Operator’s Manual

Lycoming

TIO-541 Series

Approved by FAA

3rd Edition Part No. 60297-13

December 2007
652 Oliver Street
Williamsport, PA. 17701 U.S.A.
570/323-6181
TIO-541 Series Operator’s Manual
Lycoming Part Number: 60297-13

©2007 by Lycoming. All rights reserved.

Lycoming and “Powered by Lycoming” are trademarks or registered trademarks of
Lycoming.

All brand and product names referenced in this publication are trademarks or registered
trademarks of their respective companies.

For additional information:

Mailing address:

Lycoming Engines
652 Oliver Street
Williamsport, PA 17701 U.S.A.

Phone:

Factory: 570-323-6181
Sales Department: 570-327-7268
Fax: 570-327-7101

Lycoming’s regular business hours are Monday through Friday from 8:00 AM
through 5:00 PM Eastern Time (-5 GMT)

Visit us on the World Wide Web at:

http://www.lycoming.com
 LYCOMING OPERATOR’S MANUAL

ATTENTION

OWNERS, OPERATORS AND MAINTENANCE PERSONNEL

This operator’s manual contains a description of the engine, its specifications, and detailed information on
how to operate and maintain it. Such maintenance procedures that may be required in conjunction with
periodic inspections are also included. This manual is intended for use by owners, pilots and maintenance
personnel responsible for care of Lycoming powered aircraft. Modifications and repair procedures are
contained in Lycoming overhaul manuals; maintenance personnel should refer to these for such procedures.

SAFETY WARNING

Neglecting to follow the operating instructions and to carry out periodic maintenance procedures can result
in poor engine performance and power loss. Also, if power and speed limitations specified in this manual
are exceeded, for any reason, damage to the engine and personal injury can happen. Consult your local
FAA approved maintenance facility.

SERVICE BULLETINS, INSTRUCTIONS, AND LETTERS

Although the information contained in this manual is up-to-date at time of publication, users are urged to
keep abreast of later information through Lycoming Service Bulletins, Instructions and Service Letters,
which are available for all Lycoming distributors or, from the factory by subscription. Consult the latest
revision of Service Letter No. L114 for subscription information.

SPECIAL NOTE

The illustrations, pictures and drawings shown in this publication are typical of the subject matter they
portray; in no instance are they to be interpreted as examples of any specific engine, equipment or part
thereof.

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 LYCOMING OPERATOR’S MANUAL

IMPORTANT SAFETY NOTICE

Proper service and repair is essential to increase the safe, reliable operation of all aircraft engines. The
service procedures recommended by Lycoming are effective methods for performing service operations.
Some of these service operations require the sue of tools specially designed for the task. These special tools
must be used when and as recommended.

It is important to note that most Lycoming publications contain various Warnings and Cautions which
must be carefully read in order to minimize the risk of personal injury or the use of improper service
methods that may damage the engine or render it unsafe.

It is also important to understand that these Warnings and Cautions are not all inclusive. Lycoming could
not possibly know, evaluate or advise the service trade of all conceivable ways in which service might be
done or of the possible hazardous consequences that may be involved. Accordingly, anyone who uses a
service procedure must first satisfy themselves thoroughly that neither their safety nor aircraft safety will be
jeopardized by the service procedure they select.

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 LYCOMING OPERATOR’S MANUAL

TABLE OF CONTENTS

Page

SECTION 1 DESCRIPTION 1-1

SECTION 2 SPECIFICATIONS 2-1

SECTION 3 OPERATING INSTRUCTIONS 3-1

SECTION 4 PERIODIC INSPECTIONS 4-1

SECTION 5 MAINTENANCE PROCEDURES 5-1

SECTION 6 TROUBLE-SHOOTING 6-1

SECTION 7 INSTALLATION AND STORAGE 7-1

SECTION 8 TABLES 8-1

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 LYCOMING OPERATOR’S MANUAL

¾ Left Front View – TIO-541-E1B4

Right Side View – TIO-541-A1A

vi
 LYCOMNG OPERATOR’S MANUAL

¾ Right Rear View – TIO-541-E1B4

WARNING

THESE ENGINES ARE EQUIPPED WITH A DYNAMIC COUNTERWEIGHT SYSTEM AND

MUST BE OPERATED ACCORDINGLY; AVOID HIGH ENGINE SPEED, LOW
MANIFOLD PRESSURE OPERATION. USE A SMOOTH STEADY MOVEMENT OF THE
THROTTLE (AVOID RAPID OPENING AND CLOSING). IF THIS WARNING IS NOT
HEEDED, THERE COULD BE SEVERE DAMAGE TO THE COUNTERWEIGHTS,
ROLLERS AND BUSHINGS.

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 LYCOMING OPERATOR’S MANUAL

SECTION 1
DESCRIPTION

Page

General.......................................................................................................................................................... 1-1

Cylinders....................................................................................................................................................... 1-1

Valve Operating Mechanism ...................................................................................................................... 1-1

Crankshaft .................................................................................................................................................... 1-1

Crankcase ..................................................................................................................................................... 1-1

Oil Sump ....................................................................................................................................................... 1-1

Connecting Rods .......................................................................................................................................... 1-1

Pistons ........................................................................................................................................................... 1-2

Gears ............................................................................................................................................................. 1-2

Cooling System ............................................................................................................................................. 1-2

Lubrication System...................................................................................................................................... 1-2

Induction System.......................................................................................................................................... 1-2

Turbocharger System .................................................................................................................................. 1-2

Ignition System............................................................................................................................................. 1-2

Propeller Governor Drives.......................................................................................................................... 1-2

Accessory Drives .......................................................................................................................................... 1-2

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LYCOMING OPERATOR’S MANUAL SECTION 1
TIO-541 SERIES DESCRIPTION

SECTION 1

DESCRIPTION

General – The Lycoming TIO-541 aircraft engine is a six cylinder, direct drive, horizontally opposed, wet
sump, fuel injected, turbocharged, air-cooled model with side mounted accessories and incorporating piston
cooling oil jets in the crankcase.

In referring to the location of the various engine components, the parts will be described in their
relationship to the engine as installed in the airframe. Thus the power take-off section will be considered the
front and the sump section will be considered the bottom. References to the left and right sides of the engine
are made with the observer facing the rear of the engine. Thus the front cylinder on the left bank is number 1
and the rear cylinder number 5. The front cylinder on the right bank is number 2 and the rear cylinder is
number 6. The direction of rotation for the accessory drives is determined by the observer when facing the
accessory mounting pad.

Cylinders – The cylinders are of air-cooled construction with the two major parts, head and barrel, screwed
and shrunk together. The heads are made from an aluminum casting with a fully machined combustion
chamber. The cylinder barrels are machined from chrome nickel molybdenum steel forgings with deep
integral cooling fins. The interior of the barrel is nitrided; requiring the use of chrome plated piston rings.

Rocker shaft bearing supports and the rocker box housings are cast integrally with the cylinder head. The
intake and exhaust valves are angled. The intake port is on the top and the exhaust port on the bottom of the
cylinder. Long reach spark plugs are employed.

Valve Operating Mechanism – The camshaft is located parallel to and below the crankshaft and operates in
aluminum bearings. The camshaft actuates the valves by means of hydraulic lifters, which automatically
keep the valve clearance at zero. The valve rockers are supported on full floating steel shafts. The valve
springs bear against hardened steel seats.

Crankshaft – The crankshaft is made from a chrome nickel molybdenum steel forging. All bearing journal
surfaces are nitrided. The crankshaft is fitted with pendulum type dynamic counterweights.

Crankcase – The crankcase consists of two reinforced aluminum alloy castings divided vertically at the
center line of the engine and fastened together by means of thru bolts and nuts. The mating surfaces of the
crankcase are joined without the use of a gasket, and the main bearing bores are machined for use of
precision type main bearing inserts.

Oil Sump – The oil sump fastens to the bottom of the crankcase. It incorporates two oil drain plugs, the oil
suction screen housing, and a boss for mounting the fuel drain manifold assembly.

Connecting Rods – The connecting rods are made in the form of “H” sections from alloy steel forgings.
They have replaceable bearing inserts in the crankshaft ends and bronze bushings in the piston ends. The
bearing caps on the crankshaft ends of the rods are retained by means of two bolts and nuts through each
cap.

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SECTION 1 LYCOMING OPERATOR’S MANUAL
DESCRIPTION TIO-541 SERIES

Pistons – The pistons are machined from an aluminum alloy. Two compression rings and an oil regulating
ring are located above the piston pin. The pistons are equipped with full floating type pins with a plug
located at each end of the pin.

Gears – The gears are of conventional type and are precision machined. They are hardened to insure long
life and satisfactory operating qualities.

Cooling System – The air pressure cooling system is actuated by the forward speed of the aircraft. Baffles
are provided to build up a pressure between the cowling and the cylinders, thus forcing the air through the
cylinder fins. The air is then exhausted through gills usually located at the rear of the engine cowling.

Lubrication System – The lubrication system is of the pressure wet sump type.

Induction System – This engine employs a Bendix RSA type fuel injection system.

The fuel injection system is based on the principle of measuring air flow and uses the air flow signal in a
stem type regulator to convert the air force into a fuel force. This fuel force (fuel pressure differential) when
applied across the fuel metering section, makes fuel flow proportional to air flow. A manual mixture control
and idle cut-off are provided.

Turbocharger System – The turbocharger system is mounted as an integral part of the engine. Its turbine
utilizes the engine exhaust gases to drive a compressor, which furnishes air to the engine induction system
and air for pressurized cabins.

The variable pressure controller senses the compressor discharge pressure (deck pressure) and in turn
regulates the oil pressure, which controls the position of the exhaust bypass valve located on the engine
exhaust. The desired compressor discharge pressure is determined by positioning the throttle control, which
is linked to the controller cam. Engine oil pressure is utilized as the “muscle” for this control system.

The variable pressure controller employed on the “A” series has two settings, the maximum boost setting
and the minimum boost setting. The maximum setting is 37 in. hg. ± 0.5, the minimum setting is 24 – 26 in.
hg.

The action of the turbocharger control system is automatic and modulates continuously as engine power,
speed and altitude are varied. Bleed air to the cabin, on models –A1A, -E1A4 and –E1C4, is controlled by a
sonic nozzle that limits the flow of air to the cabin.

Ignition System – Dual ignition is furnished by two Scintilla –1200 series magnetos. The S6LN-1208
magneto is a retard breaker magneto providing a fixed retard and a long duration spark for easier starting.
The S6RN-1209 is a conventional magneto, which is grounded out at the time the engine is started. A source
of DC power and a starting vibrator are required to complete the installation. The –1200 series magnetos
incorporate an integral feed-thru capacitor and require no external noise filter in the ground leads.

Propeller Governor Drive – A propeller governor drive is furnished as standard equipment. The propeller
governor mounting pad is located on the lower right front side of the crankcase.

Accessory Drives – The following accessory drives are furnished as standard equipment: starter, alternator,
propeller governor, vacuum pump, hydraulic pump, tachometer and fuel pump. The “E” series incorporates
a Freon compressor drive that may be used for air conditioning.

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 LYCOMING OPERATOR’S MANUAL

SECTION 2
SPECIFICATIONS

Page

Specifications – TIO-541-E Series .............................................................................................................. 2-2

Specifications – TIO-541-A Series.............................................................................................................. 2-3

Detail Weights – TIO-541-A Series

Engine (Standard)..................................................................................................................................... 2-4

Engine Installation Standard Parts......................................................................................................... 2-4

Accessories, Drives and Optional Parts .................................................................................................. 2-4

Detail Weights – TIO-541-E1A4, -E1B4, -E1C4

Engine (Standard)..................................................................................................................................... 2-5

Detail Weights – TIO-541-E1D4

Engine (Standard)..................................................................................................................................... 2-6

Detail Weights – TIO-541-E Series

Engine Installation Standard Parts......................................................................................................... 2-6

Accessories, Drives and Optional Parts .................................................................................................. 2-6

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LYCOMING OPERATOR’S MANUAL SECTION 2
TIO-541 SERIES SPECIFICATIONS

SECTION 2

SPECIFICATIONS

NOTE

The model specifications shown on the following pages of this section are divided according
to model designation. When differences among models can be clearly stated, the
specifications of more than one model are combined in a single group; otherwise, each
model has its specifications listed separately. Also, as additional models are added to this
series, new specification pages containing data pertinent to the new models will be added.

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SECTION 2 LYCOMING OPERATOR’S MANUAL
SPECIFICAIONS TIO-541 SERIES

SPECIFICATIONS

TIO-541-E SERIES

FAA Type Certificate ..............................................................................................................................E10EA

Rated horsepower, RPM, Alt. ......................................................................................... 380 @ 2900/15,000 ft.
Performance Cruise horsepower, RPM, Alt. .................................................................. 300 @ 2750/21,000 ft.
Economy Cruise, horsepower, RPM................................................................................................247 @ 2650
Bore, inches.................................................................................................................................................5.125
Stroke, inches..............................................................................................................................................4.375
Displacement, cubic inches.........................................................................................................................541.5
Compression ratio ....................................................................................................................................... 7.3:1
Fuel Injector, Bendix type...............................................................................................................RSA-10DB1
Magnetos, (1) Scintilla (right).......................................................................................................... S6RN-1209
Magnetos, (1) Scintilla (left).............................................................................................................S6LN-1208
Firing order .......................................................................................................................................1-4-5-2-3-6
Spark occurs, degrees BTC..............................................................................................................................20
Valve rocker clearance (hydraulic liters collapsed)............................................................................. .040-.105
Dimensions:
Height, inches ..........................................................................................................................................25.17
Width, inches ...........................................................................................................................................35.66
Length, inches ..........................................................................................................................................52.07

Accessory Drive Drive Ratio *Direction of Rotation

Starter 16.556:1 Counterclockwise

Alternator 3.250:1 Clockwise
Optional Generator Drive 1.910:1 Clockwise
Optional Generator Drive 2.500:1 Clockwise
Vacuum Pump 1.000:1 Clockwise
Hydraulic Pump 1.000:1 Counterclockwise
Tachometer 0.500:1 Counterclockwise
Propeller Governor 0.895:1 Counterclockwise
Fuel Pump 1.000:1 Counterclockwise

* - Facing drive pad.

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LYCOMING OPERATOR’S MANUAL SECTION 2
TIO-541 SERIES SPECIFICATIONS

SPECIFICATIONS (CONT.)

TIO-541-A SERIES

FAA Type Certificate ..............................................................................................................................E10EA

Rated horsepower, RPM, Alt. ......................................................................................... 310 @ 2575/15,000 ft.
Performance Cruise (75% rated horsepower), Alt........................................................................ 230/25,000 ft.
Economy Cruise (65% rated horsepower) .....................................................................................................185
Bore, inches.................................................................................................................................................5.125
Stroke, inches..............................................................................................................................................4.375
Displacement, cubic inches.........................................................................................................................541.5
Compression ratio ....................................................................................................................................... 7.3:1
Fuel Injector, Bendix type...............................................................................................................RSA-10AD1
Magnetos, (1) Scintilla (right).......................................................................................................... S6RN-1209
Magnetos, (1) Scintilla (left).............................................................................................................S6LN-1208
Firing order .......................................................................................................................................1-4-5-2-3-6
Spark occurs, degrees BTC..............................................................................................................................20
Valve rocker clearance (hydraulic lifters collapsed) ........................................................................... .040-.105
Dimensions:
Height, inches ..........................................................................................................................................21.38
Width, inches ...........................................................................................................................................34.25
Length, inches ..........................................................................................................................................49.09

Accessory Drive Drive Ratio *Direction of Rotation

Starter 16.556:1 Counterclockwise

Alternator 3.250:1 Clockwise
Optional Generator Drive 1.910:1 Clockwise
Optional Generator Drive 2.500:1 Clockwise
Vacuum Pump 1.500:1 Clockwise
Hydraulic Pump 1.500:1 Counterclockwise
Tachometer 0.500:1 Counterclockwise
Propeller Governor 0.895:1 Counterclockwise
Fuel Pump 1.000:1 Counterclockwise

* - Facing drive pad.

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SECTION 2 LYCOMING OPERATOR’S MANUAL
SPECIFICAIONS TIO-541 SERIES

DETAIL WEIGHTS

TIO-541-A SERIES

1. ENGINE (STANDARD)

Basic engine ..............................................................................................................................................421.32

Turbocharger, AiResearch Model T1823 ...................................................................................................48.25
Mounting bracket, exhaust manifold, controller, oil lines and baffles .......................................................36.50
Fuel injector, Bendix RSA-10AD1...............................................................................................................8.00
Magneto, Scintilla S6LN-1208 .....................................................................................................................5.85
Magneto, Scintilla S6RN-1209.....................................................................................................................5.75
Oil cooler ......................................................................................................................................................4.50
Oil filter and adapter .....................................................................................................................................2.50
Spark plugs, shielded ....................................................................................................................................3.00
Ignition system, shielded ..............................................................................................................................5.40
Starter and alternator drive............................................................................................................................6.53
Starter, 3.38:1, geared, Prestolite with Bendix unit ....................................................................................16.90
Alternator, Delco-Remy 12V., 70A., with mounting bracket.....................................................................13.00
Intercylinder cooling baffles .........................................................................................................................1.50

Standard Engine Dry Weight (Pounds).....................................................................................................579.00

2. ENGINE INSTALLATION STANDARD PARTS

Starter switch, magnetic................................................................................................................................1.16

Transistor voltage regulator, 12V. ................................................................................................................1.25
Overvoltage relay, 12V....................................................................................................................................85

Weight of Installation Parts ..........................................................................................................................3.26

3. ACCESSORIES, DRIVES AND OPTIONAL PARTS

Alternator, Prestolite, 12V., 40A., with bracket .........................................................................................13.00

24V., 50A., with bracket.........................................................................................13.00
Starter, Prestolite, 24V................................................................................................................................16.90
Cylinder Base Thermocouples......................................................................................................................0.16
Cylinder Head Thermocouples, Bayonet Type.............................................................................................0.59
Rear Dynafocal Mounting Brackets..............................................................................................................9.50
Bed-Type Mounting Brackets.......................................................................................................................4.60

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LYCOMING OPERATOR’S MANUAL SECTION 2
TIO-541 SERIES SPECIFICATIONS

DETAIL WEIGHTS (CONT.)

TIO-541-E1A4, -E1B4

1. ENGINE (STANDARD)

Basic engine ..............................................................................................................................................452.51

Turbocharger, AiResearch Model T8123 ...................................................................................................48.25
Mounting bracket, exhaust manifold, exhaust bypass valve, controller, oil lines and baffles....................43.50
Fuel injector, Bendix RSA-10DB1 ...............................................................................................................8.00
Magneto, Scintilla S6LN-1208 .....................................................................................................................5.85
Magneto, Scintilla S6RN-1209.....................................................................................................................5.75
Oil cooler ....................................................................................................................................................10.50
Oil filter and adapter .....................................................................................................................................3.50
Spark plugs, shielded ....................................................................................................................................3.00
Ignition system, shielded ..............................................................................................................................3.86
Starter and alternator drive............................................................................................................................6.53
Starter, 3.38:1 geared, Prestolite with mounting bracket............................................................................16.90
Alternator, Prestolite 12V., 40A., with mounting bracket ..........................................................................13.00
Intercylinder cooling baffles .........................................................................................................................1.50
Compressor drive ..........................................................................................................................................2.35

Standard Engine Dry Weight (Pounds).....................................................................................................625.00

TIO-541-E1C4

Basic engine ..............................................................................................................................................453.76

Turbocharger, AiResearch Model T1879 ...................................................................................................40.00
Mounting bracket, exhaust manifold, exhaust bypass valve, controller, oil lines and baffles....................41.50
Fuel injector, Bendix RSA-10DB1 ...............................................................................................................8.00
Magneto, Scintilla S6LN-1208 .....................................................................................................................5.85
Magneto, Scintilla S6RN-1209.....................................................................................................................5.75
Oil cooler, de-congealing............................................................................................................................10.50
Oil filter and adapter .....................................................................................................................................3.50
Spark plugs, shielded ....................................................................................................................................3.00
Ignition system, shielded ..............................................................................................................................3.86
Starter and alternator drive............................................................................................................................6.53
Starter, 3/38:1 geared, Prestolite with Bendix unit .....................................................................................16.90
Alternator, Prestolite 12V., 40A., with mounting bracket ..........................................................................13.00
Intercylinder cooling baffles .........................................................................................................................1.50
Compressor drive ..........................................................................................................................................2.35

Standard Engine Dry Weight (Pounds).....................................................................................................616.00

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SECTION 2 LYCOMING OPERATOR’S MANUAL
SPECIFICATIONS TIO-541 SERIES

DETAIL WEIGHTS (CONT.)

TIO-541-E1D4

1. ENGINE (STANDARD) (CONT.)

Basic engine ..............................................................................................................................................451.76

Turbocharger, AiResearch Model T1879 ...................................................................................................40.00
Mounting bracket, exhaust manifold, exhaust bypass valve, controller, oil lines and baffles....................41.50
Fuel injector, Bendix RSA-10DB1 ...............................................................................................................8.00
Magneto, Scintilla S6LN-1208 .....................................................................................................................5.85
Magneto, Scintilla S6RN-1209.....................................................................................................................5.75
Oil cooler, de-congealing............................................................................................................................10.50
Oil filter and adapter .....................................................................................................................................3.50
Spark plugs, shielded ....................................................................................................................................3.00
Ignition system, shielded ..............................................................................................................................3.86
Starter and alternator drive............................................................................................................................6.53
Starter, 3/38:1 geared, Prestolite with Bendix unit .....................................................................................16.90
Alternator, Prestolite 12V., 40A., with mounting bracket ..........................................................................13.00
Intercylinder cooling baffles .........................................................................................................................1.50
Compressor drive ..........................................................................................................................................2.35

Standard Engine Dry Weight (Pounds).....................................................................................................614.00

2. ENGINE INSTALLATION STANDARD PARTS

TIO-541-E SERIES

Starter switch, magnetic................................................................................................................................1.16

Transistor voltage regulator ..........................................................................................................................1.25
Overvoltage relay, 12V.................................................................................................................................0.85

Weight of Installation Parts ..........................................................................................................................3.26

3. ACCESSORIES, DRIVES AND OPTIONAL PARTS

TIO-541-E SERIES

Alternator, Prestolite, 12V., 70A, with bracket ..........................................................................................13.00

24V., 50A, with bracket..........................................................................................13.00
24V., 100A., with bracket.......................................................................................22.00
Starter and alternator drive (Ford) ................................................................................................................6.53
Starter and generator drive (Lear-Siegler) ....................................................................................................7.48
Alternator brackets (Ford).............................................................................................................................0.85
Generator brackets (Lear-Siegler).................................................................................................................1.25
Starter, Prestolite, 24V................................................................................................................................16.90
Cylinder Base Thermocouples......................................................................................................................0.16

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LYCOMING OPERATOR’S MANUAL SECTION 2
TIO-541 SERIES SPECIFICATIONS

DETAIL WEIGHTS (CONT.)

3. ACCESSORIES, DRIVE AND OPTIONAL PARTS (CONT.)

TIO-541-E SERIES (CONT.)

Cylinder Head Thermocouples, Bayonet Type.............................................................................................0.59

Rear Dynafocal Mounting Brackets..............................................................................................................9.50
Bed-Type Mounting Brackets.......................................................................................................................4.60
Transistor voltage regulator, 24V. ................................................................................................................1.25
Overvoltage regulator, 24V. .........................................................................................................................0.85
Turbocharger blanket ....................................................................................................................................1.00

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 LYCOMING OPERATOR’S MANUAL

SECTION 3
OPERATING INSTRUCTIONS

Page

General.......................................................................................................................................................... 3-1

Care of New Engine ..................................................................................................................................... 3-1

Fuel ................................................................................................................................................................ 3-1

Oil Change .................................................................................................................................................... 3-1

Prestarting Procedure ................................................................................................................................. 3-1

Starting Procedure....................................................................................................................................... 3-1

Cold Weather Starting ................................................................................................................................ 3-2

Ground Running and Warm-Up ................................................................................................................ 3-2

Ground Check .............................................................................................................................................. 3-3

Operation in Flight ...................................................................................................................................... 3-3

Engine Shut-Down ....................................................................................................................................... 3-5

Engine Flight Chart ..................................................................................................................................... 3-5

Performance Curves .................................................................................................................................... 3-7

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LYCOMING OPERATOR’S MANUAL SECTION 3
TIO-541 SERIES OPERATING INSTRUCTIONS

SECTION 3

OPERATING INSTRUCTIONS

1. General. Close adherence to these instructions will greatly contribute to long life, economy and
satisfactory operation of the engine.

NOTE

YOUR ATTENTION IS DIRECTED IN PARTICULAR TO THE WARRANTIES THAT

APPEAR IN THE FRONT OF THIS MANUAL REGARDING ENGINE SPEED, THE USE
OF SPECIFIED FUELS, LUBRICANTS, REPAIRS AND ALTERATIONS. PERHAPS NO
OTHER ITEM OF ENGINE OPERATION AND MAINTENANCE CONTRIBUTES QUITE
SO MUCH TO SATISFACTORY PERFORMANCE AND LONG LIFE AS THE CONSTANT
USE OF CORRECT GRADES OF FUEL AND OIL, CORRECT ENGINE TIMING AND
FLYING THE AIRPLANE AT ALL TIMES WITHIN THE SPEED AND POWER RANGE
SPECIFIED FOR THE ENGINE. DO NOT FORGET THAT VIOLATION OF THE
OPERATION AND MAINTENANCE SPECIFICATIONS FOR YOUR ENGINE WILL NOT
ONLY VOID YOUR WARRANTY, BUT WILL SHORTEN THE LIFE OF YOUR ENGINE
AFTER THE WARRANTY PERIOD HAS PASSED.

Care of New Engine – New engines have been carefully run-in by Lycoming and therefore no further break-
in is necessary insofar as operation is concerned; however, new or newly overhauled engines should be
operated on multi-viscosity ashless dispersant oil conforming to Specification MIL-L-22581 or an FAA or
Lycoming approved synthetic lubricant. Oil grades are listed in the Flight Chart, part 9 of this section. The
latest revision of Service Instruction No. 1014 contains complete lubricating oil recommendations.

Fuel – The TIO-541 series engine is designed to operate on 100/130 (minimum) octane aviation grade fuel.

NOTE

Under no circumstances should aviation fuel of a lower octane than specified nor automotive
fuel (regardless of octane) be used.

Oil Change – It is recommended that the lubrication oil be changed every 50 hours, unless a full flow oil
filter in installed. In that case, this period can be extended as stated in latest revision of Lycoming Special
Service Publication No. SSP-885.

2. PRESTARTING ITEMS OF MAINTENANCE. Before starting the aircraft engine for the first flight of the
day, there are several items of maintenance inspection that should be performed. These are described in
Section 4 under Daily Pre-Flight Inspection. They must be observed before the engine is started.

3. STARTING PROCEDURE.

a. Set propeller governor control lever in “Full RPM” position.

b. Turn fuel valve on.

c. Mixture control in “Idle Cut-Off”.

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SECTION 3 LYCOMING OPERATOR’S MANUAL
OPERATING INSTRUCTIONS TIO-541 SERIES

d. Crack throttle to approximately ¼ travel.

e. Turn boost pump on and move mixture control to “Full Rich” position until a slight but steady flow is
indicated. Then return to “Idle Cut-Off” position.

f. Move ignition switch to “Left” and engage starter. On installations employing a combination magneto
starter switch, move the switch to “Start”.

g. As engine starts, move mixture control slowly and smoothly to “Full Rich”.

h. Turn ignition switch to “Both”. Combination spring-loaded switches will return to “Both”.

i. When engine starts, set the throttle for “Fast Idle”. If oil pressure is not indicated within thirty
seconds, stop the engine and determine trouble.

NOTE

If engine fails to achieve a normal start, assume it to be flooded and use standard clearing
procedure. Then repeat above procedure.

Hot Engine – Because of the fact that the fuel percolates and the system must be purged of vapor, it is
recommended that the same procedure, as outlined above, be used for starting a hot engine.

4. COLD WEATHER STARTING. During extreme cold weather it may be necessary to heat the engine or oil
before starting. If engine fails to start at the first attempt, another attempt should be made without priming.
If this fails, it is possible that the engine is overprimed. Turn switch to “OFF” position, open the throttle
slowly and turn the engine over approximately ten revolutions. Proceed with normal start.

CAUTION

ON INSTALLATIONS EQUIPPED WITH COMBINATION MAGNETO STARTER SWITCH,

IT IS NOT POSSIBLE TO CRANK THE ENGINE WITH SWITCH IN “OFF” POSITION.
WHEN CLEARING THESE ENGINES OF EXCESSIVE FUEL, THEREFORE, THE
IGNITION SYSTEM IS “HOT” AND THE ENGINE MAY START AT ANY TIME.

5. GROUND RUNNING AND WARM-UP. The Lycoming TIO-541 is an air-pressure cooled engine that
depends on the forward speed of the airplane to maintain proper cooling. Therefore, particular care is
necessary when operating this engine on the ground. To prevent overheating, it is recommended that the
following precautions be followed:

a. Head airplane into the wind.

b. Operate the engine on the ground only with the propeller in minimum blade angle setting.

c. Avoid prolonged idling at low RPM as this practice may result in fouled spark plugs.

d. Leave mixture control in “FULL RICH” position.

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e. Warm up engine at 800 to 1300 RPM.

6. GROUND CHECK.

a. Warm up as described above.

b. Check both oil pressure and oil temperature.

c. Leave mixture in “FULL RICH”.

d. Move propeller control through its complete range to check operation and return to full low pitch
position. Full feathering check is not recommended on the ground but the feathering action can be
checked by running the engine between 1000 and 1500, then momentarily pulling the propeller
control into the feathering position. Do not allow the RPM to drop more than 500 RPM.

e. A proper magneto check is important. Additional factors, other than the ignition system, affect
magneto drop-off. They are load-power output, propeller pitch and mixture strength. The important
thing is that the engine runs smoothly because drop-off is affected by the variables listed above. Make
the magneto check in accordance with the following procedures:

(1) With the propeller in minimum blade angle, set engine to produce 50 – 65% power as indicated by
the manifold pressure gage. Mixture control should be in full rich position, and propeller in
minimum blade angle. At these settings the ignition system and spark plugs must work harder
because of the greater pressures within the cylinders. Under these conditions ignition problems, if
they exist, will occur. Magneto checks at low power setting only indicate fuel-air-distribution
quality.

(2) Check magneto drop-off. Normal drop-off is 100 RPM. Drop-off should not exceed 175 RPM.
Drop-off between magnetos should not exceed 50 RPM. A smooth drop-off past normal is usually
a sign of a too lean or too rich mixture.

(3) Do not operate on a single magneto for too long a period. Two to three seconds is sufficient and
will prevent plug fouling.

f. The engine is warm enough for take-off when the throttle can be opened without the engine faltering.
Take-off with turbocharged engine should not be started if indicated lubricating oil pressure, due to
cold temperature, is above maximum. Excessive oil pressure can cause over boost and consequent
engine damage. If it is necessary to hold for clearance instructions, operate engine at 1400 to 1500
RPM to provide cooling and minimize spark plug fouling.

CAUTION

Do not exceed 2200 RPM while on the ground.

7. OPERATION IN FLIGHT. These engines are equipped with a dynamic counterweight system and must
be operated accordingly. Avoid rapid closing or opening of the throttle.

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See airframe manufacturer’s instructions for correct manifold pressure for power settings.

Turbocharger – The exhaust bypass valve controller used with the turbocharger system prevents
overboosting of the engine at lower altitudes and maintains a supply of air to the intake manifold to produce
sea level power at altitude.

Mixture Control – The mixture control, in addition to incorporating an idle cut-off when fully closed, is
used to manually lean the fuel/air mixture.

One of the most important factors in flying an aircraft is to maintain the proper fuel/air mixture. Proper
cruise mixture control to the engine will give maximum range, economical operation and maximum service
life.

LEANING PRECAUTIONS

Never operate an engine in excess of the maximum cylinder head temperature specified.

For continuous operation cylinder head temperatures should be maintained below 435°F (224°C).

Never exceed the maximum turbine inlet temperature of 1650°F (899°C).

Maintain mixture control in “Full Rich” position for rated take-off, rated maximum continuous climb and
cruise powers above 75% unless aircraft operator’s manual shows otherwise. However, during take-off
from high elevation airports or during climb, roughness or loss of power may result from over-richness. In
this event adjust mixture control only enough to obtain smooth operation.

Always enrich mixture before increasing power.

Manual leaning may be monitored most accurately by an exhaust gas temperature gage.

It is recommended that the following be adhered to when manually leaning with the aid of the EGT.

a. Above 75% power.

(1) Never lean beyond 150°F on the rich side of peak EGT unless airframe operator’s manual shows
otherwise. Monitor cylinder head temperature.

b. 75% Power and Below.

(1) Operate at peak EGT, or if desired, drop 50°F on the rich side of peak EGT.

NOTE

Although operation on the lean side of peak EGT will result in slightly better fuel economy
and lower cylinder head temperatures, in some cases unstable engine operation may be
encountered.

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8. ENGINE SHUT-DOWN. After landing, shut down the engine according to the following procedure:

a. Before the engine is shut down, it must be idled long enough to reduce temperatures.

b. Move the mixture control to “Idle Cut-Off”.

c. When engine stops, set ignition switch in the “OFF” position.

9. ENGINE FLIGHT CHART.

Fuel and Oil –

Fuel Aviation Grade.................................................................................................100/130 octane (minimum)

Fuel Pressure (psi above injector deck pressure) at inlet to fuel injector.

Maximum Minimum Idling

TIO-541-E 60 20 12
TIO-541-A 60 29 12

Lubricating Oil Recommendations – See latest revision of Service Instruction No. 1014 for complete
lubricating oil recommendations. TIO-541 series must be operated with ashless dispersant lubricating oil
essentially conforming to specification MIL-L-22851. However, newly overhauled engines of this series
may be run-in on the test stand with single viscosity oil, grade SAE 50 conforming with specification MIL-
L-6082.

*Recommended Grade Oil

Average Ambient Ashless Dispersant
Air Temperature Specification MIL-L-22851

Above 60°F Use grade equivalent to SAE 50 or SAE 60

Below 30°F Use grade equivalent to SAE 40

* - Consult latest revision of Service Instruction No. 1014.

*Recommended Oil Temperature

Average Ambient
Air Temperature Desired Maximum

Above 30°F 180°F 245°F

0° to 70°F 170°F 225°F
Below 10°F 160°F 210°F

* - Engine oil temperature should not be below 140°F (60°C) during continuous operation.

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-A Series -E Series

Oil Sump Capacity 14 qts. 13 qts.

Minimum safe quantity of
lubricating oil in sump 4 qts. 2-1/2 qts.

These engines are equipped with a full-flow oil filter. This feature extends the normal oil change intervals
of 50 hours by 25 to 100 percent, depending on environmental conditions, and provided the filter element is
changed after each 50 hours of operation.

Oil Pressure, psi Maximum Minimum Idling

Start and Warm-Up 100

Normal Oil Pressure 90 55 10

OPERATING CONDITIONS

TIO-541-A SERIES

Max. *Max.
Fuel Cons. Oil Cons. Cyl. Head
Operation HP Gal./Hr. Qt./Hr. Temp.

Normal Rated 310 ------ 2.06 475°F

Performance Cruise
(75% Rated) 230 20.5 1.53 475°F
Economy Cruise
(60% Rated) 185 13.5 1.23 475°F

TIO-541-E SERIES

Max. *Max.
Fuel Cons. Oil Cons. Cyl. Head
Operation HP Gal/Hr. Qt./Hr. Temp.

Normal Rated 380 ------ 2.11 475°F

Performance Cruise
(75% Rated) 300 22.9 1.66 475°F
Economy Cruise
(60% Rated) 247 16.7 1.37 475°F

* - At bayonet location – For maximum service life of the engine, maintain cylinder head temperatures
between 150°F and 435°F (65°C and 224°C) during continuous operation.

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Figure 3-1. Fuel Flow vs Percent Rated Power –

TIO-541-A Series

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Figure 3-2. Sea Level and Altitude Performance –

TIO-541-A Series

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LYCOMING OPERATOR’S MANUAL SECTION 3
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Figure 3-3. Fuel Flow vs Percent Rated Power –

TIO-541-E Series

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OPERATING INSTRUCTIONS TIO-541 SERIES

Figure 3-4. Sea Level and Altitude Performance –

TIO-540-E Series – Sheet 1 of 7

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Figure 3-5. Sea Level and Altitude Performance –

TIO-540-E Series – Sheet 2 of 7

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USING CURVE TO FIND ACTUAL HORSEPOWER –

The following is an example of how to use the Sea Level and Altitude Performance curves for
turbocharged engines, printed on these pages, to determine actual horsepower being delivered by the engine
for given altitude, RPM, manifold pressure and air inlet temperature. This example (using figures from
curve Figure 3-5) is for illustration purposes only. Example: With the aircraft flying at 13,500 feet, with a
power setting of 2750 RPM, 29 inches of manifold pressure and 48°F air inlet temperature.

1. Locate given manifold pressure and altitude performance curve (Point “A”).

2. Correct power approximately 1% for each 10°F variation in air inlet temperature from standard
altitude temperature shown below. Add correction for temperature below standard; subtract correction
for temperatures above standard. Example: With an air inlet temperature of 48°F at 13,500 feet, 48°
less 10° = 38° variation. 1% for each 10° variation is 3.8%. 3.8% of 270 HP is approximately 10 HP.
Since temperature is above standard, subtract correction.

3. 270 HP less 10 HP equals 260 HP. (Point “B”.)

STANDARD ALTITUDE TEMPERATURE IN DEGREES F

Pressure Altitude
(Thousands) SL 2 4 6 8 10 12 14 16 18 20 22 24

Standard Altitude
Temperature (°F) 59 52 45 38 31 23 16 9 + 2 -5 -12 -19 -27

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Figure 3-6. Sea Level and Altitude Performance –

TIO-541-E Series – Sheet 3 of 7

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Figure 3-7. Sea Level and Altitude Performance –

TIO-541-E Series – Sheet 4 of 7

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Figure 3-8. Sea Level and Altitude Performance –

TIO-541-E Series – Sheet 5 of 7

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Figure 3-9. Sea Level and Altitude Performance –

TIO-541-E Series – Sheet 6 of 7

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Figure 3-10. Sea Level and Altitude Performance –

TIO-541-E Series – Sheet 7 of 7

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SECTION 4
PERIODIC INSPECTIONS

Page

Pre-Starting Inspection ............................................................................................................................... 4-1

Daily Pre-Flight (Engine) ............................................................................................................................ 4-1

Daily Pre-Flight (Turbocharger) ................................................................................................................ 4-2

25-Hour Inspection ...................................................................................................................................... 4-2

50-Hour Inspection (Engine)....................................................................................................................... 4-2

50-Hour Inspection (Turbocharger) .......................................................................................................... 4-3

100-Hour Inspection (Engine)..................................................................................................................... 4-3

100-Hour Inspection (Turbocharger) ........................................................................................................ 4-4

400-Hour Inspection .................................................................................................................................... 4-5

Non-Scheduled Inspection........................................................................................................................... 4-5

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LYCOMING OPERATOR’S MANUAL SECTION 4
TIO-541 SERIES PERIODIC INSPECTIONS

SECTION 4

PERIODIC INSPECTIONS

NOTE

Perhaps no other factor is quite so important to safety and durability of the aircraft and its
components as faithful and diligent attention to regular checks for minor troubles and
prompt repair when they are found.

The operator should bear in mind that the items listed in the following pages do not constitute a complete
aircraft inspection, but are meant for the engine only. Consult the airframe manufacturer’s handbook for
additional instructions.

Pre-Starting Inspection – The daily pre-flight inspection is a check of the aircraft prior to the first flight of
the day. This inspection is to determine the general condition of the aircraft and engine.

The importance of proper pre-flight inspection cannot be overemphasized. Statistics prove that several
hundred accidents occur yearly directly responsible to poor pre-flight.

Among the major causes of poor pre-flight inspection are lack of concentration, reluctance to
acknowledge the need for a check list, carelessness bred by familiarity and haste.

1. DAILY PRE-FLIGHT (ENGINE).

a. Be sure all switches are in the “Off” position.

b. Be sure magneto ground wires are connected.

c. Check oil level.

d. See that fuel tanks are full.

e. Check fuel injector and fuel and oil line connections. Note minor indications for repair at 50-hour
inspection. Repair any leaks before aircraft is flown.

f. Open the fuel drain to remove any accumulation of water and sediment.

g. Make sure all shields and cowling are in place and secure. If any are missing or damaged, repair or
replacement should be made before the aircraft is flown.

h. Check engine controls for general condition, travel, and freedom of operation.

i. Induction system air filter should be inspected and serviced in accordance with the airframe
manufacturer’s recommendations.

j. Inspect safe tying of all drain plugs and covers.

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k. Inspect engine for evidence of leakage.

l. Check engine crankcase breather for restriction to breather.

2. DAILY PRE-FLIGHT (TURBOCHARGER SYSTEM).

a. Inspect mounting and connections of turbocharger for security, oil leakage, and air or exhaust gas
leakage.

NOTE

Exhaust gas leakage may be indicated by streaks of exhaust deposits at joints and inside
scorching of nacelles. Oil streaks under wings indicate possible oil leaks at controllers or
broken seals at the exhaust bypass valve.

3. 25-HOUR INSPECTION (ENGINE). After the first 25 hours operating time, new, rebuilt or newly
overhauled engines should undergo a 50-hour inspection including draining and renewing lubricating oil. If
a new alternator drive belt has been installed during the past 25 hours, check for correct tension adjustment.

4. 50-HOUR INSPECTION (ENGINE). In addition to the items listed for daily pre-flight inspection, the
following maintenance checks should be made after every 50 hours of operation.

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, or 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. Spark plug elbows and shielding nuts must be secure.

(3) Check ignition harness for security of mounting clamps and be sure connections are tight at spark
plug and magneto terminals.

b. Fuel and Induction System – Remove and clean the fuel inlet strainers. Remove and clean fuel injector
fuel strainer. Reinstall strainers.

NOTE

The above steps are most essential to insure proper operation of the fuel inspection system.
Failure to comply could cause irreparable damage.

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.

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LYCOMING OPERATOR’S MANUAL SECTION 4
TIO-541 SERIES PERIODIC INSPECTIONS

c. Lubrication System –

(1) Check oil lines for leaks, particularly at connections; check for security of anchorage and for wear
caused by rubbing or vibration; check for dents and cracks.

(2) Install new element in external full flow oil filter.

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 manifolds 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, install new 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 the assembly of the barrel at the factory, or by
slight gas leakage, which stops after the cylinder has been in service for awhile. This condition is
neither harmful nor detrimental to engine performance and operation. If it can be proven that the
leakage exceeds these conditions, the cylinder should be replaced.

5. 50-HOUR INSPECTION (TURBOCHARGER). All fluid power lines and mounting bracket incorporated
in turbocharger system should be checked for leaks, tightness, and any damage that may cause a restriction.

Check for accumulation of dirt or other interference with the linkage between the bypass valve and the
actuator, which may impair operation of turbocharger. Clean or correct cause of interference.

The vent line from the actuator should be checked for oil leakage. Any constant oil leakage is cause for
replacement of piston seal.

NOTE

The above operations should be performed in addition to those listed under “Daily Pre-
Flight (Turbocharger)” inspection.

6. 100-HOUR INSPECTION (ENGINE). In addition to the items listed for daily pre-flight and 50-hour
inspection, the following maintenance checks should be made after every one hundred hours of operation.

a. Electrical System –

(1) Check all wiring connected to the engine or accessories. Any shielded cables that are damaged
should be replaced. Replace any clamps or loose wires and check terminals for security and
cleanliness.

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(2) Remove spark plugs; test, clean and regap. Install new plugs, if necessary.

b. Lubrication System – Drain and renew lubricating oil. Install new filter element.

c. Magnetos – Check breaker points for pitting and minimum gap. Check for excessive oil in the breaker
compartment; if found, wipe dry with a clean lintless cloth. The felt located at the breaker points
should be lubricated in accordance with the magneto manufacturer’s instructions. Check magneto-to-
engine timing. Timing procedure is described in Section 5, 1, b of this manual.
NOTE
Engines equipped with pressurized ignition systems should be checked using the Bendix
Model 11-10090 (Lycoming Special Tool ST-395) airflow tester as described in latest
revision of Service Instruction No. 1308.

d. Engine Accessories – Engine mounted accessories such as pumps, temperature and pressure sensing
units should be checked for secure mounting and tight connections. Check alternator drive belt for
proper tension.
e. Cylinders – Check cylinders visually for cracked or broken fins.

f. Fuel Injector Nozzles and Fuel Lines – Check fuel injector nozzles for looseness, tighten to 15 – 20
ft.-lbs. torque. Check fuel lines for dye stains at connections (indicating leakage) and security of lines.
Repair or replacement must be accomplished before the aircraft resumes operation.

g. Engine Mounts – Check engine mounting bolts and bushings for security and excessive wear. Replace
any bushings that are excessively worn.

NOTE

All the above operations should be performed in addition to these listed under “Daily Pre-
Flight” and “50-Hour (Engine)”.

7. 100-HOUR INSPECTION (TURBOCHARGER). Inspect all air ducting and connections in turbocharger
system for leaks. Make inspection both with engine shut down and with engine running. Check at manifold
connections to turbine inlet and at engine exhaust manifold gasket for possible at leakage.

CAUTION

DO NOT OPERATE THE TURBOCHARGER SYSTEM IF LEAKS EXIST IN THE

DUCTING, OR IF AIR CLEANER IS NOT FILTERING EFFICIENTLY. DUST LEAKING
INTO AIR DUCTING CAN DAMAGE TURBOCHARGER AND ENGINE.

Check for dirt or dust build-up within the turbocharger. Check for uneven deposits on the impeller.
Consult AiResearch Industrial Div. Manual TP-21 for method to remove all such foreign matter.

NOTE

All the above operations should be performed in addition to those listed under “Daily Pre-
Flight” and “50-Hour (Turbocharger)” inspection.

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TIO-541 SERIES PERIODIC INSPECTIONS

8. 400-HOUR INSPECTION. In addition to the items listed for daily pre-flight, 50-hour and 100-hour
inspections, the following maintenance check should be made after every 400 hours of operation.

Valve Inspection – Remove rocker box covers and check for freedom of valve rockers when valves are
closed. Look for evidence of abnormal wear or broken parts in the area of the valve tips, valve keeper,
springs and spring seats. If any indications are found, the cylinder and all of its components should be
removed (including the piston and connecting rod assembly) and inspected for further damage. Replace any
parts that do not conform with the limits shown in the latest revision of Special Service Publication No.
SSP-1776.

9. NON-SCHEDULED INSPECTIONS. Occasionally, service bulletins or service instructions are issued by

Lycoming that require inspection procedures that are not listed in this manual. Such publications usually are
limited to specified engine models and become obsolete after corrective modification has been
accomplished. All such publications are available from Lycoming distributors, or from the factory by
subscription. Consult the latest revision of Service Letter No. L114 for subscription information.
Maintenance facilities should have an up-to-date file of these publications available at all times.

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SECTION 5
MAINTENANCE PROCEDURES

Page

Ignition and Electrical System

Ignition Harness and Wire Replacement................................................................................................ 5-1

Timing Magnetos to Engine ..................................................................................................................... 5-1

Generator or Alternator Output ............................................................................................................. 5-2

Fuel System

Repair of Fuel Lines.................................................................................................................................. 5-2

Fuel Injector Inlet Screen Assembly ....................................................................................................... 5-3

Fuel Grades and Limitations ................................................................................................................... 5-3

Air Intake Ducts and Filter...................................................................................................................... 5-3

Idle Speed and Mixture Adjustment ....................................................................................................... 5-3

Lubrication System

Oil Grades and Limitations...................................................................................................................... 5-4

Oil Pressure Relief Valve Adjustment .................................................................................................... 5-4

Cylinders

Removal of Cylinder Assembly................................................................................................................ 5-4

Assembly of Cylinder and Related Parts ................................................................................................ 5-6

Turbocharger System

Turbocharger Exhaust Bypass Valve Settings ....................................................................................... 5-8

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LYCOMING OPERATOR’S MANUAL SECTION 5
TIO-541 SERIES MAINTENANCE PROCEDURES

SECTION 5

MAINTENANCE PROCEDURES

The procedures described in this section are provided to guide and instruct personnel in performing such
maintenance operations that may be required in conjunction with the periodic inspections listed in the
preceding section. No attempt is made to include repair and replacement operations that will be found in the
applicable Lycoming Overhaul Manual.

1. IGNITION AND ELECTRICAL SYSTEM.

a. Ignition Harness and Wire Replacement – In the event that an ignition harness or an individual lead is
to be replaced, consult the wiring diagram to be sure that harness is correctly installed. Mark location
of clamps and clips to be certain that the replacement is clamped at correct locations.

b. Timing Magnetos to Engine – Magnetos are timed to the engine in the following manner:
NOTE
The retard breaker magneto is installed on the left side of the engine.

(1) Remove a spark plug from No. 1 cylinder and place a thumb over the spark plug hole. Rotate the
crankshaft in direction of normal rotation until the compression stroke is reached; this is indicated
by a positive pressure inside the cylinder, tending to push the thumb off the spark plug hole.
Continue rotating the crankshaft in direction of normal rotation until the 20°BTC advance timing
mark on the front face of the starter ring gear is in exact alignment with the small hole located on
the front face of the starter housing at the eight o’clock position.
NOTE
If the crankshaft is accidentally turned in the direction opposite normal rotation, repeat the
above procedure since accumulated backlash will make the final timing incorrect.

(2) At this point, the engine is ready for assembly of the magnetos. Remove the inspection plug from
a magneto and turn the drive shaft in direction of normal rotation until the first painted chamfered
tooth on the distributor gear is aligned in the center of the inspection window. Being sure that the
gear does not move from this position, install gasket and magneto on the engine. Secure with
washers and nuts; tighten only finger tight. Repeat for second magneto.

(3) Using a battery powered timing light, attach the positive lead to a suitable terminal connected to
the switch terminal of the magneto and the negative lead to any unpainted portion of the engine.

(4) Rotate a magneto in its mounting flange to a point where the light comes on, then slowly turn it in
the opposite direction until the light goes out. Bring the magneto back slowly until the light just
comes on. Repeat this with the second magneto.
NOTE
Use only the main breaker points when timing the retard breaker magneto to the engine.
Never attempt to time using the retard breaker points.

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Figure 5-1. Ignition Wiring Diagram

(5) After both magnetos have been timed, check, as described below, to ascertain that both magnetos
are set to fire together.

(6) Back off the crankshaft a few degrees; the timing lights should go out. Bring the crankshaft slowly
back in direction of normal rotation until the timing mark and the hole in the starter housing are in
alignment. At this point, both lights should go on simultaneously. Tighten nuts to specified torque.
Reinstall inspection plugs.

NOTE

Some timing lights operate in reverse of the manner described above; the lights come on
when the breaker points open. Check your timing light instructions.

c. Generator or Alternator Output – The generator or alternator (whichever is applicable) should be

checked to determine that the specified voltage and current are being obtained.

2. FUEL SYSTEM.

a. Repair of Fuel Lines – In the event a line or fitting is replaced, only a fuel soluble lubricant, such as
clean engine oil or Loctite Hydraulic Sealant may be used on the tapered threads. Do not use any other
form of thread compound.

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LYCOMING OPERATOR’S MANUAL SECTION 5
TIO-541 SERIES MAINTENANCE PROCEDURES

b. Fuel Injector Inlet Screen Assembly – Remove the assembly and check the screen for distortion or
openings in the strainer. Install a new screen if either of these conditions exists. Clean screen assembly
in solvent and dry with compressed air. To install the screen assembly, place the gasket on the screen
assembly and install the assembly in the throttle body and tighten to 65-70 in.-lbs. torque.

c. Fuel Grades and Limitations – Aviation grade fuel 100/130 octane minimum is the specified fuel for
these engines. In the event that the specified fuel is not available at some locations, it is permissible to
use higher octane fuel. Fuel of a lower octane than specified is not to be used. Under no circumstances
should automotive fuel be used (regardless of octane rating).
NOTE
It is recommended that personnel be familiar with the latest revision of Service Instruction
No. 1070 regarding specified fuel for Lycoming engines.

d. Air Intake Ducts and Filter – Check all air intake ducts for dirt or restrictions. Inspect and service air
filters as instructed in the airframe manufacturer’s handbook.

e. Idle Speed and Mixture Adjustment –

(1) Start the engine and warm up in the usual manner until oil and cylinder head temperatures are
normal.

(2) Check magnetos. If the “mag-drop” is normal, proceed with idle adjustment.

(3) Close throttle so that the engine idles at the airframe manufacturer’s recommended idling RPM. If
the RPM changes appreciably after making idle mixture adjustment during the succeeding steps,
readjust the idle speed to the desired RPM.
NOTE
The idle mixture must be adjusted with the fuel boost pump “ON”.
(4) When the idling speed has stabilized, move the cockpit mixture control lever with a smooth,
steady pull toward the Idle Cut-Off position and observe the tachometer for any change during the
leaning process. Caution must be exercised to return the mixture control to “Full Rich” position
before the RPM can drop to a point where the engine cuts out. An increase of more than 50 RPM
while “leaning out” indicates an excessively rich idle mixture An immediate decrease in RPM (if
not preceded by a momentary increase) indicates that the idle mixture is too lean.

If the above indicates that the idle adjustment is too rich or too lean, turn the idle mixture
adjustment in the direction required for correction, and check this new position by repeating the
above procedure. Make additional adjustments as necessary until a check results in a momentary
pick-up of approximately 50 RPM. Each time the adjustment is changed, the engine should be run
up to 2000 RPM to clear the engine before proceeding with the RPM check. Make final
adjustment of the idle speed adjustment to obtain the desired idling RPM with closed throttle. The
above method aims at a setting that will obtain maximum RPM with minimum manifold pressure.
In case the setting does not remain stable, check the idle linkage; any looseness in this linkage
would cause erratic idling. In all cases, allowance should be made for the effect of weather
conditions and field altitude upon idling adjustment.

5-3
SECTION 5 LYCOMING OPERATOR’S MANUAL
MAINTENANCE PROCEDURES TIO-541 SERIES

3. LUBRICATION SYSTEM.

a. Oil Grades and Limitations – Service the engine in accordance with the recommendations shown in
Section 3.

NOTE

TIO-541-E series engines must be operated with ashless dispersant lubrication oil as
described in latest revision of Service Bulletin No. 318.

b. The adjustable oil relief valve, located at the right rear side of the engine below the oil filter, enables
the operator to maintain the oil pressure within specified limits. If the pressure under normal operating
conditions should consistently exceed the maximum or minimum specified limits, adjust the valve as
follows:

With the engine warmed up and running at approximately 2000 RPM, observe the reading on the oil
pressure gage. If the pressure is above maximum or below minimum specified limits, stop the engine
and screw the adjusting screw in to increase pressure or out to decrease pressure. The adjusting screw
may be turned with either a screw driver or a box wrench.

4. CYLINDERS.

a. Removal of Cylinder Assembly –

(1) Remove exhaust manifold.

(2) Remove intake pipe, fuel drain lines, baffle and any clips that might interfere with the cylinder
removal.

(3) Disconnect ignition cable at spark plugs and remove spark plugs.

(4) Remove rocker box cover and rotate crankshaft until piston is approximately at top center of the
compression stroke. This approximate position may be located by observing top of piston through
the spark plug hole and by watching the valve action.

(5) Pull rocker shafts into cylinder head far enough to remove valve rockers and washers. Remove
valve stem cap from exhaust valve. Valve rocker shafts can be removed when cylinder is removed
from the engine.

(6) Remove push rods by grasping ball end and pulling out of shroud tube. Remove shroud tube by
grasping tube and turning 90° either way. This releases detent on tube from spring. Remove the
tubes by first releasing them from the seal seat in the cylinder head and then withdrawing tubes
from shroud tube adapter on crankcase. Remove shroud tube seal sleeves and seals from outer end
of tubes, also remove seals from adapter. Discard all seals. Place washers, springs, and seal sleeves
in proper compartment of cleaning basket.

NOTE

The hydraulic lifters, push rods, rocker arms, and valves must be assembled in the same
location from which they were removed.

5-4
LYCOMING OPERATOR’S MANUAL SECTION 5
TIO-541 SERIES MAINTENANCE PROCEDURES

(7) Remove cylinder base hold-down nuts; then remove cylinder by pulling directly away from the
crankcase. Be careful not to allow the piston to drop against the crankcase as the piston leaves the
cylinder.

(8) Use the old cylinder base oil seal ring and crisscross over cylinder base studs and around
connecting rod to prevent rod from striking crankcase.

NOTE

In the event that a spark plug Heli-coil must be replaced, it must be replaced with a .010
oversize Heli-coil.

b. Removal of Valves and Valve Springs from Cylinder –

(1) Place cylinder over a block of wood to hold the valves in a closed position.

(2) Compress valve springs, using a valve spring compressor.

(3) Remove tapered split keys from the end of valve stems. The valve springs and valve spring seats
may now be removed from cylinder head.

(4) Hold valve stems so that valves will not fall out. Remove cylinder from holding block.

(5) Remove valves from the inside of the cylinder.

c. Removal of Piston from Connecting Rod – Insert the piston pin puller tube through the piston pin.
Assemble the puller nut and proceed to remove the piston pin.

d. Removal, Disassemble, Cleaning, Inspection and Reassembly of Hydraulic Lifters –

(1) Remove capscrews that secure shroud tube adapter over the lifter.

(2) Remove adapter gasket. Lifter can be withdrawn by fingers.

(3) Being careful not to scratch socket, insert a screw driver into lifter and push. This will force the
trapped oil out of the vent hole and release the pressure on the circlip.

(4) Remove and discard the circlip.

CAUTION

UPON RELEASE, CIRCLIP MAY SPRING UP WITH GREAT FORCE. BE CAREFUL!

(5) Remove the spring, plunger and socket from the lifter and clean the parts and the lifter body in
solvent. Inspect the lifter body for the following imperfections.

Spalling – If the face of the lifter shows small nicks or indentations near the center of the face, it is
considered pitted or spalled. The pitting will constitute small irregular holes, not to be confused
with Rockwell hardness check marks, which are round and even. The area covered by spalling will
vary with different lifters, but regardless of the degree, the lifter must be replaced.

5-5
SECTION 5 LYCOMING OPERATOR’S MANUAL
MAINTENANCE PROCEDURES TIO-541 SERIES

Scoring – The lifter face is scored when small scratch-like lines are found on the surface. These
marks are usually found near the outer edge of the face and will appear to radiate from the center.
Other scoring marks may be present and extend to the center of the lifter face. Any lifter, with this
condition in evidence, must be replaced.

Face Wear – The operation of the lifter provides that the lifter rotates during wiping operation of
the cam. This will form a groove, or path. This path will extend all the way across the face and
deeper penetrations will be noted at the center of the face. If the wear is excessive, it will be
noticeable to the touch if the fingernail is rubbed across the lifter face. This condition requires
replacement of the lifter body.

(6) Reassemble the spring, plunger and socket into the body and secure with a new circlip.

NOTE

The lifter must be perfectly dry to obtain proper dry tappet clearance.

(7) Install the lifter assembly in its position in the crankcase. Install a new shroud tube adapter gasket
and secure the shroud tube adapter with capscrews.

e. Assembly of Valves in Cylinder –

(1) Prelubricate valve stems and interior of valve guides with Molytex Grease O or equivalent and
insert each valve stem in its respective guide.

(2) Place cylinder over a wood block so that the valves are held against the seats and assemble the
lower spring seat, auxiliary valve spring and outer valve spring over the valve stem and guide.
Place the upper spring seat on top of the springs.

NOTE

Place dampener end of spring (close-wound coils marked with dye or lacquer) toward the
cylinder.

(3) Using a valve spring compressor, compress the valve springs and place the split keys in the groove
around the upper end of the valve stem. Slowly release the pressure on the valve spring
compressor and allow the upper spring seat to lock itself in place around the valve keys.

f. Assembly of Cylinder and Related Parts –

(1) Rotate crankshaft so that the connecting rod of the cylinder being assembled is at top center
position with both tappets on the low side of the cam in a position that corresponds with both
valves closed.

(2) Assemble piston with rings so that the cylinder number stamped on the piston pin boss is toward
the front of the engine. The piston pin should be a hand push fit. During assembly always use a
generous quantity of oil, both in the piston pin hole and on the piston pin.

5-6
LYCOMING OPERATOR’S MANUAL SECTION 5
TIO-541 SERIES MAINTENANCE PROCEDURES

(3) Assemble a piston pin plug at each end of the piston pin and place a new rubber oil seal ring
around the cylinder skirt. Coat piston and rings and the inside of the cylinder generously with oil.

NOTE

Before installing cylinder hold-down nuts, lubricate crankcase thru-stud threads with any
one of the following lubricants, or combination of lubricants.
1. 90% SAE 50W engine oil and 10% STP.
2. Parker Thread Lube.
3. 60% SAE 30 engine oil and 40% Parker Thread Lube.

(4) Using a piston ring compressor, assemble the cylinder over the piston with the intake port at the
top and the exhaust port on the bottom.

(5) Push the cylinder all the way on, catching the ring compressor as it is pushed off, and install
applicable cylinder base hold-down nuts. Tighten hold-down nuts to specified torque in the
manner described in the following paragraphs.

NOTE

The front two ½ inch thru-studs on each cylinder pad are not secured by screw threads.
Therefore, torque must be applied at both ends simultaneously. At any time a cylinder is
replaced, it is necessary to retorque the cylinder base nuts on the opposite cylinder.

(6) Tighten the ½ inch cylinder base nuts to 300 in.-lbs., starting at top left and proceeding
counterclockwise.

(7) Repeat the tightening sequence and tighten all ½ inch nuts to 600 in.-lbs. torque. Be certain all
nuts are tightened in the sequence stated.

(8) Tighten the 3/8 inch nuts to 300 in.-lbs. toque. Sequence is optional.

(9) During the final tightening procedure, bearing crush or crankcase shift may have occurred,
relieving the load on certain ½ inch nuts. Therefore, as a final check, repeat step (7) above to
determine if all ½ inch cylinder base nuts are tightened to 600 in.-lbs. Hold torque wrench on each
½ inch nut for about 5 seconds. If the nut does not turn, it is presumed to be tightened to the
proper torque.

CAUTION

AFTER INSTALLATION OF CYLINDER IS COMPLETED, REMOVE ANY NICKS IN THE

CYLINDER FINS BY FILING OR BURRING.

(10) Assemble new shroud tube oil seals in the shroud tube adapter on the crankcase and on outer end
of the push rod shroud tubes; then assemble a shroud tube seal sleeve over each of the outer seals,
centering the sleeve on the seal.

5-7
SECTION 5 LYCOMING OPERATOR’S MANUAL
TIO-541 SERIES MAINTENANCE PROCEDURES

(11) Assemble shroud tube spring over inner ends of the shroud tubes so that the detent notches are
approximately 90° removed from detents on the tubes. Use shroud tube washers (maximum of
two) to bring minimum overlap between the spring and detent lugs to 1/8 inch and insert tube ends
through oil seals in the adapter. Hold both push rod shroud tubes with detent at inner end at
unlocked position and insert the outer ends of tubes in holes in cylinder head rocker box. See that
all seals are inserted squarely, and turn each shroud tube 90° thus locking the tubes by engaging
the detents with the notches in the spring. Select the proper push rods, dip ball ends in
preservative oil and insert full length through shroud tubes.

(12) Assemble cap on end of exhaust valve stem and assemble each rocker in its respective position
between the bosses; insert the thrust washer between the rocker and inner box and slide valve
rocker shaft in place to retain the rocker.

(13) Be sure that the piston is at top center of compression stroke and that both valves are closed.
Check clearance between the valve stem tip and valve rocker. In order to check this clearance,
place the thumb of one hand on the valve rocker directly over the end of the push rod and push
down so as to compress the hydraulic lifter spring. While holding the spring compressed, check
clearance with feeler gage; the clearance should be between 0.040 and 0.105 inch. If clearance
does not come within these limits, remove the push rod and insert a longer or shorter push rod as
required to correct clearance.

NOTE

Inserting a longer push rod will decrease valve clearance.

(14) Install rocker box covers, inter-cylinder baffles, spark plugs, intake pipes, ignition cables, fuel
drain lines, exhaust manifold, plus any clips that may have been removed at disassembly.

5. TURBOCHARGER EXHAUST BYPASS VALVE SETTINGS. The butterfly valve in the exhaust bypass
valve is set to a predetermined open and closed clearance. The open and closed positions and directions on
how to set them are called out in Figures 5-2 and 5-3.

6. SETTING FUEL INJECTOR AND CONTROLLER LINKAGE.

The fuel injector and controller linkage must be set as described below to provide the proper amount of
turbocharging and fuel metering to the engine.

a. Remove no. 2 and 4 intake pipes on TIO-541 engines and necessary baffling. Cover intake ports to
prevent foreign objects from falling into cylinder. Disconnect aircraft throttle cable from cross shaft
control lever. Remove injector connecting rod from both the cross shaft control lever and the throttle
lever.

NOTE

In order to insure proper settings, all washers and spacers must be installed properly as
specified in Figure 5-10.

5-8
LYCOMING OPERATOR’S MANUAL SECTION 5
TIO-541 SERIES MAINTENANCE PROCEDURES

Figure 5-2. Open and Closed Position of Exhaust Bypass Valve –

TIO-541-A1A, -E1A5, -E1B4

Figure 5-3. Open and Closed Position of Exhaust Bypass Valve –

TIO-541-E1C4, -E1D4

5-9
SECTION 5 LYCOMING OPERATOR’S MANUAL
MAINTENANCE PROCEDURES TIO-541 SERIES

b. Position the cross shaft control lever using fixture ST-319 thus: Mount the fixture over no. 4 cylinder
hold-down 3/8 inch studs and nuts. Secure with two (P/N 383-B) nuts. If unable to secure with nuts
because of insufficient thread, hold the fixture by hand. The fixture in position is shown in Figure 5-4.

c. Back off idle stop adjusting screw until it just touches the injector stop pin when the throttle butterfly
is fully closed. Check clearance with a piece of shim stock or a .0015-inch feeler gage. See Figure 5-5.

d. Place gage (ST-318) over injector stop pin with side marked “.040” down and between pin and end of
idle stop adjusting screw. Do not turn from full closed setting at this time. See Figure 5-6.

e. Align hole in ball end of injector connecting rod; hole in cross shaft control lever and hole in fixture.
Insert fixture pin through all three holes. See Figure 5-4. With throttle lever held firmly against gage
on injector, adjust the connecting rod length (maintaining approximately equal thread engagements on
both ends) and attach to throttle lever. Remove fixture (ST-319) and attach injector connecting rod to
the cross shaft control lever using hardware shown in Figure 5-10. Remove gage (ST-318).

f. Replace gage (ST-318) on injector stop pin with the side marked “.025” up. This is the desired
clearance between the pad of the throttle arm and the injector stop pin with the throttle lever in full
open position. Move cross shaft control lever forward to put injector throttle lever in full open position
and maintain a constant pressure between the throttle arm pad and the gage while completing the
following step. See Figure 5-7.

g. Remove the controller connecting rod at the controller end. Push the controller arm against the full
boost stop pin (forward). See Figure 5-8. With the controller arm in this position and the throttle lever
in the position obtained in the preceding step, adjust the controller connecting rod (maintaining
approximately equal thread engagement on both ends) to match hole locations in both the controller
arm and the connecting rod. Attach the connecting rod to the controller arm and remove the gage from
the injector stop pin. See Figure 5-9.

h. Check to make certain that all connecting rods are installed with the proper hardware (see Figure 5-
10); jam nuts and linkage nuts are tight, and safety the linkage nuts with cotter pins.

i. Reset the idle stop adjusting screw until correct idle is obtained. If throttle lever on the aircraft console
is misaligned, adjustment may be made either at the ball end of the aircraft throttle cable or by moving
the bracket which holds the throttle cable to the engine. Attach aircraft throttle cable to top hole of the
cross shaft control lever.

5-10
LYCOMING OPERATOR’S MANUAL SECTION 5
TIO-541 SERIES MAINTENANCE PROCEDURES

Figure 5-4. Fixture ST-319 Installed and Showing Cross Shaft

Control Level in Closed Throttle Position

Figure 5-5. Setting Idle Adjusting Screw at Injector Stop Pin

5-11
SECTION 5 LYCOMING OPERATOR’S MANUAL
MAINTENANCE PROCEDURES TIO-541 SERIES

Figure 5-6. Obtaining Clearance of Throttle Lever in Closed Position

Figure 5-7. Obtaining Clearance of Throttle Lever in Full Open Position

5-12
LYCOMING OPERATOR’S MANUAL SECTION 5
TIO-541 SERIES MAINTENANCE PROCEDURES

Figure 5-8. View Showing Controller Arm in Full Boost Position

Figure 5-9. View Showing Controller Connecting Rod Secured

To Controller Arm in Full Boost Position

5-13
SECTION 5 LYCOMING OPERATOR’S MANUAL
MAINTENANCE PROCEDURES TIO-541 SERIES

Figure 5-10. Fuel Injector and Controller Rods Attaching Parts

5-14
 LYCOMING OPERATOR’S MANUAL

SECTION 6
TROUBLE-SHOOTING – ENGINE

Page

Failure of Engine to Start............................................................................................................................ 6-1

Failure of Engine to Idle Properly.............................................................................................................. 6-1

Low Power and Uneven Running............................................................................................................... 6-2

Failure of Engine to Develop Full Power................................................................................................... 6-2

Rough Engine ............................................................................................................................................... 6-2

Low Oil Pressure.......................................................................................................................................... 6-3

High Oil Temperature ................................................................................................................................. 6-3

Excessive Oil Consumption......................................................................................................................... 6-3

TROUBLE-SHOOTING – TURBOCHARGER

Excessive Noise or Vibration....................................................................................................................... 6-4

Engine Will Not Deliver Rated Power ....................................................................................................... 6-4

Critical Altitude Lower Than Specified..................................................................................................... 6-5

Engine Surges or Smokes ............................................................................................................................ 6-5

High Deck Pressure (Compressor Discharge Pressure) ........................................................................... 6-5

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LYCOMING OPERATOR’S MANUAL SECTION 6
TIO-541 SERIES TROUBLE-SHOOTING

SECTION 6

TROUBLE-SHOOTING

Experience has proven that the best method of trouble-shooting is to decide on the various possible causes
of a given trouble and then to eliminate causes one by one, beginning with the most probable. The following
charts list some of the more common troubles which may be encountered in maintaining aircraft engines and
turbochargers; their probable causes and remedies.

1. TROUBLE-SHOOTING – ENGINE.

TROUBLE PROBABLE CAUSE REMEDY

Failure of Engine to Start Lack of fuel. Check fuel system for leaks. Fill
fuel tank. Clean dirty lines,
strainers, or fuel valves.

Overpriming. Unload engine by standard

clearing procedure.

Incorrect throttle setting. Open throttle to ¼ of its range.

Defective spark plugs. Clean and adjust or replace spark

plugs.

Defective ignition wire. Check with tester and replace any

defective wires.

Improper operation of magneto. Clean points. Check timing.

Internal failure. Check oil screens for metal

particles. If found, complete
overhaul of engine is indicated.

Failure of Engine to Idle Properly Incorrect idle mixture. Adjust mixture control.

Incorrect idle speed. Adjust idle speed.

Leak in induction system. Tighten all connections and

replace any defective parts.

Uneven cylinder compression. Check condition of piston rings

and valve seats.

Faulty ignition system. Check ignition system.

6-1
SECTION 6 LYCOMING OPERATOR’S MANUAL
TROUBLE-SHOOTING TIO-541 SERIES

TROUBLE PROBABLE CAUSE REMEDY

Low Power and Uneven Running Mixture too rich; indicated by Readjustment of fuel injector is
sluggish engine, red exhaust indicated.
flame. Extreme cases indicated by
black smoke at exhaust.

Mixture too lean; indicated by Check fuel lines for restrictions.

overheating and back firing. Readjust mixture.

Leak in induction system. Tighten all connections, replace

any defective parts.

Defective spark plugs. Clean and gap or replace spark

plugs.

Improper fuel. Fill tank with fuel of

recommended grade.

Magneto breaker points not Clean points, check timing.

working properly.

Defective ignition wire. Check wires with tester, replace

any defective wires.

Defective spark plug terminal Check and replace connectors if

connectors. necessary.

Failure of Engine to Develop Full Leak in induction system. Tighten all connections, replace
Power any defective parts.

Throttle lever out of adjustment. Check travel of throttle linkage.

Improper fuel flow. Check strainers and flow at fuel

injector.

Restriction in air scoop. Examine air scoop and remove

any obstructions.

Improper fuel. Drain and refill tank with fuel of

recommended grade.

Faulty ignition. Check ignition system.

Rough Engine Cracked engine mount. Replace or repair mount.

Defective mounting busing. Replace bushing.

Uneven compression. Check condition of piston rings

and valve seats.

6-2
LYCOMING OPERATOR’S MANUAL SECTION 6
TIO-541 SERIES TROUBLE-SHOOTING

TROUBLE PROBABLE CAUSE REMEDY

Low Oil Pressure Insufficient oil. Fill sump with oil.

Air lock or dirt in relief valve. Remove and clean oil pressure
relief valve.

Dirty oil strainers. Remove and clean oil strainers.

High oil temperatures. See “High Oil Temperatures” in

“Trouble” column.

Defective pressure gage. Replace gage.

Stoppage in oil pump intake Check line for obstruction.

passage.

High Oil Temperature Insufficient oil supply. Fill sump with oil of
recommended grade.

Low grade of oil. Drain and fill sump with oil

conforming to specifications.

Clogged oil lines or strainers. Clean oil lines and strainers.

Excessive blow-by. Usually caused by worn or struck

rings.

Failed or failing bearings. Examine oil strainers for metal

particles. If found, overhaul of
engine is indicated.

Defective temperature gage. Replace gage.

Excessive Oil Consumption Low grade of oil. Fill sump with oil conforming to
specifications.

Failing or failed bearings. Examine oil strainers for metal

particles. If found, overhaul of
engine is indicated.

Worn piston rings. Install new rings.

Incorrect installation of piston Install new rings.

rings.

Failure of rings to seat (new Climb to cruise altitude at full

nitrided barrels). power and operate at 75% cruise
power setting until consumption
stabilizes.

6-3
SECTION 6 LYCOMING OPERATOR’S MANUAL
TROUBLE-SHOOTING TIO-541 SERIES

2. TROUBLE-SHOOTING – TURBOCHARGER

TROUBLE PROBABLE CAUSE REMEDY

Excessive Noise or Vibration Improper bearing lubrication. Supply required oil pressure.
Clean or replace oil line. If trouble
continues, overhaul turbocharger.

Leak in engine intake or exhaust Tighten loose connections, or

manifold. replace manifold gaskets as
necessary.

Engine Will Not Deliver Rated Clogged manifold system. Clean all ducting.
Power

Foreign material lodged in Disassemble and clean.

compressor impeller or turbine.

Excessive dirt build-up in Thoroughly clean compressor

compressor. assembly. Service air cleaner and
check for leakage.

Leak in engine intake or exhaust Tighten loose connections, or

manifold. replace manifold gaskets as
necessary.

Rotating assembly bearing Overhaul turbocharger.

seizure.

Restriction in return lines from Remove and clean lines.

exhaust bypass valve to variable
pressure controller.

Variable pressure controller out of Adjust variable pressure

adjustment. controller.

Oil pressure too low. Tighten fittings, replace lines or

hoses. Increase oil pressure.

Oil inlet to exhaust bypass valve Remove oil line at inlet and clean
clogged. orifice.

Variable pressure controller Adjust controller. Install new

malfunction. controller if needed.

Exhaust bypass valve not closing Check for oil pressure difficulty.
because of low oil pressure or Examine shaft for evidence of
butterfly shaft binding. binding.

6-4
LYCOMING OPERATOR’S MANUAL SECTION 6
TIO-541 SERIES TROUBLE-SHOOTING

TROUBLE PROBABLE CAUSE REMEDY

Engine Will Not Deliver Rated Impeller binding, frozen or Check bearings for evidence of
Power (Cont.) fouling housing. failure. Overhaul turbocharger.
Piston seal in exhaust bypass Replace piston seal.
valve actuator leaking.
Critical Altitude Lower Than Controller not getting enough oil Check pump outlet pressure, oil
Specified pressure to close bypass valve. filters and lines for leaks or
obstructions.
Chips under metering valve in Replace controller.
controller holding it open.
Metering jet in exhaust bypass Remove exhaust bypass valve
valve actuator plugged. actuator and clean jet.
Exhaust bypass valve actuator Clean cylinder and replace piston
piston seal leaking excessively. seal.
Exhaust bypass valve sticking. Clean and free action.
Engine Surges or Smokes Air in oil lines or exhaust bypass Bleed system.
valve actuator.
Controller metering valve stem Replace controller.
seal leaking oil into manifold.
Exhaust bypass valve actuator to Correct cause of binding.
bypass valve linkage binding.
Clogged breather. Check breather for restriction to
air flow.
NOTE
Smoke would be normal if engine has idled for a prolonged period.
High Deck Pressure (Compressor Controller metering valve not Replace controller.
Discharge Pressure) opening.
Exhaust bypass valve sticking Shut off valve in return line
closed. inoperative.
Controller return line restricted. Clean or replace line.
Oil pressure too high. Reduce oil pressure.
Exhaust bypass valve actuator Disassemble actuator, check
piston locked in closed position. condition of piston and packing.
Variable pressure controller Replace controller.
malfunction.

6-5
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 LYCOMING OPERATOR’S MANUAL

SECTION 7
INSTALLATION AND STORAGE

Page

Unpacking..................................................................................................................................................... 7-1

Preparation of Engine for Installation....................................................................................................... 7-1

Inspection of Engine Mounting .................................................................................................................. 7-2

Attaching Engine to Mounts ....................................................................................................................... 7-2

Engine Accessories ....................................................................................................................................... 7-2

Location of Accessories, Drives, and Oil and Fuel Connections ............................................................. 7-2

Corrosion Prevention in Engines Installed in Inactive Aircraft.............................................................. 7-2

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LYCOMING OPERATOR’S MANUAL SECTION 7
TIO-541 SERIES INSTALLATION AND STORAGE

SECTION 7

INSTALLATION AND STORAGE

1. UNPACKING.

General – Lycoming TIO-541 series aircraft engines are securely packed for shipment, one to the crate in a
horizontal position. The attaching parts are packed in a separate carton within the engine crate.

Unpacking – Open shipping crate. Remove inner carton containing loose attaching parts. Attach lifting cable
to lifting eyes. With a suitable hoist take up the slack cable. Remove the bolts and lift engine clear of
shipping crate. With the engine in this position, remove the bottom plugs from each cylinder and rotate
crankshaft a few revolutions to drain the oil from the cylinders. Assemble spark plugs and clean the exterior
of the engine thoroughly.

2. PREPARATION OF ENGINE FOR INSTALLATION. Before installing an engine that has been prepared
for storage, remove all dehydrator plugs and preservative oil. Should any of the dehydrator plugs, containing
crystals of silica-gel or similar material, be broken during their term of storage or upon their removal from
the engine, and if any of the content shall fall into the engine, that portion of the engine must be
disassembled and thoroughly cleaned before using the engine. Preservative oil can be removed by removing
the bottom spark plugs and turning the crankshaft three or four revolutions by hand. The preservative oil
will then drain through the spark plugholes. Draining will be facilitated if the engine is tilted from side to
side during the above operation. Preservative oil which has accumulated in the sump can be drained by
removing the oil sump drain plug. Engines that have been stored in a cold place should be removed to an
environment of at least 70°F (21°C) for a period of 24 hours before preservative oil is drained from the
cylinders. If this is not possible, heat the cylinders with heat lamps before attempting to drain the engine.

After the oil sump has been drained, the plug should be replaced, safety-wired, and the sump filled with
lubricating oil. The latest revision of Service Instruction No. 1014 contains complete lubricating oil
recommendations. The crankshaft should again be turned several revolutions to saturate the interior of the
engine with clean oil. When installing spark plugs, make sure that they are clean; if not, wash them in clean
petroleum solvent. Of course, there will be a small amount of preservative oil remaining in the engine but
not in sufficient quantity to prove harmful. However, after twenty-five hours of operation, the lubricating oil
should be drained while the engine is hot. This will remove any residual preservative oil that may be
present.

CAUTION

DO NOT ROTATE THE CRANKSHAFT OF AN ENGINE CONTAINING PRESERVATIVE

OIL BEFORE REMOVING THE SPARK PLUGS, BECAUSE IF THE CYLINDERS
CONTAIN ANY APPRECIABLE AMOUNT OF THE MIXTURE, THE RESULTING
ACTION, KNOWN AS HYDRAULICING, WILL CAUSE DAMAGE TO THE ENGINE.
ALSO, ANY CONTACT OF THE PRESERVATIVE OIL WITH PAINTED SURFACES
SHOULD BE AVOIDED.

7-1
SECTION 7 LYCOMING OPERATOR’S MANUAL
INSTALLATION AND STORAGE TIO-541 SERIES

The oil strainers should be removed and cleaned in gasoline or some other hydrocarbon solvent. The fuel
filter screen located in the fuel inlet of the throttle body should also be removed and cleaned in a
hydrocarbon solvent. Inject clean fuel into the fuel inlet with the fuel outlets uncapped until clean fuel flows
from the outlets. Do not exceed 15 psi inlet pressure. The operator should also note if any valves are
sticking. If they are, this condition can be eliminated by coating the valve stem generously with lubricating
oil.

Inspection of Engine Mounting – If the aircraft is one from which an engine has been removed, make sure
that the engine mounts are not bent or damaged by distortion or misalignment. If so, abnormal stresses can
be produced within the engine.

Attaching Engine to Mounts – See aircraft manufacturer’s recommendations for method of mounting engine.

Engine Accessories – Considerable time and effort can be saved if the accessories are assembled on the
engine before installation in the airframe.

CORROSION PREVENTION IN ENGINES INSTALLED IN INACTIVE AIRCRAFT

Corrosion can occur, especially in new or overhaul engines, on cylinder walls of engines that will be
inoperative for periods as brief as two days. Therefore, the following preservation procedure is
recommended for inactive engines and will be effective in minimizing the corrosion condition for a period
up to thirty days.

NOTE

Ground running the engine for brief periods of time is not a substitute for the following
procedure; in fact, the practice of ground running will tend to aggravate rather than
minimize the corrosion condition.

a. As soon as possible after the engine is stopped, move the aircraft into the hangar, or other shelter
where the preservation process if to be performed.

b. Remove sufficient cowling to gain access to the spark plugs and remove both spark plugs from each
cylinder.

c. Spray the interior of each cylinder with approximately two (2) ounces of corrosion preventive oil
while cranking the engine about five (5) revolutions with the starter. The spray gun nozzle may be
placed in either of the spark plug holes.

NOTE

Spraying should be accomplished using an airless spray gun (Spraying Systems Co.,
“Gunjet” Model 24A-8395 or equivalent). In the event an airless spray gun is not available,
personnel should install a moisture trap in the air line of a conventional spray gun and be
certain oil is hot at the nozzle before spraying cylinders.

d. With the crankshaft stationary, again spray each cylinder through the spark plug holes with
approximately two (2) ounces of corrosion preventive oil. Assemble spark plugs and do not turn
crankshaft after cylinders have been sprayed.

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LYCOMING OPERATOR’S MANUAL SECTION 7
TIO-541 SERIES INSTALLATION AND STORAGE

The corrosion preventive oil to be used in the foregoing procedure should conform to specification MIL-
L-6529, Type 1, heated to 200°F/220°F (93°C/104°C) spray nozzle temperature. It is not necessary to flush
preservative oil from the cylinder prior to flying the aircraft. The small quantity of oil coating the cylinders
will be expelled from the engine during the first few minutes of operation.

NOTE

Oils of the type mentioned are to be used in Lycoming aircraft engines for corrosion
prevention only, and not for lubrication. See the latest revision of Lycoming Service
Instruction No. 1014 and Service Bulletin No. 318 for recommended lubricating oil.

Figure 7-1. Installation Drawing – Left Side View – TIO-541-A Series

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SECTION 7 LYCOMING OPERATOR’S MANUAL
INSTALLATION AND STORAGE TIO-541 SERIES

Figure 7-2. Installation Drawing – Right Side View – TIO-541-A Series

Figure 7-3. Installation Drawing – Left Side View – TIO-541-E Series

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LYCOMING OPERATOR’S MANUAL SECTION 7
TIO-541 SERIES INSTALLATION AND STORAGE

Figure 7-4. Installation Drawing – Right Side View – TIO-541-E Series

7-5
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 LYCOMING OPERATOR’S MANUAL

SECTION 8
TABLES

Page

Ground Run After Top Overhaul .............................................................................................................. 8-2

Flight Test After Top Overhaul.................................................................................................................. 8-3

Table of Speed Equivalents ......................................................................................................................... 8-4

Centigrade-Fahrenheit Conversion Table................................................................................................. 8-5

Inch Fractions Conversions ........................................................................................................................ 8-6

This Page Intentionally Left Blank.
LYCOMING OPERATOR’S MANUAL SECTION 8
TIO-541 SERIES TABLES

SECTION 8

TABLES

FOR TIGHTENING TORQUE RECOMMENDATIONS AND INFORMATION

CONCERNING TOLERANCES AND DIMENSIONS THAT MUST BE MAINTAINED
IN LYCOMING AIRCRAFT ENGINES, CONSULT LATEST REVISION OF SPECIAL
SERVICE PUBLICATION NO. SSP-1776.

CONSULT LATEST REVISION OF LYCOMING SERVICE INSTRUCTION NO. 1029

AND NO. 1150 FOR THE PROPER PROCEDURE FOR TIGHTENING CYLINDER
BASE HOLD DOWN NUTS TO CORRECT TORQUE.

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SECTION 8 LYCOMING OPERATOR’S MANUAL
TABLES TIO-541 SERIES

8-2
LYCOMING OPERATOR’S MANUAL SECTION 8
TIO-541 SERIES TABLES

8-3
SECTION 8 LYCOMING OPERATOR’S MANUAL
TABLES TIO-541 SERIES

TABLE OF SPEED EQUIVALENTS

Sec./Mi. M.P.H. Sec./Mi. M.P.H. Sec./Mi. M.P.H.

72.0 50 27.7 130 17.1 210

65.5 55 26.6 135 16.7 215
60.0 60 25.7 140 16.4 220
55.4 65 24.8 145 16.0 225
51.4 70 24.0 150 15.6 230
48.0 75 23.2 155 15.0 240
45.0 80 22.5 160 14.4 250
42.3 85 21.8 165 13.8 260
40.0 90 21.2 170 13.3 270
37.9 95 20.6 175 12.8 280
36.0 100 20.0 180 12.4 290
34.3 105 19.4 185 12.0 300
32.7 110 18.9 190 11.6 310
31.3 115 18.4 195 11.2 320
30.0 120 18.0 200 10.9 330
28.8 125 17.6 205 10.6 340

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LYCOMING OPERATOR’S MANUAL SECTION 8
TIO-541 SERIES TABLES

CENTIGRADE-FAHRENHEIT CONVERSION TABLE

Example: To convert 20°C to Fahrenheit, find 20 in the center column headed (F-C); then read 68.0°F in
the column (F) to the right. To convert 20°F to Centigrade; find 20 in the center column and read –6.67°C in
the (C) column to the left.

C F-C F C F-C C

-56.7 -70 -94.0 104.44 220 428.0

-51.1 -60 -76.0 110.00 230 446.0
-45.6 -50 -58.0 115.56 240 464.0
-40.0 -40 -40.0 121.11 250 482.0
-34.0 -30 -22.0 126.67 260 500.0
-28.9 -20 -4.0 132.22 270 518.0
-23.3 -10 14.0 137.78 280 536.0
-17.8 0 32.0 143.33 290 554.0
-12.22 10 50.0 148.89 300 572.0
-6.67 20 68.0 154.44 310 590.0
-1.11 30 86.0 160.00 320 608.0
4.44 40 104.0 165.56 330 626.0
10.00 50 122.0 171.11 340 644.0
15.56 60 140.0 176.67 350 662.0
21.11 70 158.0 182.22 360 680.0
26.67 80 176.0 187.78 370 698.0
32.22 90 194.0 193.33 380 716.0
37.78 100 212.0 198.89 390 734.0
43.33 110 230.0 204.44 400 752.0
48.89 120 248.0 210.00 410 770.0
54.44 130 266.0 215.56 420 788.0
60.00 140 284.0 221.11 430 806.0
65.56 150 302.0 226.67 440 824.0
71.00 160 320.0 232.22 450 842.0
76.67 170 338.0 237.78 460 860.0
82.22 180 356.0 243.33 470 878.0
87.78 190 374.0 248.89 480 896.0
93.33 200 392.0 254.44 490 914.0
98.89 210 410.0 260.00 500 932.0

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SECTION 8 LYCOMING OPERATOR’S MANUAL
TABLES TIO-541 SERIES

INCH FRACTIONS CONVERSIONS

Decimals, Area of Circles and Millimeters

Inch Decimal Area MM Inch Decimal Area MM

Fraction Equiv. Sq. In. Equiv. Fraction Equiv. Sq. In. Equiv.

1/64 .0156 .0002 .397 1/2 .5 .1964 12.700

1/32 .0312 .0008 .794 17/32 .5312 .2217 13.494
3/64 .0469 .0017 1.191 35/64 .5469 .2349 13.891
1/16 .0625 .0031 1.587 9/16 .5625 .2485 14.288
3/32 .0937 .0069 2.381 19/32 .5937 .2769 15.081
7/64 .1094 .0094 2.778 39/64 .6094 .2916 15.478
1/8 .125 .0123 3.175 5/8 .625 .3068 15.875
5/32 .1562 .0192 3.969 21/32 .6562 .3382 16.669
11/64 .1719 .0232 4.366 43/64 .6719 .3545 17.065
3/16 .1875 .0276 4.762 11/16 .6875 .3712 17.462
7/32 .2187 .0376 5.556 23/32 .7187 .4057 18.256
15/64 .2344 .0431 5.593 47/64 .7344 .4235 18.653
1/4 .25 .0491 6.350 3/4 .75 .4418 19.050
9/32 .2812 .0621 7.144 25/32 .7812 .4794 19.844
19/64 .2969 .0692 7.540 51/64 .7969 .4986 20.241
5/16 .3125 .0767 7.937 13/16 .8125 .5185 20.637
11/32 .3437 .0928 8.731 27/32 .8437 .5591 21.431
23/64 .3594 .1014 9.128 55/64 .8594 .5800 21.828
3/8 .375 .1105 9.525 7/8 .875 .6013 22.225
13/32 .4062 .1296 10.319 29/32 .9062 .6450 23.019
27/64 .4219 .1398 10.716 59/64 .9219 .6675 23.416
7/16 .4375 .1503 11.112 15/16 .9375 .6903 23.812
15/32 .4687 .1725 11.906 31/32 .9687 .7371 24.606
31/64 .4844 .1842 12.303 63/64 .9844 .7610 25.003

8-6