The engine is finally back!

[Viperdoc]

After sending my Lycoming AEIO-540 to the factory for a mandatory repair it
has finally returned. At Oshkosh this year the people at the Lycoming booth
swore it would take only two weeks, but when the actual paperwork arrived
everything said one month in the shop. It ended up taking a little over a
month, from the day it was crated by my mechanic to the day it was returned.

Lycoming says they will pay for the costs of removing and remounting the
engine, along with the shipping as well as the repairs. Mine only had a
little over 300TT. I guess they figure the costs of the new crankshafts as
well as the repairs for all of the engines would be a lot cheaper than
series of very expensive product liability lawsuits!

Anyway, it looks like it'll need mineral oil for a while, and then there's
also the risk of something else working loose or breaking after the removal
and install- we'll have to wait and see in this regard. I may take it and
run it hard for a few hours, and then take it back to the mechanic to pull
the cowling and make sure everything stayed tight.

I've heard a lot of different advice on breaking in a new engine- run at
full power, don't run at any power for a long period of time, vary the power
settings (MP and prop), etc. Any advice? When do you switch back to regular
detergent oil?

[[email protected]]

Viperdoc wrote:

> I've heard a lot of different advice on breaking in a new engine- run at
> full power, don't run at any power for a long period of time, vary the power
> settings (MP and prop), etc. Any advice? When do you switch back to regular
> detergent oil?

Lycoming should have sent a copy of their recommended procedure with
the engine. If not, I'd get on them to give you a set of guidelines so
that if there is a failure during the breakin period they can't tell
you that you used the incorrect procedure.

Craig C.

[Paul kgyy]

As others have said, follow the Lycoming recommendations to the letter.
It will involve high power settings until the rings seat (assuming you
have new rings) and you will use mineral oil until that happens. The
event will declare itself with lower CHT and reduced oil consumption.

I did my first 30 minutes orbiting the airport with tower permission.

[Jim Burns]

Glad you got it back! Hopefully it will be a smooth install and no future
problems.

Google "Lycoming engine break in " and you'll get several hits directly from
Lycoming's site regarding break in. If there is any warranty remaining, I
would call Lycoming and ask them directly, then document the call and their
advise. (just in case) :)

Congrats. Glad you got it back.

Jim

"Viperdoc" > wrote in message
...
> After sending my Lycoming AEIO-540 to the factory for a mandatory repair
it
> has finally returned. At Oshkosh this year the people at the Lycoming
booth
> swore it would take only two weeks, but when the actual paperwork arrived
> everything said one month in the shop. It ended up taking a little over a
> month, from the day it was crated by my mechanic to the day it was
returned.
>
> Lycoming says they will pay for the costs of removing and remounting the
> engine, along with the shipping as well as the repairs. Mine only had a
> little over 300TT. I guess they figure the costs of the new crankshafts as
> well as the repairs for all of the engines would be a lot cheaper than
> series of very expensive product liability lawsuits!
>
> Anyway, it looks like it'll need mineral oil for a while, and then there's
> also the risk of something else working loose or breaking after the
removal
> and install- we'll have to wait and see in this regard. I may take it and
> run it hard for a few hours, and then take it back to the mechanic to pull
> the cowling and make sure everything stayed tight.
>
> I've heard a lot of different advice on breaking in a new engine- run at
> full power, don't run at any power for a long period of time, vary the
power
> settings (MP and prop), etc. Any advice? When do you switch back to
regular
> detergent oil?
>
>

[dlevy]

Same here.

"Paul kgyy" > wrote in message
ups.com...
><snip>
> I did my first 30 minutes orbiting the airport with tower permission.
>

[BTIZ]

I'll echo that... we did an overhaul by a local shop. Piper Pawnee
O-540-235HP with STC to 250HP

He did his normal run at the shop.. then once installed.. it was a quick
(short) static run (mag check) to check oil pressures and leaks.. then shut
down inspect...

Then it was start and go.. no ground time.. it was 100F out and we did not
want to overheat on the ground... FULL Power climb to 10,000MSL where the
outside temps were cooler and we could run it full throttle at cruise.
Stayed there for 1+30 monitoring oil temp and pressure (no CHT available).

A few more flights at altitude to accumulate about 5 hours total before
putting it to work, glider tow.

Over 55 hours on the engine now and just swapped from Mineral to regular AD.
All appears well.

BT

"dlevy" > wrote in message
.. .
> Same here.
>
> "Paul kgyy" > wrote in message
> ups.com...
>><snip>
>> I did my first 30 minutes orbiting the airport with tower permission.
>>
>
>

[Fly]

Before starting the last engine I put together, I borrowed a oil pressure
pot to fill the galleys.
Attached at the oil pressure takeoff and pushed oil in by air pressure
before the first start.
Used a quart or so. It not only fills the galleys but also pumps up the
lifters.
Engine fired on the 2 blade and ran smooth!

Kent Felkins
Tulsa


"Viperdoc" > wrote in message
...
> After sending my Lycoming AEIO-540 to the factory for a mandatory repair
it
> has finally returned. At Oshkosh this year the people at the Lycoming
booth
> swore it would take only two weeks, but when the actual paperwork arrived
> everything said one month in the shop. It ended up taking a little over a
> month, from the day it was crated by my mechanic to the day it was
returned.
>
> Lycoming says they will pay for the costs of removing and remounting the
> engine, along with the shipping as well as the repairs. Mine only had a
> little over 300TT. I guess they figure the costs of the new crankshafts as
> well as the repairs for all of the engines would be a lot cheaper than
> series of very expensive product liability lawsuits!
>
> Anyway, it looks like it'll need mineral oil for a while, and then there's
> also the risk of something else working loose or breaking after the
removal
> and install- we'll have to wait and see in this regard. I may take it and
> run it hard for a few hours, and then take it back to the mechanic to pull
> the cowling and make sure everything stayed tight.
>
> I've heard a lot of different advice on breaking in a new engine- run at
> full power, don't run at any power for a long period of time, vary the
power
> settings (MP and prop), etc. Any advice? When do you switch back to
regular
> detergent oil?
>
>

[George Patterson]

Fly wrote:
> Before starting the last engine I put together, I borrowed a oil pressure
> pot to fill the galleys.

I did something similar when I replaced the engine in a van I owned long ago. I
scavenged an empty freon tank, removed the valve, and poured four quarts of oil
into it with a funnel (seemed to take forever). Then I put the valve back in and
hooked it up to an air compressor. Once I got it pressurized, I turned it upside
down, hooked it up to the hole for the oil pressure sending unit, and opened the
valve.

George Patterson
Coffee is only a way of stealing time that should by rights belong to
your slightly older self.

[[email protected]]

>At Oshkosh this year the people at the Lycoming booth swore it would >take only two weeks, but when the actual paperwork arrived everything >said one month in the shop. It ended up taking a little over a month, >from the day it was crated by my mechanic to the day it was returned.

You've never been lied to before? You dumbass MoFo.

[[email protected]]

>I did something similar when I replaced the engine in a van I owned long ago. I
>scavenged an empty freon tank, removed the valve, and poured four quarts of oil
>into it with a funnel (seemed to take forever). Then I put the valve back in and
>hooked it up to an air compressor. Once I got it pressurized, I turned it upside
>down, hooked it up to the hole for the oil pressure sending unit, and opened the
>valve.

Probably think you're clever don't you asshole?

[Gig 601XL Builder]

> wrote in message
oups.com...
> >At Oshkosh this year the people at the Lycoming booth swore it would
> > >take only two weeks, but when the actual paperwork arrived everything
> > >said one month in the shop. It ended up taking a little over a month,
> > >from the day it was crated by my mechanic to the day it was returned.
>
> You've never been lied to before? You dumbass MoFo.
>

I don't know that he was lied to. You got to figure it took a week to get
from him to them and then a week from them to him. That means the work took
2 weeks.

[Jim Burns]

BT,
Can I ask how much the OH cost at your local shop? I'm always interested
for when the day comes we'll have to OH one of ours.
Thanks
Jim

"BTIZ" > wrote in message
news:6qnqf.6557$LB5.5831@fed1read04...
> I'll echo that... we did an overhaul by a local shop. Piper Pawnee
> O-540-235HP with STC to 250HP
>
> He did his normal run at the shop.. then once installed.. it was a quick
> (short) static run (mag check) to check oil pressures and leaks.. then
shut
> down inspect...
>
> Then it was start and go.. no ground time.. it was 100F out and we did not
> want to overheat on the ground... FULL Power climb to 10,000MSL where the
> outside temps were cooler and we could run it full throttle at cruise.
> Stayed there for 1+30 monitoring oil temp and pressure (no CHT available).
>
> A few more flights at altitude to accumulate about 5 hours total before
> putting it to work, glider tow.
>
> Over 55 hours on the engine now and just swapped from Mineral to regular
AD.
> All appears well.
>
> BT
>
> "dlevy" > wrote in message
> .. .
> > Same here.
> >
> > "Paul kgyy" > wrote in message
> > ups.com...
> >><snip>
> >> I did my first 30 minutes orbiting the airport with tower permission.
> >>
> >
> >
>
>

[Eduardo K.]

In article <6qnqf.6557$LB5.5831@fed1read04>,
BTIZ > wrote:
>
>Then it was start and go.. no ground time.. it was 100F out and we did not
>want to overheat on the ground... FULL Power climb to 10,000MSL where the
>outside temps were cooler and we could run it full throttle at cruise.
>Stayed there for 1+30 monitoring oil temp and pressure (no CHT available).
>

When I was member of a local club full of old pilots, they had a cilinder
crack on a 0-300 form a C172B. They pulled the cilinders, topped it and
then proceeded to 'break it in' by insisting on reduced power for the next
100hours...

I quit that club and joined another.


--
Eduardo K. | Darwin pone las reglas.
http://www.carfun.cl | Murphy, la oportunidad.
http://e.nn.cl |
| Yo.

[Viperdoc]

They actually told me two weeks total- from the day it was shipped to the
day it was returned.

[BTIZ]

I'd have to check with the treasurer... but I think the shop price came
close to $19K.. plus we did out own "in house" labor for the R&R, plus new
braided oil lines..

BT

"Jim Burns" > wrote in message
...
> BT,
> Can I ask how much the OH cost at your local shop? I'm always interested
> for when the day comes we'll have to OH one of ours.
> Thanks
> Jim
>
> "BTIZ" > wrote in message
> news:6qnqf.6557$LB5.5831@fed1read04...
>> I'll echo that... we did an overhaul by a local shop. Piper Pawnee
>> O-540-235HP with STC to 250HP
>>
>> He did his normal run at the shop.. then once installed.. it was a quick
>> (short) static run (mag check) to check oil pressures and leaks.. then
> shut
>> down inspect...
>>
>> Then it was start and go.. no ground time.. it was 100F out and we did
>> not
>> want to overheat on the ground... FULL Power climb to 10,000MSL where
>> the
>> outside temps were cooler and we could run it full throttle at cruise.
>> Stayed there for 1+30 monitoring oil temp and pressure (no CHT
>> available).
>>
>> A few more flights at altitude to accumulate about 5 hours total before
>> putting it to work, glider tow.
>>
>> Over 55 hours on the engine now and just swapped from Mineral to regular
> AD.
>> All appears well.
>>
>> BT
>>
>> "dlevy" > wrote in message
>> .. .
>> > Same here.
>> >
>> > "Paul kgyy" > wrote in message
>> > ups.com...
>> >><snip>
>> >> I did my first 30 minutes orbiting the airport with tower permission.
>> >>
>> >
>> >
>>
>>
>
>

[Jim Burns]

Thanks

"BTIZ" > wrote in message
news:KTLqf.13950$LB5.5023@fed1read04...
> I'd have to check with the treasurer... but I think the shop price came
> close to $19K.. plus we did out own "in house" labor for the R&R, plus new
> braided oil lines..
>
> BT
>
> "Jim Burns" > wrote in message
> ...
> > BT,
> > Can I ask how much the OH cost at your local shop? I'm always
interested
> > for when the day comes we'll have to OH one of ours.
> > Thanks
> > Jim
> >
> > "BTIZ" > wrote in message
> > news:6qnqf.6557$LB5.5831@fed1read04...
> >> I'll echo that... we did an overhaul by a local shop. Piper Pawnee
> >> O-540-235HP with STC to 250HP
> >>
> >> He did his normal run at the shop.. then once installed.. it was a
quick
> >> (short) static run (mag check) to check oil pressures and leaks.. then
> > shut
> >> down inspect...
> >>
> >> Then it was start and go.. no ground time.. it was 100F out and we did
> >> not
> >> want to overheat on the ground... FULL Power climb to 10,000MSL where
> >> the
> >> outside temps were cooler and we could run it full throttle at cruise.
> >> Stayed there for 1+30 monitoring oil temp and pressure (no CHT
> >> available).
> >>
> >> A few more flights at altitude to accumulate about 5 hours total before
> >> putting it to work, glider tow.
> >>
> >> Over 55 hours on the engine now and just swapped from Mineral to
regular
> > AD.
> >> All appears well.
> >>
> >> BT
> >>
> >> "dlevy" > wrote in message
> >> .. .
> >> > Same here.
> >> >
> >> > "Paul kgyy" > wrote in message
> >> > ups.com...
> >> >><snip>
> >> >> I did my first 30 minutes orbiting the airport with tower
permission.
> >> >>
> >> >
> >> >
> >>
> >>
> >
> >
>
>

[Gig 601XL Builder]

"Viperdoc" > wrote in message
...
> They actually told me two weeks total- from the day it was shipped to the
> day it was returned.
>
>

Well they were idiots for saying that and you have every right to be ****ed.
I assume you or they didn't ship the engine one or two day air. They really
should quote "time in the shop". It's not like they can control how long it
takes to ship.

[CriticalMass]

BTIZ wrote:

> I'll echo that... we did an overhaul by a local shop. Piper Pawnee
> O-540-235HP with STC to 250HP
>
> Then it was start and go.. no ground time.. it was 100F out and we did not
> want to overheat on the ground... FULL Power climb to 10,000MSL where the
> outside temps were cooler and we could run it full throttle at cruise.

Well, glad to hear it's still doing OK, but in a normally aspirated
engine, you're not gonna' make the higher power settings you need for a
good breakin at 10,000msl. You're prolly not going to be able to make
much more than 55% power, even *at* full throttle.

Would have been better to stay lower where you could make 65-75% power
with that engine during those critical, first break-in hours.