Template: Engine

Lycoming IO-540-C4B5 Serial #: L-15798-48 Parallel valve, narrow deck.

Rebuild

I have rebuilt this core engine after it suffered a prop strike during a gear-up landing in a Piper Aztec in 2014. Nearly every component of the bottom end was in good serviceable condition save for the crankshaft, which was cranked at an oil cross tube. Replacement crankshaft is from a O-540-F1A5 out of a Robinson R-44.

To do:

• Bolt cylinders on
• Install oil drain-back nipples in case
• Install idler gears
• Determine which gears are being omitted from accessory case
• Clean pushrods in Graham's parts washer
• Powdercoat intake tube clamps or find machined new ones
• Cut new intake pipe hose into 1.75-2.00" sections
• Constant pressure clamp pliers

Ignition and injection

Plan is to use FlyEFII System32.

To do:

• Fuel valve mount bracket placement.
• Fuel line routing and design

Lycoming resources

File name	Type	Size
Lycoming overhaul manual	PDF	15.2 MB
IO-540 Parallel Valve Narrow deck IPC	PDF	7.6 MB

File:Io540-c4-parts.pdf