Replacement Cylinders

Replacement Cylinder - It Needs a Break-in Flight too

Replacement Cylinder Break-in Flight Procedures:
RAM Nickel+Carbide Bore Process Cylinders -- One Flight Only.

When even one cylinder is replaced, the replacement cylinder must be broken-in with the same care as was given to all the original cylinders when the engine was broken-in the first time in the test cell.
Break-in oil and break-in procedures should be followed when replacing one cylinder
or six cylinders, and that includes using a Multi-Viscosity Mineral Oil
such as SAE 20W-50 Phillips Type-M.
The minimum break-in period should be considered the first twenty-five ( 25 ) hours
of operation.
Turbocharged engines typically break-in sooner due to higher peak cylinder pressures. Therefore, the oil should be changed as soon as oil consumption stabilizes, but no later than the first twenty-five ( 25 ) hours.
At that time, the oil should be changed to an (AD) Ashless Dispersant Mineral Based Oil.
ONLY ONE BREAK-IN FLIGHT IS REQUIRED.
There should be a replacement cylinder break-in flight based upon the following steps.
Information presented in this maintenance tip is as performed by rpm when breaking-in
a TCM TSIO-520, GTSIO-520, IO-520, or IO-550 replacement nickel+carbide processed bore cylinder or cylinders.
The cylinder break-in flight should be performed in day VFR conditions.
FULL POWER SHOULD ALWAYS BE USED AS
REQUIRED IN THE EVENT OF AN EMERGENCY.
Avoid excess weight. Required Crew Only.
Ample runway length and environmental conditions are considered essential, and are the responsibility of the pilot in command.
Keep initial ground run to a minimum, only long enough to verify no fuel or oil leaks prior to the break-in flight.
Handle radio and flight plan work prior to engine start.
Once the engine is started, remain in motion for maximum air flow through the cowling to support engine cooling.
DO NOT GROUND CYCLE THE PROPELLER.
Perform "Before Takeoff" check list during taxi - as practical. If landing traffic requires you to hold before taking position on the runway for takeoff, face into the wind in the run-up area.
DO NOT GROUND CYCLE THE PROPELLER.
Prop cycling induces excessive pressure on the new replacement cylinder.
FULL POWER SHOULD ALWAYS BE USED AS
REQUIRED IN THE EVENT OF AN EMERGENCY.

The Replacement Cylinder Break-in Flight:
First 15 Minutes and Initial Stages -- One Flight Only.

DO NOT GROUND CYCLE THE PROPELLER.
Apply power slowly and smoothly.
Limit manifold pressure to 30" inches for TSIO-520 and GTSIO-520 engines,
and full power for IO-520 and IO-550 engines.

1. First 15 minutes of departing the airport:
( Cowl flaps - open )

• MP remains: 30" MP
• RPM: Takeoff redline
• Fuel Flow: Full Rich

2. After first 15 minutes, rotate rpm during the cruise climb every 5 minutes between full redline rpm and climb power rpm. Set Manifold Pressure ( MP ) as recommended for climb on IO engines. MP remains at 30” for TSIO-520 and GTSIO-520 engines.

FULL POWER SHOULD ALWAYS BE USED AS
REQUIRED IN THE EVENT OF AN EMERGENCY.

3. When appropriate altitude is reached, set up 75% power @ 100°F – Rich of Peak. Cruise for approximately 45 minutes, rotating rpm every 5 minutes in increments of 100 rpm within your recommended cruise rpm range.

Replacement Cylinder Break-in
Descent and Return to Base:

Advance props to 2700 rpm on TSIO-520, IO-520 and IO-550,
or to 1900 rpm on GTSIO-520.

Slowly reduce the throttles to 23" inches Manifold Pressure ( MP )
on TSIO-520 engines, and 25"on GTSIO-520 engines,
and as required on IO-520 and IO-550 engines
for descent.
Lean the mixture to maintain approximately the same EGT as demonstrated
during the cruise break-in period.
Adjust airspeed as required to maintain 300 fpm to 500 fpm rate of descent
through the landing approach.
Full rich mixtures should not be necessary until the aircraft is on the ground.
FULL POWER SHOULD ALWAYS BE USED AS
REQUIRED IN THE EVENT OF AN EMERGENCY.

Post Break-in Flight
and Future Flights:

After completing the above break-in procedures, the replacement cylinder
break-in flight is finished. All future flights may be flown as normal.
Inspect for leaks. Review the flight data with your aircraft mechanic.
Correct accordingly.