler Gear Installation
  224
- Crankshaft-To-Camshaft Timing Check
  229
Accessory Housing Maintenance

231
- Accessory Housing Removal
  231
- Oil Pump Removal
  232
- Oil Pump Installation
  232
- Accessory Housing Installation
  233
Cylinder Maintenance

235
- General
  235
- Visual Cylinder Inspection
  235
- Cylinder Compression Check
  236
- Intercylinder Baffle Inspection
  241
Cylinder Maintenance (Cont.)

242
Subject

242
- Cylinder Borescope Inspection
  242
- Exhaust Valve and Guide Inspection
  243
- Cylinder Removal
  248
- Piston Removal
  253
- Cylinder Assembly Inspection
  254
- Piston Inspection
  260
- Piston Ring Replacement
  264
- Piston Installation
  265
- Intake Valve Replacement
  266
- Exhaust Valve Replacement
  267
- Corrective Action for Valve Sticking
  275
- Intake and Exhaust Valve Guide Replacement
  277
- Heli-Coil ® Replacement
  278
- Hour Turbocharger Inspection
  283
Turbocharger Maintenance

284
- Hour Turbocharger Inspection
  284
- Turbocharger Installation
  286
- Exhaust Bypass Valve Replacement
  287
Lubrication System Maintenance

289
- Oil Pressure Adjustment
  289
- Oil Hose Replacement (General Instructions for any Oil Hose)
  290
Lubrication System Maintenance (Cont.)

291
Subject

291
Accessory Drives

297
- Accessory Drive Inspection
  297
Electrical System Maintenance

299
- Wiring Inspection
  299
- Alternator Belt Inspection
  300
- Alternator and Bracket Removal
  302
- Alternator Belt Replacement
  303
- Power Box and PMA
  304
- Wiring Harness Connectors
  305
- Sensor Replacement Procedures
  312
- Engine-To-Firewall Wiring Harness Removal
  323
- Engine-To-Firewall Wiring Harness Installation
  325
- Airframe Interface Wiring Harness Removal
  326
- Airframe Interface Wiring Harness Installation
  327
Electrical System Maintenance (Cont.)

328
Subject

328
- ECU Removal
  328
- Power Box Removal
  329
- Starter Replacement
  330
- Starter Ring Gear Support Replacement
  331
- Starter Ring Gear Replacement
  332
Induction System Maintenance

335
Engine Fuel and Control - Distribution

339
- Fuel System Inspection
  339
- Fuel Hose Inspection
  341
- Table 1 - Corrective Action for Fuel Hoses
  343
- Fuel System Inspection Checklist
  344
- Fuel Hose Replacement
  347
- Fuel Injector Rail Assembly Replacement
  349
- Fuel Injector Replacement
  351
- Fuel Injector Adapter Replacement
  352
- Fuel Pump Filter Replacement
  353
- Fuel Pump Replacement
  354
- Fuel Pressure Regulator Replacement
  355
Subject

359
Engine Fuel and Control - Controlling

359
- Ignition Lead Removal
  361
- Spark Plugs
  363
- Spark Plug Inspection
  364
  - Spark Plug Fouling
    365
  - Spark Plug Cleaning
    366
- Spark Plug Installation
  367
- Coil Box Access
  369
Coil Assembly and Coil Box Maintenance

370
- Coil Assembly Replacement
  370
- Coil Box Removal
  371
- Coil Box Installation
  372
Exhaust System Maintenance

373
- Heat Shield Removal
  373
- Hour Exhaust System Inspection
  374
- Heat Shield Installation
  377
- Exhaust System Installation
  378
Appendix A

381
Subject

381
Appendix A

381
- Stud Replacement
  381
- Air Bleed Nozzle Installation
  382
- Wiring Diagrams
  383
Appendix B

389
- Schematic T-11327-Y
  389
- Communications Bus Data
  397
Appendix C

399
Appendix C

399
Appendix D

425
Appendix D

425
- Troubleshooting Guide Abbreviations and Acronyms
  425
- Troubleshooting Guide
  426

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Lycoming TEO-540-C1A Manuals

Lycoming TEO-540-C1A Maintenance Manual (568 pages)

Table of Contents

Record of Revisions

Service Document List

Table of Contents

Abbreviations and Acronyms

Introduction

Airworthiness Limitations

Required Maintenance

General

List of Tools for Service and Maintenance

Time Limits / Inspections

Engine Inspection Schedule for TEO-540-C1A Engines

Required Engine Inspections for TEO-540-C1A Engines

Cleaning

Subject

Unscheduled Corrective Maintenance

Subject

Servicing - Replenishing

Subject

Crankcase Maintenance (Cont.)

Fault Isolation

Engine Removal and Return to Service

Subject

Engine Disassembly

Engine Assembly

Propeller Flange Bushing Replacement

Crankcase Maintenance

Accessory Housing Maintenance

Cylinder Maintenance

Cylinder Maintenance (Cont.)

Subject

Turbocharger Maintenance

Lubrication System Maintenance

Lubrication System Maintenance (Cont.)

Subject

Accessory Drives

Electrical System Maintenance

Electrical System Maintenance (Cont.)

Subject

Induction System Maintenance

Engine Fuel and Control - Distribution

Subject

Engine Fuel and Control - Controlling

Coil Assembly and Coil Box Maintenance

Exhaust System Maintenance

Appendix A

Subject

Appendix A

Appendix B

Appendix C

Appendix C

Appendix D

Appendix D

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