MOTOR LYCOMING TEO-540

PROPULSION LABORATORY

PROFESSOR
ING. CARLOS QUINTERO

STUDENTS
LUIS CARLOS ESTRADA GÓMEZ
MARÍA CECILIA GARCÍA BULA
SEBASTIÁN SÁNCHEZ
SEBASTIÁN SUÁREZ
DANIEL MARTÍNEZ
WILSON HEREDIA
JUAN CARLOS VILLA

UNIVERSIDAD PONTIFICIA BOLIVARIANA

FACULTY OF ENGINEERING
AERONAUTICAL ENGINEERING
MEDELLÍN/ANTIOQUIA/COLOMBIA
06/SEPTIEMBRE/2019

INTRODUCTION
This document presents a detailed report of the parts that compose an aviation engine and a description
of the process undertaken to carry out the disarmament and assembly of the Lycoming TEO engine-
540-C1A; this process is part of the methodology proposed by the Universidad Pontificia Bolivariana
UPB in order to complement the theoretical knowledge of the Propulsion I course through the
laboratory.
Each engine component and accessories were dismantled and assembled for the acquisition of
knowledge of coupling and operation of each of them which will be explained throughout the process,
supported by a section where the photographic record or log of the procedure performed is evidenced.
Laboratory practice aims to bring the student closer to the industry.
GENERAL
Type/ Model
Lycoming TEO-540 / Lycoming TEO-540-C1A
Type Certificate Holder Lycoming Engines An Operating Division of AVCO Corporation 652 Oliver
Street Williamsport, Pennsylvania, 17701, USA

EASA Type Certification: Type certificate number EASA.IM.E.119, certified 12 December 2018 and
last issued 06 September 2019.

Installed in:

AAC Angel Aero Commander Akaflieg München Bárcenas B-01

500 series Mü30 Schlacro
Bellanca Viking 300 Bellanca 17-31ATC Britten-Norman Britten-Norman
(17-31 and 17- Turbo Viking Islander Trislander
31TC)
Brantly 305 CallAir A-9 Cessna 182 Dornier Do 28
Dream Tundra Embraer EMB 202 Enaer T-35 Pillan Evangel 4500
Ipanema
Gippsland GA8 Gippsland GA200 Helio/Maule M5- Mooney M20
235
Moynet 360-6 Murphy Moose PAC CT/4E Piaggio P.166
Jupiter
Piper Aerostar Piper Aztec Piper Saratoga Piper PA-24
Comanche
Piper PA-25 Piper PA-31 Navajo Piper PA-46 Malibu Pitts Special
Pawnee variants
Robinson R44 Rockwell Sharp Nemesis Socata TB-20
Commander 114 NXT
Socata TB-30 Utva Lasta Utva-65 Privrednik Van's Aircraft RV-
Epsilon 10
Zlin Z-143 Zlín Z 50 Embraer Ipanema

TECHNICAL CHARACTERISTICS:

Type Design Definition

TEO-540-C1A: Engine Parts Catalogue TEO-540-C1A; Part Number PC-TEO-540-C1A and
Installation Drawing No. 04D63629

Description

The Lycoming TEO-540 engine is an electronically controlled, fuel injected, turbocharged, horizontally
opposed, six-cylinder, four strokes, spark ignited, aircooled, wet sump engine incorporating provisions
for front and rear mounted accessories. The Electronic Engine Control System is single lever
controlled.

The letter T stands for turbocharged, E for independent electronic sensors and fuel injection for each
cylinder and O for opposing cylinders.

Constant speed propellers such as MT Propeller MTV-14-B-C-F/CF195-30 (EASA TCDS n° P.017)

are fitted, thanks to a governor system being present in the engine system.

Displacement: 8.873 dm3

Bore x stroke: 130.175 mm x 111.125 mm

Compression ratio: 7.3:1

Gear ratio: N/A

Dry weight: 251kg (553.5lb; weight without starter, alternator, Engine Control Unit (ECU) and Power
Box)

Speed Limit: Max. Overspeed (3 seconds, Momentary overspeed): 2833 rpm

Ratings

Rating TEO-540-C1A
Power, kW (HP) Take-off and Maximum 280 (375)
Continuous, full throttle at at 2575 rpm
sea level pressure altitude.

The Lycoming TEO-540-C1A engine model is equipped with an electronic ignition and injection
system. The software of the Electronic Engine Control System Software is verified to level B according
to RTCA Document DO-178B.

Fluids (Fuel, Oil, Coolant, Additives)

Fuel: Aviation Gasoline, minimum grade 100 or 100LL. See latest revision of Lycoming Service
Instruction No. 1070

Oil sump capacity

12 quarts – 11 liters. The minimum safe oil level: 2,75 quarts – 2,6 liters.

DIMENSIONS

TEO-540-C1A
Overall Length 1303 mm (51.32 in.)
Overall Height 569 mm (22.42 in.)
Width 871 mm (34.31 in.)

AIRCRAFT ACCESSORY DRIVES

Rotation Max.
Max. Torque Nm
Designatio direction Speed ratio to Overhang
(in. lbs)
n (facing drive crankshaft moment
Continuous static
pad) Nm (in. lbs)
Prop. 14.12 (125) 248.57
CW 0.947:1 2.82 (25)
Governor (2200)
Starter• CCW 16.556:1 50.84 (450) 16.95 (150)
6.78 (60) 13.56
Alternator• CW 3.10:1
(120)
19.77 (175)
2.82 (25) 50.84
Fuel Pump CW 1.0:1 2.82 (25)
(450)
Accessory 7.91 (70) 90.39
CCW 1.3:1 2.82 (25)
1× (800)
Accessory 11.30 (100) 90.39
CW 1.385:1 4.52 (40)
2× (800)
Accessory 4.52 (40) 33.89
CW 3.54:1 2..82 (25)
3x (300)

TEMPERATURE LIMITS

Cylinder head (well type thermocouple): 260 °C (500 °F)

Oil inlet: 118 °C (245 °F)

Exhaust Gas: 899 °C (1650 °F)

Speed Limits

Max. Overspeed (3 seconds, Momentary overspeed): 2833 rpm See latest revision of Lycoming Service
Bulletin No. 369

Pressure Limits

Fuel Pressure
Inlet to fuel pump: Minimum: -13.8 kPa (-2.0 psig) Maximum: 448.2 kPa (65.0 psig)

Fuel Rail Pressure: 296.5 kPa (43.0 psid, above Manifold pressure)

Oil Pressure: Minimum (idle): 172 kPa (25 psig) Normal (flight, take-off): 379...655 kPa (55...95
psig) Maximum (starting, warm-up, taxi) 793 kPa (115 psig)

Manifold Air Pressure: Maximum: 196.07 kPa (57.9 inHg absolute)

Turbocharger Exhaust Back Pressure: Maximum: 1.69 kPa (0.5 inHg)

Operating Altitude: Maximum altitude: 7620 m (25000 ft)

OPERATING AND SERVICE INSTRUCTIONS

Manuals

TEO-540-C1A
Operation and Installation Manual IOM-TEO-540-C1A

Instructions for Continued Airworthiness

TEO-540-C1A
Maintenance Manual MM-TEO-540-C1A
Overhaul Manual OHM-TEO-540-C1A
Parts Catalogue PC-TEO-540-C1A

METHODOLOGY

UNINSTALLING

Uninstalling gearbox (Ratchet 14 mm) (8 nuts, but there are 4 functional)

Cylinder 2 Cylinder 4 Cylinder 6

Uninstalling 4 6 8 even 8 screws, 8 washers, 1 8 screws, 8 washers, 1
cylinders (BLADE cover with gasket cover with gasket
SCREWDRIVER): started
with the opening of the 4 nuts 2 washers, 2 side 4 nuts, 4 washers, 2 side
cylinder cover (8 screws 8 plates plates
 washers) (Cylinder cover 1
gasket) 8-cylinder nuts - carter 1-cylinder nuts - carter (3/8)
4 nuts (1/2) two lower and
 4 Side nut 4 Wrench Q-0 to disassemble upper plates
washers (7/16 8 (4-3 / 8) (4-1 / 2) nut
ratchet) cylinder-carter (Upper- and Disassembled cylinder 6:
lower-cylinder; cylinder - two internal tubes, two
 2 side plates carter) hollow tubes, two green
(cover) gaskets, 1 normal washer, 2
Disassembled cylinder 4: washers with numbering
Wrench Q-0 to disassemble two internal tubes, two 201 (varied geometry)
8 (4-3 / 8) (4-1 / 2) hollow tubes, two green
cylinder-carter nut (Upper gaskets, 2 normal washer, 2
cylinder plate - carter) washers with numbering
201 (varied geometry)
Disassembled cylinder 2:
two internal tubes, two
hollow tubes, two green
gaskets, 2 normal washers,
2 washers with numbering
201 (varied geometry)

Disassembled accessory drive - nut removal.

Removal of crankcase nuts (a support is without a nut).

The accessory drive was removed.

Removal screws that connect crankcase to oil carter (1st right side, 2nd left side).

Oil carter was removed.

Removal screw union of crankcase (located in accessory drive).

Removal of lower union screws crankcase (7 screws).

Piston 2 Piston 4 Piston 4

1 lubrication rings and 2 2 smooth rings 1 lubrication 2 smooth rings and (1
smooth rings (piston 2) ring (broken lubrication) lubrication ring (with half a
(damage lubrication ring) piece of good packaging))

The crankcase, camshaft and crankshaft were removed.

INSTALLING
Aircrafts that use this engine

Tecnam P2012

Bibliography

[1] "Tecnam," [Online]. Available: https://www.tecnam.com/aircraft/p2012-traveller/. [Accessed 2

September 2019].

https://www.easa.europa.eu/sites/default/files/dfu/TCDS_EASA.IM_.E.119_iss2.pdf