Engine Maintenance Manual (Principal Manual) HIO-390-A1A Engine October 2017 Part No. MM-HIO-390-A1A © 2017 Avco Corporation. All Rights Reserved. HIO-390-A1A Engine Maintenance Manual Lycoming Part Number: MM-HIO-390-A1A Contact Us: Mailing Address: Lycoming Engines 652 Oliver Street Williamsport, PA 17701 USA Phone: U.S. and Canada Toll Free: +1 (800) 258-3279 Factory Direct: +1 (570) 323-6181 Technical Support Hotline • +1 (877) 839-7878 (Toll Free) • +1 (570) 327-7222 • Email [email protected] Lycoming’s regular business hours are Monday through Friday from 8:00AM through 5:00PM Eastern Time (-5 GMT). Visit us Online: www.lycoming.com HIO-390-A1A Engine Maintenance Manual RECORD OF REVISIONS Revision Revised Revision Date By Revision Description Original Original Release of Maintenance Manual - Part No. MM-HIO-390-A1A © 2017 Avco Corporation. All Rights Reserved Record of Revisions October 2017 Page i HIO-390-A1A Engine Maintenance Manual This page intentionally left blank. Record of Revisions © 2017 Avco Corporation. All Rights Reserved Page ii October 2017 HIO-390-A1A Engine Maintenance Manual SERVICE DOCUMENT LIST NOTICE: The following is a list of service documents referenced in or incorporated into the information in this manual. Always refer to the latest revision of any service document (including any supplements) for changes or additional information. Number Incorporation Subject Date S.B. 201 10/17 Inspection of Crankshaft Flange S.B. 225 10/17 Replacement of Valve Rocker Thrust Washers S.B. 240 10/17 Mandatory Parts Replacement at Overhaul and During Repair or Maintenance S.B. 342 10/17 Fuel Line (Stainless Steel Tube Assy.) and Support Clamp Inspection and Installation S.B. 357 10/17 Engine Inspection After an Engine Has Been Soaked or Immersed S.B. 369 10/17 Engine Inspection after Overspeed S. B. 388 10/17 Procedure to Determine Exhaust Valve and Guide Condition S.B. 398 10/17 Recommended Corrective Action for Use of Incorrect Fuel S.B. 399 10/17 Action to Take If Loss of Oil Pressure S.B. 401 10/17 Recommendations for Aircraft Struck by Lightning S.B. 475 10/17 Crankshaft Gear and Crankshaft Gear End Inspection and Corrective Action S.B. 533 10/17 Recommended Action for Sudden Engine Stoppage, Propeller/Rotor Strike or Loss of Propeller/Rotor Blade or Tip S.B. 630 10/17 Connecting Rod Bushing Inspection S.I. 1009 10/17 Required Time Between Overhaul (TBO) Schedule S.I. 1011 10/17 Tappets and Lifters S.I. 1014 10/17 Lubricating Oil Recommendations S.I. 1029 10/17 Tightening Procedures for Crankcase Thru-Studs and Bolts S.I. 1037 10/17 Approved Pistons, Rings and Cylinders for Use on Lycoming Aircraft Engines S.I. 1042 10/17 Approved Spark Plugs S.I. 1043 10/17 Spark Plug Heli-Coil® Insert Replacement S.I. 1047 10/17 Inspection and Reconditioning Procedures for Nitride Hardened Steel Cylinders © 2017 Avco Corporation. All Rights Reserved Service Document List October 2017 Page iii HIO-390-A1A Engine Maintenance Manual SERVICE DOCUMENT LIST (CONT.) Incorporation Number Subject Date S.I. 1059 10/17 Pre-Lubrication of Parts Before Assembly S.I. 1060 10/17 Push Rod Identification S.I 1070 10/17 Specified Fuels for Spark Ignited Gasoline Aircraft Engine Models S.I. 1080 10/17 Maintenance Items for Special Attention S.I. 1098 10/17 Propeller Flange Bushing Location S.I. 1129 10/17 Methods of Checking DC Alternator and Generator Belt Tension S.I. 1132 10/17 Magneto Drop-off S.I. 1140 10/17 Salvage Repair of Magneto Bearing Recess in Crankcase S.I. 1154 10/17 FAA-Approved Starters and Alternators S.I. 1172 10/17 Adjustable Oil Pressure Relief Valve Installation and Valve Seat Repair or Replacement S.I. 1191 10/17 Cylinder Compression Check S.I. 1241 10/17 Pre-oil the Engine Prior to Initial Start S.I. 1243 10/17 Piston Identification S.I. 1267 10/17 Piston Pin Plug Usage S.I. 1285 10/17 Non-Destructive Testing of Lycoming Engine Parts S.I. 1301 10/17 Identification of Primer and Fuel Injector Lines S.I. 1316 10/17 Valve Seat Refacing on Oil Cooler Bypass Valves S.I. 1324 10/17 Crankshaft Oil Seals S.I. 1340 10/17 Piston Pin Identification S.I. 1409 10/17 Lycoming Engines P/N LW-16702 Oil Additives S.I. 1425 10/17 Suggested Maintenance Procedures to Reduce the Possibility of Valve Sticking S.I. 1427 10/17 Field Run-In and Break-In S.I. 1458 10/17 Connecting Rod Bolts (Identification and Installation) S.I. 1485 10/17 Exhaust Valve and Guide Identification Procedure S.I. 1492 10/17 Piston Pin Plug Wear Inspection S.I. 1514 10/17 Roller Tappets Part Information Update S.I. 1529 10/17 Hydraulic Lifter and Tappet Body Part Numbers S.I. 1530 10/17 Engine Inspection in Particulate-Laden Environments S.I. 1555 10/17 Piston Removal, Cleaning, Inspection, and Installation Service Document List © 2017 Avco Corporation. All Rights Reserved Page iv October 2017 HIO-390-A1A Engine Maintenance Manual SERVICE DOCUMENT LIST (CONT.) Incorporation Number Subject Date S.I. 1565 10/17 Replacement Thermostatic Oil Cooler Bypass Valve S.I. 1566 10/17 Lycoming Engines Approves the Use of Safety Cable L114 10/17 Reciprocating Engine and Accessory Maintenance Publications L171 10/17 General Aspects of Spectrometric Oil Analysis L180 10/17 Engine Preservation for Active and Stored Aircraft L192 10/17 Spark Plug Fouling L193 10/17 Engine Firing Order L197 10/17 Recommendations to Avoid Valve Sticking L221 10/17 Warranty Repair of Precision Airmotive Corporation Fuel Control Products L247 10/17 Shelf Life Requirements L253 10/17 Warranty Repair of AVStar Fuel Systems, Inc. Fuel Control Products L270 10/17 Extended Maintenance Intervals for Spark-Ignited Engines Operated on Unleaded Fuels © 2017 Avco Corporation. All Rights Reserved Service Document List October 2017 Page v HIO-390-A1A Engine Maintenance Manual This page intentionally left blank. Service Document List © 2017 Avco Corporation. All Rights Reserved Page vi October 2017 HIO-390-A1A Engine Maintenance Manual TABLE OF CONTENTS Subject Page Title Page _______________________________________________________________________ Record of Revisions .............................................................................................................................. i Service Document List ....................................................................................................................... iii Table of Contents .............................................................................................................................. vii Abbreviations and Acronyms ........................................................................................................ xvii Introduction ...................................................................................................................................... xix Airworthiness Limitations ............................................................................................................. xxiii Required Maintenance ........................................................................................ 05-00 — Required Maintenance ............................................................................................................. 1 — General ..................................................................................................................................... 1 —Table 1 - Tools for Service and Maintenance ...................................................................... 1 — Time Between Overhaul (TBO) ............................................................................................... 2 — Safety Precautions - Before Engine Maintenance .................................................................... 3 — Maintenance Practices .............................................................................................................. 3 — General Engine Inspection Criteria .......................................................................................... 5 — Requirements for Engine Maintenance .................................................................................... 5 — Approved Parts ......................................................................................................................... 5 Time Limits / Inspections .................................................................................... 05-10 — Engine Inspection Schedule for HIO-390-A1A Engines ......................................................... 7 Required Engine Inspections for HIO-390-A1A Engines ................................ 05-20 — Engine Inspections .................................................................................................................... 9 — Visual Inspection for HIO-390-A1A Engines .......................................................................... 9 — Visual Inspection Checklist for HIO-390-A1A Engines ........................................................ 10 — Operational Leak Check Sheet for HIO-390-A1A Engines .................................................... 16 — 10-Hour Initial Engine Inspection Checklist for HIO-390-A1A Engines .............................. 17 — 25-Hour Engine Inspection Checklist for HIO-390-A1A Engines ......................................... 18 — 50-Hour Engine Inspection Checklist for HIO-390-A1A Engines ......................................... 20 — 100-Hour or Annual Engine Inspection Checklist for HIO-390-A1A Engines ...................... 23 — 400-Hour Engine Inspection Checklist for HIO-390-A1A Engines ....................................... 28 — 500-Hour Engine