TEO-540-A1A Engine Maintenance Manual

TEO-540-A1A Engine Maintenance Manual

2. Spark Plugs
Two long reach spark plugs (Figure 5) are installed on each cylinder head (Figure 2) of the
engine for a total of 12 spark plugs per engine.

Figure 5
Long Reach Spark Plug & Location
NOTICE: Typically, engines with long reach spark plugs are identified by yellow paint on the
cylinder fins between the spark plug hole and the rocker covers where shown in
Figure 5.
Refer to the TEO-540-A1A Illustrated Parts Catalog to identify the correct spark plug approved
for use in these engines.
3. Spark Plug Removal
A. Make sure that the battery is disconnected from the engine.
B. Hold the ferrule and loosen the spark plug nut and disconnect it from the ignition 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 gasket from the spark plug.
4. Ignition Lead Inspection
NOTICE: The ignition leads are an all-weather, shielded wire constructed with over-braid.
A. Examine spark plug ignition leads (Figures 1 and 2) and spark plug ceramics for corrosion
and deposits.
B. Examine each ignition lead for chafing, insulation breakdown, frayed wiring, deterioration,
heat damage, wear, and cracking. Replace the harness if any lead shows chafing, cracks, or
wear, frayed wiring, or damage.
C. Examine the ignition lead connections. Make sure the ignition lead connections (Table 1) are
secure.
D. Make sure the ignition lead mounting clamps are tight.

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TEO-540-A1A Engine Maintenance Manual
5. Spark Plug Inspection
NOTICE: Corrosion and deposits are evidence of leaking spark plugs or incorrect cleaning of
the spark plugs or connector ends.
A. Remove the spark plug connector nuts.
B. Examine each spark plug and ceramics for chafing, corrosion, wear, and cracking during
every inspection. Replace any worn, cracked or corroded spark plug with a new spark plug.
NOTICE: The general guidelines in Table 2 identify acceptable and unacceptable spark plugs.
The figures in Table 2 show the condition of the fine wire ground and center
electrodes as well as the level of wear indication and condition of the spark plug.
Refer to your spark plug manufacturer’s manual for specific instructions.
Table 2
General Spark Plug Wear/Replacement Guidelines
Condition of Fine Wire Condition of
Spark Plug Findings Ground Electrode on Center Electrode What to do
Spark Plug on Spark plug
Acceptable Insulator tip gray, Clean, set the spark
Spark Plugs tan or light brown plug gap and install
No ash deposits the spark plug per
Electrodes intact, applicable sections
not burnt or eroded in this chapter and
in Chapter 05-30.

Partially Ash deposits Discard the spark

Worn Spark Electrode burnt plug and replace
Plugs and/or eroded to with a serviceable
less than half of the spark plug.
original thickness
More voltage has
been necessary to
fire the spark plugs
Worn Spark Erosion of center Look for excessive
Plugs and ground heat sources.
electrode Discard the spark
Extensive necking plug and replace
of the fine wire with a serviceable
ground electrode spark plug.

C. To be acceptable, the spark plug must not have any of the following:
(1) Fine wire plugs with loose center or ground electrodes.
(2) Electrodes that show signs of metal or impact damage.
(3) Massive electrode plugs with copper run-out of the center electrode.
(4) Ceramic core nose with a cracked or crazed rough surface.

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TEO-540-A1A Engine Maintenance Manual
TEO-540-A1A Engine Maintenance Manual
D. Measure the spark plug gap (identified by the spark plug manufacturer) to make sure it is at
the correct tolerance per the spark plug manufacturer’s instruction. Reset the spark plug gap
if it is not correct. Refer to the "Spark Plug Gap Setting" procedure in this chapter.
6. Spark Plug Fouling
A. Lead deposits can collect on the spark plug electrodes when the engine operates at lower-
than-specified temperatures with fuel-rich mixtures (fuel-rich mixtures do not enable
vaporization of lead in aviation gas). These deposits can cause misfiring.
B. Recommendations to prevent spark plug fouling:
• If the engine is approved for use with unleaded fuel per Appendix A in the TEO-540-A1A
Engine Installation and Operation Manual, use unleaded fuel after purging the fuel
system.
• Rotate top and bottom spark plugs every 100 operating hours or annually – refer to the
“Spark Plug Rotation” procedure in this chapter.
• Operate the engine between 1000 and 1200 rpm after engine start and during warm-up.
(At these speeds the spark plug core temperatures are sufficiently hot to activate the lead
scavenging agents to prevent lead deposits on the spark plugs and exhaust valve stems.)
• 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 rpm until operating
temperatures are stable and EGTs drop below 1100°F (593°C). Then increase engine
speed to 1800 rpm for 15 to 20 seconds. Then decrease engine speed to between 1000 and
1200 rpm before engine shutdown.
7. Spark Plug Port Seal Inspection
NOTICE: This inspection is usually done to complete the check of the Heli-coil® spark plug insert
in the cylinder head.
A. Disconnect the battery and remove the ignitions leads from all spark plugs.
B. Apply a soap solution to the spark plug seating area of the cylinder head.
C. Turn the propeller/crankshaft by hand to move the piston, in the cylinder to be inspected, to
top dead center of the compression stroke.
D. Look for bubbles around the spark plug. If bubbles are seen, replace the Heli-coils®. Replace
all loose or damaged spark plug Heli-coil® inserts with oversize inserts per instructions in
Chapter 72-30.
E. Examine the spark plugs (if not already done). Refer to the section “Spark Plug Inspection”
procedure in this chapter.
F. Examine the surface of the cylinder (covered with soap) for cracks. Refer to the “Visual
Cylinder Inspection Procedure" in Chapter 72-30.

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TEO-540-A1A Engine Maintenance Manual
8. Spark Plug Cleaning
Refer to the spark plug manufacturer’s cleaning instructions.
9. Spark Plug Gap Setting
A. Make sure the “Spark Plug Cleaning” procedure in Chapter 05-30 was completed and that the
inside of the spark plug barrel is clean and dry and does not have any residue from cleaning.
NOTICE: Serviceable spark plugs are to be re-installed, otherwise use new replacement long-
reach spark plugs per the TEO-540-A1A Illustrated Parts Catalog.
B. Before spark plug installation set the spark plug gap in accordance with the spark plug
manufacturer’s instructions.
C. Reset and test the spark plugs in accordance with the spark plug manufacturer’s instructions.
10. Spark Plug Rotation
NOTICE: As part of routine service, rotate spark plugs in different locations per Table 3 every 100
hours of engine operation 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.
USE CARE TO PREVENT THE COPPER-BASED ANTI-SEIZE FROM
GETTING ON THE SPARK PLUG ELECTRODE OR IN THE COMBUSTION
CHAMBER.
DO NOT APPLY A GRAPHITE-BASED COMPOUND TO THE SPARK
PLUG THREADS.
D. Apply Copper-Based Anti-Seize (Figure 6) or engine oil to
the threads of each spark plug (starting two full threads from
the electrode.)
E. Rotate acceptable spark plugs - move the bottom spark plugs
to the upper position; move the upper spark plugs to the
bottom position, per the rotation scheme in Table 3.
Figure 6
F. Refer to the “Spark Plug Installation” procedure in this
Copper-Based Anti-Seize
chapter.
Applied to Spark Plug Threads
Table 3
Spark Plug Rotation Scheme
#1 Top with #6 Bottom
#2 Top with #5 Bottom
#3 Top with #4 Bottom
#4 Top with #3 Bottom
#5 Top with #2 Bottom
#6 Top with #1 Bottom

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TEO-540-A1A Engine Maintenance Manual
11. Spark Plug Installation
NOTICE: Complete the “Spark Plug Gap Setting” procedure and as necessary the “Spark Plug
Gap Rotation” procedure in this chapter before spark plug installation.
A. If not already done, apply C5-A Copper-Based Anti-Seize (Figure 6) or engine oil to the
threads of each spark plug (starting two full threads from the electrode.)
CAUTION FAILURE TO INSTALL A NEW SPARK PLUG GASKET ANY TIME A
SPARK PLUG IS INSTALLED CAN RESULT IN INCOMPLETE
SEALING OF THE COMBUSTION CHAMBER, LOSS OF SPARK PLUG
HEAT TRANSFER, SPARK PLUG OVERHEATING, POSSIBLE
REIGNITION/DETONATION, AND INTERNAL ENGINE DAMAGE.
CAUTION NEVER INSTALL A SPARK PLUG THAT HAS BEEN DROPPED ON
THE FLOOR.
B. Install a new spark plug gasket with the spark plug. A new gasket must be installed whether
the spark plug is new or is acceptable and being reused.
C. Install a spark plug in the cylinder top and bottom (Figure 2) according to the manufacturer’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 MAKE SURE THE BATTERY HAS BEEN DISCONNECTED FROM THE
ENGINE.
NOTICE: If a new ignition lead (Figure 7) is to be installed, refer to the TEO-540-A1A Illustrated
Parts Catalog to identify the correct part number of the replacement ignition lead.
A. Examine the ignition leads as per the procedure "Ignition Lead Inspection" in this chapter.
NOTICE: The coil box lid is marked with a letter and number for each ignition lead
identifying a spark plug on each respective cylinder. An ignition lead position
marked "T1" identifies the top spark plug on cylinder #1 to which that ignition lead
is to be connected. An ignition lead position marked "B4" identifies the bottom
spark plug on cylinder #4 to which that ignition lead is to be connected.
B. Apply C5A Copper Based Anti-Seize or
equivalent to the threads (Figure 7) on the
coil box end of the ignition lead.

Figure 7
Ignition Lead

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