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www.lycoming.com

SERVICE
INSTRUCTION

DATE:

February24,2014

ServiceInstructionNo.1009AW
(SupersedesServiceInstructionNo.1009AV)
EngineeringAspectsare
FAAApproved

SUBJECT:

RecommendedTimeBetweenOverhaulPeriods

MODELSAFFECTED:

AllLycomingPistonAircraftEngines
NOTE

Incompletereviewofalltheinformationinthisdocumentcancauseerrors.Readtheentire
ServiceInstructiontomakesureyouhaveacompleteunderstandingoftherequirements.
This Service Instruction identifies the established Time Between Overhaul (TBO) for Lycoming piston
aircraft engines that have genuine Lycoming parts only. The TBOs, herein, do not apply to Lycoming
enginemodelsthatcontainpartsotherthanthosesuppliedbyLycomingEngines.
The information in this revision of Service Instruction 1009 is approved as an Alternative Means of
Compliance(AMOC)forcompliancewithAD20121901,paragraphs(f)(1)(i)and(f)(2)(i).
The TBOs take into account service experience, variations in operating conditions, and frequency of
operation. However, because of variations in the manner in which engines are operated and
maintained, Lycoming Engines cannot give assurance that any individual operator will achieve the
TBOsidentifiedherein.
Continuousserviceassumesthattheaircraftwillnotbeoutofserviceformorethan30consecutivedays.
Iftheaircraftistobeoutofserviceformorethan30consecutivedays,refertothelatestrevisionofService
LetterL180.
Engine deterioration in the form of corrosion (rust) and the drying out and hardening of
compositionmaterialssuchasgaskets,seals,flexiblehosesandfuelpumpdiaphragmscanoccurifan
engineisoutofserviceforanextendedperiodoftime.Duetothelossofaprotectiveoilfilmafteran
extendedperiodofinactivity,abnormalwearonsoftmetalbearingsurfacescanoccurduringengine
start. Therefore, all engines that do not accumulate the hourly period of TBO specified in this
publicationarerecommendedtobeoverhauledinthetwelfthyear.
Table1identifiestheTBOsforLycomingenginemodelsusedinfixedwingaircraft.Table2containsthe
TBOsforLycomingenginemodelsusedonrotarywingaircraft.

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2014 byLycoming.AllRightsReserved
LycomingEnginesis adivisionofAvco Corporation.

NOTE
TherecommendedTBOsidentifiedinTables1and2donotapplytoenginesusedforcrop
dusting or other aircraft used for chemical application. The TBO for engines in these
applicationsisamaximumof1500hours,oratrecommendedTBO,whicheverislower.
Engineaccessoriesandpropellerscouldrequireoverhaulpriortoengineoverhaul.Completetheoverhaul
ofthesecomponentsinaccordancewiththeaccessorymanufacturersrecommendation.
Reliabilityandaverageservicelifecannotbepredictedwhenanenginehasundergoneany modification
notapprovedbyLycomingEngines.TheTBOsshowninTables1and2arerecommendationsforengines
asmanufactured,withoutconsideringanymodificationsthatcouldalterthelifeoftheengine.Refertonotes
shownafterTables1and2andidentifiedbynumberinTables1and2foradditionalspecificdetails.
Table1
FixedWingAircraft
RecommendedTimeBetweenOverhaulPeriods
EngineModels

SeeNote
12
13

1,10,11
11
1,10,11
4,6,10,11
2,4,10,11
6
6
1
1,4,10,11
4,11
11
4,5,6,10,11
1,4,10,11
3,11
3,4,11
6
3,11
6
6
11
6

1
1,10
1,11
10,11

O235Series(exceptF,G, J)
O235F,G,J
O290D
O290D2
O320Series(exceptO320H)
O320H
IO320A,E
IO320B, D, F
IO320C
AIO320(160HP)
AEIO320Series
O340Series
O360Series(exceptO360E, J2A)
O360E
IO360L2A
IO360A,C, D,J(200HP)
IO360B, E, F,M(180HP)
TO360C,FTIO360C
TO360E(180HP)
AIO360(200HP)
TIO360ASeries
AEIO360Series(180HP)
AEIO360Series(200HP)
IO390A
AEIO390A
O435GO435
GO,GSO480IGSO480
O540A,B, E4A5
O540E4B5, E4C5
O540G, H, J

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Hours
2400
2000
2000
1500
2000
2000
2000
2000
1800
1600
1600
2000
2000
2000
2000
2000
2000
1800
1800
1400
1200
1600
1400
2000
1400
1200
1400
2000
2000
2000

Table1(Cont.)
FixedWingAircraft
RecommendedTimeBetweenOverhaulPeriods
EngineModels

SeeNote
2,11
1,10,11

1,10,11
1,10
1,10,11
2,10
2,10
10
11
10,11
6

3,4,11
3,4,7,11
3,4,11,14
3
3,9
3
11
6
11

O540L3C5D
IO540A,B(290HP)
IO540AG1A5
IO540C
IO540D
IO540E, G, P
IO540S, AA
IO540J, R
IO540J4A5
IO540AB1A5,AC1A5,AF1A5
IO540K,L, M, N, T, V, W
AEIO540Series
IGO&IGSO540Series
TIO540V, W,AE
TIO540C,AA,AB,AF,AG,AH,AJ,AK
TIO540A, F,J, N,R,S, U
TIO541A(320HP)
TIO541E(380HP)
TIGO541(425HP)
IO580B1A
AEIO580B1A
IO720Series

Hours
2000
1400
1800
2000
2000
1600
1800
1800
2000
2000
2000
1400
1200
2000
2000
1800
1300
1600
1200
2000
1400
1800

Table2
RotaryWingAircraft
RecommendedTimeBetweenOverhaulPeriods
EngineModels
O320A2C,B2C
O320B2C(RobinsonHelicopteronly)
HO360C1A
O360C2B,C2DHO360(exceptC1A)HIO360B
O360J2A
O360J2A(RobinsonHelicopteronly)
HIO360A,C, D,E, FSeries
HIO360G1A
VO360ASeries
VO360BIVO360
VO435ASeries
VO435BSeries
TVO435Series
O540F1B5

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SeeNote
11
15
11

11
15

11

3
11
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Hours
2000
2200
2000
1500
2000
2200
1500
2000
600
1000
1200
1200
1000
2000

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Table2(Cont.)
RotaryWingAircraft
RecommendedTimeBetweenOverhaulPeriods
EngineModels
O540F1B5(Robinson Helicopteronly)
IO540AE1A5
IO540AE1A5(RobinsonHelicopteronly)
VO540Series
IVO540Series
TVO,TIVO540Series

SeeNote
15
11
15
8

3,8

Hours
2200
2000
2200
1200
600
1200

NOTES
1. Onlyenginesbuiltwith1/2in.(12.7mm)dia.exhaustvalvestems.Enginesofthisserieswith7/16
in.(11.1mm)dia.exhaustvalvesmustnotexceed1200hoursbetweenoverhaulsregardlessofthe
typeofoperation.Newandrebuiltenginesbuiltwith1/2in.(12.7mm)dia.exhaustvalvestemsare
identified,respectively,byserial numbersanddate inthe latestrevisionofServiceInstructionNo.
1136.
2. Theseenginesaredesignedtoincorporateexhaustturbocharging.
3. Turbochargerscouldrequireremoval,priortoengineoverhaul,forcarbonremovalandrepair.
4. Engineswith reverserotationhavesameoverhaultimesascorrespondingnormalrotationengines.
5. 1200HOURS: Enginesthatdonothavelargemainbearingdowelsmustnotbeoperatedmorethan
1200hoursbetweenoverhauls.
1400HOURS: Enginesthathavelargemainbearingdowelscanbeoperatedto1400hoursbetween
overhauls.TheseincludeengineswithserialnumbersL710051Aandup,andL10167Aandup
engines which are in compliance with the latest revision of Service Bulletin No. 326 and
remanufacturedenginesshippedafterJanuary26,1970.
2000HOURS: Engines that have large main bearing dowels and redesigned camshafts can be
operatedto2000hoursbetweenoverhauls.TheseincludeengineswithserialnumbersL976251A
andupIO360C1E6engineswithserialnumbersL972351AandupLIO360C1E6engineswith
serialnumbersL52467AandupenginesthatareincompliancewiththelatestrevisionofService
BulletinNo.326andServiceInstructionNo.1263.Rebuilt enginesshippedafterOctober1,1972,
canbeoperatedto2000hoursbetweenoverhaulsexceptthosewithserialnumbersL234951Aand
L785251A which do not have the redesigned camshaft and must not exceed 1400 hours of
operatingtimebetweenoverhauls.
6. The reliability and service life of engines can be detrimentally affected if they are repeatedly
operated at alternating high and low power applications which cause extreme changes in cylinder
temperatures. Flight maneuvers which cause engine overspeed also contribute to abnormal wear
characteristicsthattendtoshortenenginelife.ThesefactorsmustbeconsideredtoestablishTBOof
aerobatic engines therefore it is the responsibility of the operator to determine the percentage of
timetheengine isused foraerobaticsandestablish hisownTBO.The maximumrecommended is
thetimespecifiedinthisinstruction.
7. TIO540C Series engines with serial numbers L175461 and up, TIO540C Series engines that
wererebuilt oroverhauledatLycomingEngines,Williamsport,PAafterMarch1,1971,andTIO
540Cseriesenginesthathavebeenmodifiedtoincorporatelargemainbearingdowelsasdescribed
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inthelatestrevisionofServiceInstructionNo.1225canbeoperatedto2000hours.Enginesthatdo
notincorporatethismodificationmustnotexceed1500hoursbetweenoverhauls.
8. VO, TVO and TIVO540 engines built with P/N 77450 connecting rods as described in the latest
revisionofServiceBulletinNo.371canbecontinuedinserviceto1200hours.Enginesthatdonot
incorporatethisnewconnectingrodarerestrictedto1000hoursforVO540modelsand900hours
forTVOandTIVO540.SeethelatestrevisionofServiceBulletinNo.371forimprovedconnecting
rodassembly.
9. TIO541EseriesengineswithserialnumbersL80459andup,rebuiltenginesshippedafterMarch
1,1976,andallenginesthatincorporatetheimprovedcrankcasesandcylinderassembliesdescribed
in the latest revision to Service Bulletin Nos. 334 and 353 can be operated for 1600 hours before
overhaul. Engines not in compliance with these requirements are limited to 1200 hours
recommendedtimebetweenoverhaul.
10. Someenginesinthefieldhavebeenalteredtoincorporateaninvertedoilsysteminordertoperform
aerobaticmaneuvers.Wheneverthismodificationisdonetoanengine,theTBOoftheenginemust
bedeterminedinthesamemannerlistedforAEIOenginesofthesamemodelseries.
11. Ifanengineisbeingusedinfrequenttypeserviceandaccumulates40hoursormorepermonth,
andhasbeensooperated consistentlysincebeingplacedinservice,add200hourstoTBOtime.
12. To qualify for the 2400 hour TBO, highcompression, O235s must have the increased strength
pistons(P/NLW18729).See thelatestrevisionofServiceLetterNo.L213.
13. The highcompression O235F, G and J series do not have the increasedstrength pistons (P/N
LW18729)therefore,theydonotqualifyforthe2400hourTBO.
14. TIO540A series engines with serial numbers L188061 and up, TIO540A series engines that
wererebuilt oroverhauledatLycomingEngines,Williamsport,PAafterMarch1,1971,andTIO
540Aseriesenginesthathavebeenmodifiedtoincorporatelargemainbearingdowelsasdescribed
inthelatestrevisionofServiceInstructionNo.1225canbeoperatedto1800hours.Enginesthatdo
notincorporatethismodificationmustnotexceed1500hoursbetweenoverhauls.
15. Only engines built to specifications intended for and installed in Robinson Helicopter applications
areapprovedfor2200hourTBO.Notenumber11nolongerappliestotheseengines.

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