Lycoming TEO-540-C1A User manual

© 2018 Avco Corporation. All Rights Reserved.
Engine Maintenance Manual
(Principal Manual)
TEO-540-C1A Engine
November 2018
Part No. MM-TEO-540-C1A

TEO-540-C1A Engine
Maintenance Manual
Lycoming Part Number: MM-TEO-540-C1A
Contact Us:
Mailing Address:
Lycoming Engines
652 Oliver Street
Williamsport, PA 17701 USA
Phone:
Factory
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Direct:
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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 notification whenever Lycoming publishes a new
or revised technical publication, including any revisions to this Engine Maintenance Manual.

TEO-540-C1A Engine Maintenance Manual
© 2018 Avco Corporation. 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

TEO-540-C1A Engine Maintenance Manual
Record of Revisions © 2018 Avco Corporation. All Rights Reserved
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TEO-540-C1A Engine Maintenance Manual
© 2018 Avco Corporation. All Rights Reserved Service Document List
November 2018 Page iii
TEO-540-C1A Engine Maintenance Manual
SERVICE DOCUMENT LIST
NOTICE: The following is a list of service documents referenced in or incorporated into the
information in this manual. Always refer to the latest revision of any service document
(including any supplements) for changes or additional information. Supplements to a
service document contain information relevant to the service document but not yet
added to the service document.
The latest revision of all service documents in this list can be downloaded from our
website https://www.lycoming.com/contact/knowledge-base/publications.
To narrow the search parameters and limit the number of returns, enter only the
numerical portion of the service document number in the Search box on the website.
Number
Incorporation
Date
Subject
S.B. 201
11/18
Inspection 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 Corrective Action for Use of
Incorrect Fuel
S.B. 399
11/18
Action to Take If Loss of Oil Pressure
S.B. 401
11/18
Recommendations for Aircraft Struck by Lightning
S.B. 475
11/18
Crankshaft Gear Modification and Assembly
Procedures
S.B. 480
11/18
Oil, Oil Filter, Oil Pressure Screen, and Oil Suction
Screen Servicing
S.B. 533
11/18
Recommended Action for Sudden Engine Stoppage,
Propeller/Rotor Strike or Loss of Propeller/Rotor
Blade or Tip
S.B. 592
11/18
Engine Inspection after Overboost
S.I. 1009
11/18
Time Between Overhaul (TBO) Schedules
S.I. 1011
11/18
Tappets and Lifters
S.I. 1012
11/18
Counterweights and Rollers on Engine Models
S.I. 1014
11/18
Lubricating Oil Recommendations
S.I. 1043
11/18
Spark Plug Heli-Coil®Insert Replacement

TEO-540-C1A Engine Maintenance Manual
Service Document List © 2018 Avco Corporation. All Rights Reserved
Page iv November 2018
TEO-540-C1A Engine Maintenance Manual
SERVICE DOCUMENT LIST (CONT.)
Number
Incorporation
Date
Subject
S.I. 1047
11/18
Inspection and Reconditioning Procedures for
Nitride Hardened Steel Cylinders
S.I. 1059
11/18
Pre-Lubrication of Parts Before Assembly
S.I. 1070
11/18
Specified Fuels for Spark-Ignited Gasoline Aircraft
Engine Models
S.I. 1080
11/18
Maintenance Items for Special Attention
S.I. 1098
11/18
Propeller Flange Bushing Location
S.I. 1129
11/18
Methods of Checking DC Alternator and Generator
Belt Tension
S.I. 1142
11/18
Replacement of Crankshaft Counterweight Bushings
S.I. 1172
11/18
Adjustable Oil Pressure Relief Valve Installation and
Valve Seat Repair or Replacement
S.I. 1191
11/18
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. 1316
11/18
Valve Seat Refacing on Oil Cooler Bypass Valves
S.I. 1324
11/18
Crankshaft Oil Seals
S.I. 1340
11/18
Piston Pin Identification
S.I. 1409
11/18
Lycoming Engines P/N LW-16702 Oil Additives
S.I. 1425
11/18
Suggested Maintenance Procedures to Reduce the
Possibility of Valve Sticking
S.I. 1427
11/18
Field Run-In and Break-In
S.I. 1458
11/18
Connecting Rod Bolts (Identification and
Installation)
S.I. 1462
11/18
Propeller Oil Control Leak Test Procedure
S.I. 1485
11/18
Exhaust Valve and Guide Identification Procedure
S.I. 1492
11/18
Piston Pin Plug Wear Inspection
S.I. 1514
11/18
Roller Tappets Part Information Update

TEO-540-C1A Engine Maintenance Manual
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November 2018 Page v
TEO-540-C1A Engine Maintenance Manual
SERVICE DOCUMENT LIST (CONT.)
Number
Incorporation
Date
Subject
S.I. 1530
11/18
Engine Inspection in Particulate-Laden
Environments
S.I. 1535
11/18
Counterweight and Roller Removal, Inspection, and
Installation
S.I. 1562
11/18
Turbocharged Exhaust System Installation
S.I. 1566
11/18
Lycoming Engines 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
11/18
Recommendations to Avoid Valve Sticking
L247
11/18
Shelf Life Requirements
L253
11/18
Warranty Repair of AVStar Fuel Systems, Inc. Fuel
Control Products
L270
11/18
Extended Maintenance Intervals for Spark-Ignited
Engines Operated on Unleaded Fuels

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TEO-540-C1A Engine Maintenance Manual
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TABLE OF CONTENTS
Subject Page
Title Page _______________________________________________________________________
Record of Revisions.............................................................................................................................. i
Service Document List.......................................................................................................................iii
Table of Contents..............................................................................................................................vii
Abbreviations and Acronyms ........................................................................................................xvii
Introduction...................................................................................................................................... xxi
Airworthiness Limitations............................................................................................................xxvii
Required Maintenance ................................................................................................. 05-00
—Required Maintenance ............................................................................................................. 1
—General..................................................................................................................................... 1
—List of Tools for Service and Maintenance.............................................................................. 1
—Table 1 - Tools for Service and Maintenance..................................................................... 1
—Time Between Overhaul (TBO)............................................................................................... 3
—Safety Precautions - 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-540-C1A Engines................................................... 16
—10-Hour Initial Engine Inspection for TEO-540-C1A Engines.............................................. 17
—25-Hour Engine Inspection for TEO-540-C1A Engines......................................................... 19
—50-Hour Engine Inspection for TEO-540-C1A Engines......................................................... 21
—100-Hour or Annual Engine Inspection for TEO-540-C1A Engines ..................................... 24
—250-Hour Engine Inspection for TEO-540-C1A Engines....................................................... 29
—400-Hour Engine Inspection for TEO-540-C1A Engines....................................................... 30
—1000-Hour Engine Inspection for TEO-540-C1A Engines..................................................... 32

TEO-540-C1A Engine Maintenance Manual
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Page viii November 2018
TEO-540-C1A Engine Maintenance Manual
Subject Page
Cleaning ......................................................................................................................... 05-30
—Cleaning Guidelines................................................................................................................ 35
—Table 1 - Cleaning Guidelines for Engine Components.................................................... 36
—Crankshaft Cleaning................................................................................................................ 38
—Crankshaft Counterbore Cleaning........................................................................................... 38
—Crankshaft Trigger Gear Assembly Cleaning......................................................................... 39
—Tappet Cleaning...................................................................................................................... 40
—Crankcase Cleaning................................................................................................................. 40
—Grit-Blasting............................................................................................................................ 40
—Soft Carbon Removal.............................................................................................................. 41
—Hard Carbon Removal ............................................................................................................ 42
—Cylinder Cleaning................................................................................................................... 42
—Piston Cleaning....................................................................................................................... 43
—Steel, Aluminum, or Magnesium Parts Cleaning.................................................................... 43
—Spark Plug Cleaning................................................................................................................ 44
—Lead Deposit Removal............................................................................................................ 44
—Volcanic 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
—Volcanic Ash/Particulate Contamination................................................................................ 53
—Table 2 - Action to Take in Volcanic Ash Conditions...................................................... 54
—Valve Sticking......................................................................................................................... 55
—Oil Starvation/Sudden Loss of Oil Pressure ........................................................................... 55
—Metal Contamination of the Lubrication System.................................................................... 56
—NTO & TLO Illumination on the Control Panel..................................................................... 56
—Propeller Strike, Sudden Engine Stoppage or Loss of a Propeller Blade Tip......................... 57
—Non-Destructive Testing
(Magnetic Particle Inspection and Fluorescent Penetrant Inspection.)................................... 64

TEO-540-C1A Engine Maintenance Manual
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TEO-540-C1A Engine Maintenance Manual
Subject Page
Servicing - Replenishing............................................................................................... 12-10
—Refueling................................................................................................................................. 65
—Oil Level Check ...................................................................................................................... 65
—Oil Consumption..................................................................................................................... 66
—Oil Type and Viscosity ........................................................................................................... 66
—Add Oil to the Engine ............................................................................................................. 66
—Oil Leak Check ....................................................................................................................... 67
—Oil Servicing Schedule............................................................................................................ 67
—Table 1 - Oil Servicing Schedule....................................................................................... 67
—Oil Change Procedure............................................................................................................. 68
—Engine Pre-Oil Procedure ....................................................................................................... 69
—Oil Suction Screen Removal/Inspection/Cleaning/Installation............................................... 71
—Oil Filter Replacement............................................................................................................ 72
—Oil Filter Inspection ................................................................................................................ 73
—Identification of Metallic Solids After Oil Servicing.............................................................. 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
—Recommended Approach to Fault Isolation............................................................................ 81
—Table 1 - Fault Isolation Guide.......................................................................................... 81
Engine Removal and Return to Service...................................................................... 72-00
—Engine Removal Prerequisites.............................................................................................. 101
—Engine Removal Procedure................................................................................................... 101
—Engine Installation Preparation Requirements...................................................................... 103
—Table 1 - Materials and Procedures to Prepare a Serviced Engine for Installation ........ 104
—Operational Ground Check ................................................................................................... 104
—Engine Mount Inspection...................................................................................................... 105
—Return to Service Procedure ................................................................................................. 105

TEO-540-C1A Engine Maintenance Manual
Table of Contents © 2018 Avco Corporation. All Rights Reserved
Page x November 2018
TEO-540-C1A Engine Maintenance Manual
Subject Page
Engine Disassembly....................................................................................................... 72-05
—Engine Disassembly Procedure............................................................................................. 107
—Table 1 –Sequence of Engine Disassembly Procedure................................................... 107
Engine Assembly........................................................................................................... 72-10
—Corrosion Prevention ............................................................................................................. 113
—Painting the Engine and Engine Components........................................................................ 113
—Table 1 –Paint Stripping and Painting Guidelines for Components............................... 113
—Limits and Clearances............................................................................................................ 115
—Inspections ............................................................................................................................. 115
—Engine Assembly Procedure................................................................................................. 116
—Table 2 –Sequence of 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 Bearing Surface Inspection................................................................................. 151
—Table 1 - Crankshaft Undersize Codes ............................................................................ 151
—Bearing Shell Surface Inspection.......................................................................................... 152
—Gear Inspection..................................................................................................................... 152
—Screwed Fitting Inspection.................................................................................................... 152
—Camshaft Disassembly and Inspection ................................................................................. 153
—Connecting Rod Inspection................................................................................................... 154
—Connecting Rod Bushing Replacement ................................................................................ 158
—Connecting Rod Parallelism / Squareness Check................................................................. 159
—Tappet Inspection.................................................................................................................. 160

TEO-540-C1A Engine Maintenance Manual
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November 2018 Page xi
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Subject Page
Crankcase Maintenance (Cont.).................................................................................. 72-20
—Crankshaft Assembly............................................................................................................ 164
—Piston Cooling Nozzle Installation (if removed) .................................................................. 174
—Oil Plug Installation (if removed)......................................................................................... 174
—Tappet Assembly Installation................................................................................................ 175
—Crankshaft Bearing and O-Ring Installation......................................................................... 176
—Propeller Governor Drive Installation................................................................................... 177
—Table 2 - Thrust Washer Thickness ................................................................................. 177
—Camshaft Assembly and Installation..................................................................................... 179
—Crankshaft Installation.......................................................................................................... 182
—Table 3 - Slinger Clearance at 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 Housing Removal................................................................................................ 201
—Oil Pump Removal................................................................................................................ 202
—Oil Pump Installation............................................................................................................ 202
—Accessory Housing Installation ............................................................................................ 203
Cylinder Maintenance .................................................................................................. 72-30
—General.................................................................................................................................. 205
—Table 1 - Regularly Scheduled Cylinder Inspections...................................................... 205
—Visual Cylinder Inspection.................................................................................................... 205
—Cylinder Compression Check ............................................................................................... 206
—Table 2 - Summary of Cylinder Compression Check Results and Corrective Action.... 210
—Intercylinder Baffle Inspection ............................................................................................. 211

TEO-540-C1A Engine Maintenance Manual
Table of Contents © 2018 Avco Corporation. All Rights Reserved
Page xii November 2018
TEO-540-C1A Engine Maintenance Manual
Subject Page
Cylinder Maintenance (Cont.).....................................................................................72-30
—Cylinder Borescope Inspection............................................................................................. 212
—Table 3 - Borescope Inspection Steps, Results, and Corrective Action........................... 213
—Exhaust Valve and Guide Inspection.................................................................................... 213
—Cylinder Removal ................................................................................................................. 218
—Piston Removal..................................................................................................................... 223
—Cylinder Assembly Inspection.............................................................................................. 224
—Piston Inspection................................................................................................................... 230
—Piston Ring Replacement...................................................................................................... 234
—Piston Installation.................................................................................................................. 235
—Intake Valve Replacement .................................................................................................... 236
—Exhaust Valve Replacement ................................................................................................. 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 Inspection....................................................................................... 254
—Turbocharger Removal ......................................................................................................... 254
—Turbocharger Installation...................................................................................................... 256
—Exhaust Bypass Valve Replacement......................................................................................257
Lubrication System Maintenance................................................................................ 72-50
—Oil Pressure Adjustment ....................................................................................................... 259
—Oil System Inspection........................................................................................................... 259
—Oil Hose Inspection............................................................................................................... 259
—Oil Hose Replacement (General Instructions for Any Oil Hose) ......................................... 260
—Oil Filler Extension and Oil Level Gage Assembly Removal.............................................. 260

TEO-540-C1A Engine Maintenance Manual
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November 2018 Page xiii
TEO-540-C1A Engine Maintenance Manual
Subject Page
Lubrication System Maintenance (Cont.)...................................................................72-50
—Oil Filler Extension and Oil Level Gage Assembly Installation .......................................... 261
—Oil Pressure Relief Valve Removal...................................................................................... 261
—Oil Pressure Relief Valve Inspection.................................................................................... 261
—Oil Pressure Relief Vale Installation..................................................................................... 262
—Oil Cooler Bypass Valve Removal....................................................................................... 262
—Oil Cooler Bypass Valve Cleaning....................................................................................... 262
—Oil Cooler Bypass Valve Installation.................................................................................... 262
—Oil Sump Removal................................................................................................................ 263
—Oil Sump Inspection.............................................................................................................. 264
—Oil Sump Installation............................................................................................................ 264
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 System Includes Three Wiring Harnesses..................................................... 274
—Wiring Harness Connectors .................................................................................................. 275
—Table 2 –Wiring Harness Connector Guidelines ........................................................... 275
—Sensor Replacement Procedures........................................................................................... 282
—Table 3 - Sensor Replacement Procedures...................................................................... 282
—Engine-to-Firewall Wiring Harness Removal....................................................................... 293
—Engine-to-Firewall Wiring Harness Installation................................................................... 295
—Airframe Interface Wiring Harness Removal....................................................................... 296
—Airframe Interface Wiring Harness Installation.................................................................... 297

TEO-540-C1A Engine Maintenance Manual
Table of Contents © 2018 Avco Corporation. All Rights Reserved
Page xiv November 2018
TEO-540-C1A Engine Maintenance Manual
Subject Page
Electrical System Maintenance (Cont.)....................................................................... 72-70
—ECU Removal....................................................................................................................... 298
—ECU Installation.................................................................................................................... 298
—Power Box Removal ............................................................................................................. 299
—Power Box Installation.......................................................................................................... 299
—Permanent Magnet Alternator (PMA) Replacement............................................................. 299
—Starter Replacement.............................................................................................................. 300
—Starter Ring Gear Support Replacement............................................................................... 301
—Starter Ring Gear Replacement............................................................................................. 302
Induction 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 Checklist......................................................................................... 314
—Fuel Hose Replacement ........................................................................................................ 317
—Fuel Injector Rail Assembly Replacement............................................................................ 319
—Fuel Injector Replacement.................................................................................................... 321
—Fuel Injector Adapter Replacement ...................................................................................... 322
—Fuel Pump Filter Replacement.............................................................................................. 323
—Fuel Pump Replacement ....................................................................................................... 324
—Fuel Pressure Regulator Replacement .................................................................................. 325

TEO-540-C1A Engine Maintenance Manual
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November 2018 Page xv
TEO-540-C1A Engine Maintenance Manual
Subject Page
Engine Fuel and Control - Controlling....................................................................... 73-20
—(Electronic) Throttle Body Replacement.............................................................................. 329
—Operational Test of Throttle Body........................................................................................ 330
Ignition System Maintenance....................................................................................... 74-20
—Ignition Lead Removal.......................................................................................................... 331
—Table 1 - Ignition Leads................................................................................................... 330
—Spark Plugs ........................................................................................................................... 333
—Spark Plug Removal.............................................................................................................. 333
—Ignition Lead Inspection ....................................................................................................... 333
—Spark Plug Inspection ........................................................................................................... 334
—Table 2 - General 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
—Coil Box Installation..............................................................................................................342
Exhaust System Maintenance...................................................................................... 78-00
—Heat Shield Removal.............................................................................................................343
—50-Hour Exhaust System Inspection .....................................................................................344
—100-Hour Exhaust System Inspection....................................................................................344
—250-Hour Exhaust System Inspection....................................................................................344
—Heat Shield Installation..........................................................................................................347
—Exhaust System Removal ......................................................................................................347
—Exhaust System Installation...................................................................................................348

TEO-540-C1A Engine Maintenance Manual
Table of Contents © 2018 Avco Corporation. All Rights Reserved
Page xvi November 2018
TEO-540-C1A Engine Maintenance Manual
Subject Page
Appendix A....................................................................................................................
—Stud Replacement..................................................................................................................351
—Air Bleed Nozzle Installation ................................................................................................352
—Fin Stabilizer Installation.......................................................................................................352
Appendix B ....................................................................................................................
—Wiring 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
Appendix D....................................................................................................................
—Troubleshooting Guide Abbreviations and Acronyms..........................................................395
—Troubleshooting Guide..........................................................................................................398

TEO-540-C1A Engine Maintenance Manual
© 2018 Avco Corporation. All Rights Reserved Abbreviations and Acronyms
November 2018 Page xvii
TEO-540-C1A Engine Maintenance Manual
ABBREVIATIONS AND ACRONYMS
A
ADL
Data Logger
AMM
Airframe Manufacturer’s Manual
ATA
Air Transportation Association
C
C
Celsius
CAM
Camshaft Speed Sensor
CHT
Cylinder Head Temperature
CIP-P
Primary Compressor Inlet Pressure
CIP-S
Secondary Compressor Inlet Pressure
cm
Centimeter
CRANK
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 Penetrant Inspection
FPP
Fuel Pump Pressure Sensor
FOD
Foreign Object Debris
FPI
Fluorescent Penetrant Inspection
FPP
Fuel Pump Pressure Sensor
FST
Field Service Tool
ft.-lb.
Foot Pound (torque)
FUEL-P
Fuel (Rail) Pressure Sensor
FUEL-T
Fuel Temperature Sensor

TEO-540-C1A Engine Maintenance Manual
Abbreviations and Acronyms © 2018 Avco Corporation. All Rights Reserved
Page xviii November 2018
TEO-540-C1A Engine Maintenance Manual
ABBREVIATIONS AND ACRONYMS (CONT.)
I
ICA
Instructions for Continued Airworthiness
ID
Identification; Inside/Inner Diameter
in.-lb.
Inch Pound (torque)
in.
Inch, inches
In-Hg
Inches of Mercury
IOM
Engine Installation and Operation Manual
K
KNOCK
Knock Sensor
kPa
Kilopascal
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 Equipment Manufacturer
OIL-P
Oil Pressure Sensor
OIL-T
Oil Temperature Sensor
P
PMA
Permanent Magnet Alternator or Parts Manufacturer Approval
P/N
Part Number
POH
Pilot’s Operating Handbook
ppm
Parts per Million
psi
Pounds per square inch