Professional Documents
Culture Documents
IR/JJIU~
Dlrec) Drive
Engine
~fpproved by F.A.A.
C)
LYC O n~ I N rz3
VVILLIAMSPORT,
Fifth
Decernb er 1974
D I v is 1 ~7 N
PENNSYLVANIA 17701
Part
No.
802 94
Price
2~.00
A Textmn
Company
TECHNICAL
PUBLICATION REVISION
REVISION NO.
PUBLICATION
PUBLICATION NO.
PUBLICATION DATE
Direct Drive
Overhaul Manual
60294-7-9
s) fUrnished herewith
are
1966
5-3, 5-6; 8-5
April
July 1967
5-8; 6-1 thru 6-18, 6-23, deleted pages 6-25 thru 6-32
April 1968
4-2 thru 4-8
December 1968
Section 11
January 1970
i, ii, deleted pages iv and v; 1-1, 1-2, deleted pages 1-3; 2-1
thru 2-6, deleted pages 2-7 thru 2-12; 3-1 thru 3-5; 4-1; 9-1,
9-2, 9-4, deleted page 9-7; 10-1 thru 10-36, deleted pages
10-37 thru 10-47
January 1971
i, ii; 6-19 thru 6-24; 7-1 thru 7-19; 9-3, 9-5, 9-6
May 1972
Added page 2-7; 3-1, 3-5; 5-1, 5-2, 5-3, 5-4, 5-5, 5-6, 5-7, 5-8,
5-9, 5-10, 5-11, deleted pages 5-12, 5-13, 5-14; 6-1, 6-17, 6-18,
6-22, 6-13; 8-1, 8-2, 8-3, 8-4, 8-5, 8-6, deleted pages 8-7, 8-8;
9-3
October 1973
i, ii, iii; 1-1; 3-3, 3-4, 3-5; 4-1, 4-3, 4-4, 4-5, 4-6, 4-7, 4-8; 5-1,
5-5, 5-6, 5-7, 5-9, 5-10; 6-2, 6-7, 6-10, 6-11, 6-12, 6-13, 6-17,
6-20, 6-21, 6-22, 6-23; 7-4, 7-16, 7-17, 7-18, 7-19, 9-1, 9-2
February 1992
June 1993
60294-7
December 1974
June 2002
7-10B
OVERHAUL MANUAL
REVISIONS, ADDITIONAL
OF, AND
IS TO BE USED IN CONJUNCTION
THIS OVERHAUL MANUAL, THE ENGINE OPERATORS MANUAL, AND ALL APPLICABLE SERVICE BULLETINS AND INSTRUCTIONS ARE ISSUED iN COMPLIANCE WITH EA.R
period of three (3) years new and revised pages for this manual will be furnished to
who
fill out the registration card and return it to Textron Lycoming. Registered owners
owners,
of this manual will be notified of any changes in revision policy or cost of revisions.
For
Service
Bulletins, Service Instructions and Service Letters are available from all Textron Ly-
Distributors
series. Consult the Service Publication Section of the latest revision to Service Letter No. L114
illustrations, pictures and drawings shown in this publication are typical of the subject
they portray; in no instance are they to be interpreted as examples of any specific engine,
equipment or part thereof.
The
matter
TABLE OF CONTENTS
PAGE
SECTION
7
CRANKCASE, CRANKSHAFT
(CONT.
AND
RECIPROCATING PARTS
7-1
Removal of Accessories
Disassembly
Starter Ring
Gear
Support
7-1
7-1
Crankshaft
7-1
Hydro
Control Valve
Generator
7-17
Alternator Drive
or
Belt
Crankshaft Idler Gears
7-17
7-18
7-3
Counterweights
Sludge Tubes
C leaning
7-3
General
Piston
7-17
Crankshaft OilSeal
7-1
Crankcase
PAGE
SECTION
8-1
7-3
General
7-3
Disassembly
Intake Pipes
Inspection
Carburetor
7-4
Bearings
8-1
or
Fuel
Injector
Induction Housing
Crankcase
7-4
Crankshaft
Visual
7-4
Dimensional
7-4
Visual
7-5
Dimensional
7-5
7-5
Dimensional
7-6
Parallelism Check
Squareness Check
7-6
Bushings
Cooling Oil Jets
Repair and Replacement
Carburetor
8-1
8-1
7-6
7-6
7-7
8-2
8-2
Assembly
Repair and Replacement
8-2
7-8
Counterweight Bushings
Counterweight Bushings
Connecting Rod Bushings
7-9
8-3
Pipes
Carburetor
8-3
Fuel
Injector
Reassembly
Induction Housing
8-3
Flow Dividers
8-6
Intake
8-6
Pipes
Nozzle Assembly
7-7
8-1
Injector
Crankshaft
Bearing Surfaces
Straightening Flange
8-1
Fuel
Intake
7-6
8-1
Carburetor
Nozzle
Crankshaft Counterweight
Piston
8-1
Fuel Injector
Injector Nozzles
Inspection
Oil Sump
Camshaft
8-1
Oil
Sump
Cleaning
Oil Sump
7-4
Visual
Dimensional
8-1
8-4
8-6
TEST PROCEDURES
7-10
7-10
General
Test Limits
9-1
9-2
Turbocharged Engines
9-3
Pressure Carburetors
9-3
7-10
7-10
7-10
7-11
7-12
Crankcase
7-12
Assy.
7-12
Reassembly
Crankshaft
Sludge
Tubes
9-3
Run-in Schedule
9-3
Oil
Run-in Procedure
7-12
Consumption
Run
9-4
9-4
9-5
(Engine)
Expansion Plug
7-12
Preservation
7-12
Preservation and
Gear
7-12
Storage
Carburetors and Fuel Injec-
7- 12
tors
Counterweight Assembly
Connecting Rods
7-14
Crankcase
7-15
Governor Drive
Run
9-6
9-6
7-14
Camshaft
Propeller
9-4
7-15
10
TABLE OF LIMITS
iii
01
SECTION
Section 1
i..
INTRODUCTION
1- 1.
for the
letters
identified.
portion of the text is divided into sections corresponding to the basic engine components.
Additional sections are provided for general description, general overhaul andinspection procedures, preservation and storage information, and other items of
a non-specific nature.
1-2.
The main
pertinent
components
will be
var-
designated
catalogs, for specific models, may be orfrom the department listed in paragraph 1-3.
Tools.
section.
inders
on
the
right side.
Parts
dered
covers
the entire
series of
en-
as
the crankshaft, as viewed from the rear is counterclockwise on all models withthe letter L in the model
references to
asviewed
1-1
Section 1
Introduction
Revised
January, 1970
Section 2
Generol
Description
SECTION 2.
GE NE RAL
DE SCRIPTION
2-4. Avco Lycoming incorporates a color code painted
on cylinder heads designating differences in the cylinder barrels and spark plug lengths. It is essential
that
cylinders
are
of air cooled
personnel
as
described
con-
major parts, head andbarrel, screwed and shrunk together. The heads are made from an
aluminum alloy casting with a fully machined combustion chamber. Valve guides and valve seats are
1181.
Rocker
recesses
in the head.
ton
rings
or
application
to your
particular
in-
stallation.
2- 3. The
nickel
are
al camshaftis locatedabove and parallelto the crankshaft. The camshaft actuates tappets which operate the
ground and
Example:
541
EIB4D
t
L
PREFIX
DISPLACE~1ENT
000*
SUFFIX
-Fbwer Sectlbn 8
Rotin~
Cubic in.
T Turbochorged
-Nose Section
V -i~tical Hdiropter
B -Accessory
H -Horizontol Helicopfer
4 -COwlterweisM Applicotion
Aerobatic
-Dual
Secfion
Mogneto
-Fuel
Injected
accessory drive
Subsequent changes
Supercharged
are
to Mode~s
reflectedin this Section
O opposed Cylinder
Figure 2-1. Description of Engine Model Code
Revised
January, 1970
2-1
Sec~ion 2
General
rockers.
Thevalve
are
valves.
NOTE
to
justing
plunger
its seat.
ROCKERPIRM
moves
BUSHINGS
SPLASH OIL TO ROCKER
ARMS,VALVE STEMS,ETC.
DRAIN ML TO SUMP
I
I TAPPETS
LEFT BANK
PUSH RODS
PUSH ROD SOCKETS
CRANKCASE OIL HEADER-LEFT
PINSFP~MS,ETC I
PINS,CP~MS,ETC.
I CRANKSHAFT IDLER GEARS
CAMSHAFT
BEARING NO. I
NO.IMPIIN
BEARING
NO.eMAINr(
NO.3MAIN
BEARING
BEARING
TACHOMETER
DRIVE
aRMs,va~vE
DRIVE
RIGHT BANK
YICUUMPUMP9 ~P
ROCKER FIRM
VACUUM PUMP
TAPPETS
PUSHROOS
BUSHINGS
srEhns,
GRAVITY OIL THRU
PRESSURE SCREEN
SHROUD TUBES
~OIL RELIEF
VALVE
BY-PASS VALVE
L____~
SUCTION SCREEN
OIL SUMP
Cylinder Engines
Revised
January, 1970
Section 2
Generol
of
dynamic counterweights,
bration,
some
is
four
Description
system
is machined from
assembly consists
alloy castings divided at
the centerline of the engine and fastened together by
a series of studs, bolts and nuts. The mating surfaces
of the two castings are joined withoutthe use of a gas-
on
machined
piston ends.
ket, and the main bearing bores are machined for the
use of precision type main bearing inserts. The crankcase forms the bearings for the camshaft.
CRANKSHAFT. The crankshaft is made from a
molybdenum steel forging and all journal surfaces are nitrided. Earlier models were providedwith sludge tubes at each crankpin. These sludge
tubes are not incorporatedin later models. Thisis not
to imply that sludge tubes may be removed and not replaced in crankshafts originally manufactured with
sludge tubes. These tubes must be removed and re2-9.
2-13. PISTONS.
chrome nickel
aluminum
and
ring combinations.
2-14.
LUBRICATION SYSTEM.
of the AIO
exception
with the
placed at overhaul.
All
subject engines,
employ a full
series,
OIL TO ROCKER
SPLASH
V~LYE
qR_O~
:l,"s~_
GOV
GOVERNOR
IDLER SHAFT
PUSH RODS
TAPPETS
~JC--V--V
URN OIL
TO SUMP
SPLASH OIL 10
PISTONS,PISTONPINS.
ii
II
1 i
LEFT BflNK
PUSH RWSOCKETS
SPLASH OIL TO
CRANKCASE
Oil
HEADER-LEFT
PISTONS.PISTON PINS,CI\MS,ETC.
CAMS, ETC.
CRPINKPIN----K----t---r(
To PROP
c~
-1
CAMSHAFT
BEARING
)I
NO.ZMPIIN~
I
BEARING
MAIN
N0.4MellN~
BEARING
BEARING
)SPLelSHOIITO
t
mCH.ORIYE
CRnNKCP.SE HEADER-RIGHT
BEARING
TAPPETS
IHYD.PUMP
RIGHT BANK
IAND
DRIVE
PUMPpuMp
PUSH RODS
,,Mp
eRMS.V~LYE
BU5HNt5
DRAIN OILTO SUMP
THRU OIL DRAIN TUBES
GRelVITYOliTHRU
SHROUD TUBES
JOILRELIEF
VALVE
SPRING
OIL COOLER
OIL PUMP
BY-PASS
VI\LYEI
DRAIN
OiL TO SUMP
IJ;
SuCiioN SCREEN
OIL COOLER
OIL SUMP
Cylinder Engines
2-3
Section 2
General
Delcription
Oil Filler
Check Valve
6
oil
oi~
Near Side
Line
On
AVCO
LYCOMING
Dipstick
Breather Line
Engine
Separator
Scavenge Pump
Scavenge O~
AVCO
LYCOMING
360"
Oil Pick
Up
Breather
Oil Tank
Far Side
Oil Suction Line
Breather Line
Check Valve
Oi\ Return
inder lubrication
to be
for sche-
)--Vacuum
pressure
No. of teeth 10
Ratio 1.30:1
~-Mogneto
Gear
No. of teeth 13
Ratio 1.I
i
Cam
Magneto
Gear
No. of teeth 13
Ratio I:I
Ifl
Crankshaft Gear
No. of teeth 13
0-235, 0-290-D
Revised
January, 1970
Section 2
General DePcription
Camshaft Gear a
Tachometer Drive
Ratio .50: 1
Crankshaft IdlerGear
Crankshaft Gear
Magneto Gear-7/
MagnetoGear
RoB I:
a6oil
Cam
Fuel
Fuel
II
Ratio I:I
An Type
-e
Fuel
Pump Drive
Diaphragm Type
Ratio .50:1
Typical
Cylinder Engine
Drive Gear
Ratio .895:1
r?
Pump
I
Crankshaft Idler
Gear
Drive Gear
Ratio 1.30:1
Gear a
Eccentric
Tachometer Drive
Ratio .50:1
Gear
MZq~,G,eyr71 i
,~r,
I~
Fuel
Fuel
reldIpmuPGear
Idler Gear
Pump Drive
Diaphrogm Type
Ratio .50: 1
Fuel
Pump Drive
An Type
i:
Pump
t
Ratio I:I
Driven Gear
Ratio 1385:1
Typical
Cylinder Engine
2-5
Section r
Generol bemription
The position of the exhaust bypass valve establishes the amount of supercharging delivered to the
engine. Increasing oil pressure closes the valve and
good distribution of the fuel-air mixture to each cylinder is obtained through the center zone induction
system, which isintegralwith the oilsump and is submerged in oil, insuring a more uniform vaporization
of fuel and
The
From
to the
cylinder by
(Engines Employing
Fuel
Injectors).
tude.
altitude.
control
struction No.
Prop.
1042 for
list of Avco
No. of teeth 15
Ratio .895:1
Ratio 1.30:1
i/e
Magneto
Camshaft Gear
Tachometer Drive
No. of teeth 26
Ratio .50:1
(2.4375 PD)
Crankshoft Gear
No. of teeth 13
Gear
Magneto
Ratio I:I
t
-C
Fuel
ap-
/--Camshaft
19 teeth
Lycoming
Gear
700 Series Magneto
Ratio .500:1
1200 Series Magneto
Ratiol:I
625734.2(
Gear
No. of teeth 10
Ratio 1.30:1
Fuel
Pump Drive
Type
nAraeG
No. of teeth 13
Ratio 1.00:1
Timing
~of
marks
No.l
are as
crankpin is at
shown when
T.C.
16 teeth(2.00 Fl D.)
Ratio .59: 1
27 teeth(2.25 F!D.)
Ratio .50: 1
January, 1970
OVERHAUL
Section 2
General
Dercription
Vacuum
Pump Drive
Gear
No. of Teeth lO
Ratio ~30/
Eccentric
Cronkshoft Gear
No, of Teeth /3
Magneto Gear
hb, of ~eeffiN
Ratio l:I
Patio t083/
Cmnkshaft/d/er Gear
20 Teeth /3.250 RD)
Fuel
Pump Drive
Diaphrogm Type
Ratio .50/
i i
Fuel Pump Drive Shaft
Ratio t30;i
L--
Gear-(ANTypel
Figure 2-10.
Gear
No. of Teeth lO
No, of Teeth .N
Ratio
Ratio/.30./
Gear Train
Diagram
Typical
Camshoff
Tech.Drive
No. of Teeth 26
--7
Ratio.50l
These Gears at Frontof Engine
---i~/
PumpDNLe
Gear
No. or Teeth /O
Ratio t.30:/
ldlerGear
26 Teeth 13~250 f?D.I
30 Teet~lZ.SZSl PD/
Clankshaft Gear
NO.OfTeefh/3
71
Eccentric
Magneto Gear
No. of Teeth ~O
Ratio .750~
FuelPumpDrive
Rof/b.SOIDiaphragm
~ype
FuelPump ~er
Geor(aNTypel
Gear-----"
Noof Teeth /9
May, 1972
CrankshaftldlerGeor
~s TeefhN.250 F~a/
Gear
No. of ~elh lO
Ratio L301
Train
Diagram
Typical
03
OVERHAUL
Sec~ion 3
SECTION 3.
GE N E RA L
O VE RH AU L
PROCEDURES
3-1. This manual willdescribe in separate sections
the complete major overhaul procedures for each in-
furnace oil
Operators
whichthey
for all
as
Varsol
or a
or
suitable
com-
Perm-A-Chlor.
published
by their respective manufacturer. Only such assembly
and disassembly as requiredby engine installationwill
be covered,
immediately
3- 2. No
attempt
overhaul pro-
are
ac-
cause
oil
after
cleaning
in order to
prevent
cor-
rosion.
3-3. Just prior to or immediately after removing the
engine from the airframe, remove the oil drain plug
and drain the oil from the engine.
Attach the engine lifting cable to the engine and
from the airframe.
3-4.
remove
3-5.
(ST-278) in
(STadapter (ST-165) to
162).
the
on
the
en-
3-7. Inasmuch
while
moval,
on many interior surfaces. To facilitate rethese deposits must first be loosened by im-
mersion in
tank
(usually heated).
like the
fall
soluble decarbonizers.
CAUTION
as
bly, all individual parts should be laid out in an orderry manner as they are removed from the engine.
No cleaning operation should be performed until this
initialvisual inspection has been completed. All loose
studs, cracked cooling fins, loose or damaged fittings,
and the like, should be carefully noted and tagged to
prevent their being overlooked during regular inspection.
C LEANING
3-8.
imperative to clean all engine parts thorinspection. Two processes are involvedin cleaning engine parts; degreasingto remove
dirt and sludge (soft carbon) and the removal of hard
carbon by decarbonizing, brushing or scraping and
grit-blasting.
It is
oughly
to facilitate
3-9. DEGREASING.
immersing
Revised
or
Degreasing is accomplished by
spraying the part in solution of white
May, 1972
3-1
Sec~ion 3
3- 12. When
metallic abrasives.
mildly
baked
abrasive
organic
substances
such
as
rice,
or
bearing surfaces
in the
engine will do
part, provided
cause
for
no
harm and
of the
rejection
Even
may
come
visually
ad-
flaking
or
cut
side of
be used.
the glaze which tends to form (particularly on the exhaust valve seat) thus facilitating subsequent valve seat
reconditioning. Under
no
matter.
3-13. The decarbonizing solution will generally remost of the enamel from exterior surfaces. All
remaining enamel should be removed by grit-blasting
particularly in the crevices between cylinder cooling
move
operations,
rinse
of
preservative oil
to all surfaces.
3-15. The
defects in
inspection should precede all other inspection procedures. Do not clean any parts prior to
visual inspection, Since indications of dangerous operating condition can often be detectedfrom the residual deposits found in some particular recess of the
engine.
3-16. Visual
3-17. Structural failures can be determined by several different methods depending on the part involved.
The following are a few of the methods employed: magnetic particle, dye penetrant, penetrant, x-ray and
an
procedures
can
as
list of all
an
inspection
and
over-
assure
that
no
on
the out-
should be
of
of all gears should be free from deep scratches. However, minor abrasions may be dressed out with a fine
abrasive cloth.
CORROSION ON STRESSED AREAS.
can cause
are as
re
suiting
Fitted
sur-
from corrosion
should be
part
must be
rejected.
replaced
with
a new one.
haulform, containing
All
on
of
inspection
INSPECTION
races.
feel for
races
round condition.
face s in
the parts in petroleum solvent, dry and remove any
loose particles by air-blasting. Apply a liberal coating
the
by
checked for
3- 22.
fins.
and
pitting of
part is inadvertenly
over-
threads,
looked.
All
bearing surfaces
should be examined for scoring, galling andwear. Considerable scratching and light scoring of aluminum
3-20. BEARING SURFACES.
3-2
3-25. Proper judgment must also be used in determining the amount of current (amperage) applied; too
little current will not sufficiently magnetize the part,
while too
heavy
an
application
will
permanently
Revised
dam-
January, 1970
Section 3
age the
on
the
part of
the
Again,
operator
are
thin
areas
ad-
skill and
experience
of the utmost import-
ance.
No.
to the electrodes.
jacent
inspection,
utes in
dichromate to
parts.
num
as
Defective threads
can
sometimes
be
repaired
with
be removed
cleaned and
accumulation of
are
E-7729).
a.
area
available
on
stud,
use
collet
If the collet
b.
type
tool cannot be
guide
3-28. PA~TED PARTS. Parts requiring use of paint
for protection or appearance should be painted in ac-
pockets of paint.
Employ
used, drill a
pilot bushing to
Redrillthe hole
to
c.
removed,
size extractor.
JAN-A-669,
using
replacement.
lubricant, Specifica-
NOTE
3-34. CORROSION-PREVENTION.
All machined
before
bosses
painting.
should be
Do not
paint
torque
masked
areas
is
under
of all
At the conclusion
required.
REASSEMBLY
chromate
bake
at
250"F,
to
300"F,
repainted omitting
the
primer coat.
3- 35.
assembly
parts should be cleaned to remove alltraces of preservative oiland accumulated
foreign matter. During assembly, cover allsteel parts
with a heavy coat of preservative oil. This mixture
should be used on all machined surfaces, especially
on bearing surfaces, cylinder bores and piston rings.
The practice of using plain lubricating oil during assembly is not recommended.
of
subassemblies,
all
cleaned
to
painting.
cleaning all
by using a neudegreasing medium followed by a
3-36.
SEMBLY.
tral,
traced
non-corrosive
3-3
Ssc)ion 3
Generol Overkaul PNKedur~,
that the
3-44.
bevel gears.
a.
its
Gear
Pitch
Showing E~Etreme
Alignment
properly lubricated, or an
inferior lubricant is used, many of the engine parts
will become scored before the engine oilgoes through
its first cycle and has had a chance to lubricate the
engine. This, of course, will lead to prematureparts
failure prior to normal service life, and in some cases,
lead to engine failure before normal service hours have
been accumulated. It is of utmost importance, therefore, that the following recommendations be adhered
to at engine assembly. Consult the latest edition of
assembly.
If
parts
are
not
housing using such gaskets and shims as are specifled by the applicable parts catalog. Secure the gear
mountings temporarily.
b. Remove or add shim laminations
to obtain correct backlash.
as
required
1059.
3-40.
SHIMS AT TWESE
COCATIONS CCN~OL
BACICtASH AND
PI7CH ALIGNMENT
OF GEARS
for
Support
Section 3
Visually,
c.
the
mating gears
and
are even.
gears.
and gaskets throughout the engine. For complete replacement sets of seals and gaskets available for these
engines, consult applicable parts catalog.
NOTE
corrected before
is made
provided
served. The
or
Allcirclips, lockplates
addition
Piston
will
one
rings
and retaining
rings
connecting rods)
fastenings
overhaul.
Damaged Ignition
bolts
flange
cables
mating machined parts, the clearmoving parts which are in close contact
with each other and the torque limits for various nuts,
screws and fastenings,
clearance between
ance
between
Crankshaft
3-49.
counterweight bushings
The fuel
supply
properly
correct locations.
c an
become
installed and
damagclamped
335 and 342 for inspection procedures, configuration of lines and location of clamps, and Service
Nos.
oil seals
Instruction No.
fuel line.
3-5
04
Sec~ion 4
Igni~ion Sy~tem
SECTION 4.
IGNITION
SYSTEM
four, six and eight cylengines are equipped with high tension ignition
systems which deliver high tension current directly
tothe spark plug outlets. Some eight cylinder engines
are equipped with a low tension ignition system. This
system carries the low tension current, produced by
inder
the
the
1042 and
4-8.
NOTE
Before
met
it
to
point out
the correct
RETARD
gromof each.
neto follows,
4-4.
BREAKER
MAGNETO.
The
retard
lead.
4-5. ENGINE FIRING ORDER. 4 cylinder engines (exLIO series) 1-3-2-4. LIO series 1-4-2-3. 6 cylinder engines, 1-4-5-2-3-6, LIO series 1-6-3-2-5-4.
8 cylinder engines, 1-5-8-3-2-6-7-4.
(5)
nut
(3)
to
the
the
and
MAGNETOS.
remove
the
NOTE
See Service Instruction 1252 for the
version
of 8
series
cylinder engine
magnetos
netos engine.
withthe
the
(4)
drive shaft.
the washer
and
cept
engine models; however, for purposes of description, all harnesses are composed of the same basic
components. Basically, each lead is composed of a
Replace
prevent damage
4-11. MAGNETOS.
5/16-18
to
-1200
with
con-
-700
series mag-
Loosen
nuts, lockwashers
and clamps. Remove magnetos, gaskets (1), adapters
(7) and gaskets (6). Reach inside the drive pad and removethe drive cushions (11), retainers (15), centering
plates (16) and magneto gears (5). No disassembly of
the -700 series magneto is required.
the
nuts
4-1
Sectian 9
Ignition Syrtem
bisb671 riPi/t~
biI 84I
IMPULSE COUPLING
10
12
I/I h ~!be6
13
10
35
12
-iili ~M
i.
Magneto
Gasket
2. Cotter Pin
3* Drive Shaft Nut
4. Washer
5. Magneto Gear
Adapter Gasket
7. Magneto Adapter
8. Impulse Coupling Gear
9. Woodruff Key
6.
10. Bushing
11. Drive Cushions
Figure 4-1.
4-2
Magneto
12.
13.
14.
15.
16.
Ball
Bearing
Coupling
Drive
Drive Plate
Cushion Retainer
Centering
Plate
Drive Assemblies
Revised
April 1968
Section 4
Igni,ion
NOTE
Slick)
given
are
The
mentioned
gears
in
the
are
1153.
removed
or
(Slick).
Individual
leads
or
preceding
from the
(5)
cutting pliers,
close to the outside of the housing, and using a drift
tapthe ferrule (4) from the housing. Remove the spring
(1) and electrode screw (2) from the lead by turning
re-
assembled.
the
spring
counter-clockwise
(2).
with
with
Remove the
LUBRICATE
trode
screw
(10)
and sleeve
(11)
as
a pulling action.
spark plug nut (7)
spring (12) elec-
described above.
using
TABLE 4-1
LENGTH OF INDTVIDUAL CABLES
(Slick Harness)
Cable
Magneto
1 Bottom
Right
32
3 Bottom
24
Right
Right
Right
Top
4 Top
1 Top
3 Top
Lengt
(Inches)
No.
38
32
1 Left
41
2 Left
34
2 Bottom
3 Left
32
4 Bottom
4 Left
25
INSPECT ION
4-12. IGNITION HARNESS. Unless the harness
bly
assem-
TIMING MARK
is in
4-13. MAGNETOS.
As
previously mentioned,
IDLER GEAR
this
manual willnot endeavor to describe overhaul procedures for trade accessories. Consult the manufac-
turers
applicable overhaul
manualfor
inspection pro-
cedures.
REPAIR AND REPLACEMENT
Although replacement of
ignition harness is recommended, it must be noted
that many parts of the harness may be reused in fabricating a new assembly. Instructions for fabricating
the
employed (except
Gear
Timing
Mark
4-3
Section 4
Ignition Sphm
4-19. SPARK PLUG END. Install hex ferrule (8) over
leadwithflange endtoward endofwire. After assembly
of this
ferrule,
over
plate (figure 4- 6)
in a bench vise. Set hex ferrule in slot of drive plate and,
usingthe drive tool (figure 4-6) drive the drive ferrule
flush against the hex ferrule. Install spark plug nut (7)
drive ferrule until
on
tight.
Mount drive
(5)
under
drive
tool,
housing.
(3
and
10) inpin
vise
(figure 4-6)
and assemble
the
screw
screw
large
coil of the
screw
is flush
spring.
Figure 4-4.
Marked Teeth
on
the end
conductor should
this will
conductor,
later
step.
1
3
12
i.
Spring
Sleeve
6.
7.
(Insulator)
Spark Plug
Nut
8. Hex Ferrule
9. Drive Ferrule
Electrode Screw
Drive Ferrule
Housing
Cable
4-22. MAGNETOS.
As
Slick Harness
previously mentioned,
4-4
Lead
Assembly ~Slick)
this
Figure 4-5.
2.
3.
4.
5.
publications should
Section 4
Ignition Sy~tem
a gasket (1), adapter (7) and gasket (6)
magneto mountingpads. Assemblethe ballbearing (12) onthe magneto gear and retainer (5) and install
4-1. Assemble
onthe
the assemblies engaging the marked toothof the magneto gear (See figure 4-3) between the two marked
teeth
8\\
Ij
ii
on
4-4).
In-
NOTE
The
FIRING ORDER
IC
1/
1-3-2-4
ii
REASSEMBLY
(Four,
six and
cylinder
is onthe
4-23. MAGNETOS
the
on
stalled.
magneto
(4)
cure
with cotter
pin (2).
or retardbreaker magneto and assemcoupling (13) over the key. On all magnetos
as semble the Woodruff key (9) and bushing (10) on shaft,
install nut (3), tighten to specified torque and secure
with cotter pin (2).
4-26.
MAGNETOS
removed at
II
11
ii I,
As the
F!RING
ORDER 1-3-
disassembly
jl
j/l
INSTALLATION
See
figure
Four
Cylinder Engines
Optional
4-5
Section 4
Igni~irn Sy~tem
ling will not move beyond the point where it trips and
spark occurs. Reverse the rotation approximately
25" until the timing pin hole appears in the center of
the vent plug hole.
the
I\
2
line the
~1
ni
P
1\
ously through
"i~
(without impulse),
1/8" away from
(L.
H.
vigor-
strong spark
occurs
timing pin
are
4-38.
\i
drive
on
on
the
figure
4-12.
4-39. Hold the
_,--
magneto
in the above
position
and
as-
series). Using
positive lead
NOTE
The advance
the
timing mark
engine nameplate.
is
specified
on
4-32.
the
painted
aligned
shaft
the
ling).
the
on
:I
.Ir
5
F~
7
U~.
"--~-----t-a
magneto.
wire
1/16"
4-6
Sectian 4
Ignition Syltem
_P
7~3
FIRING ORDER
1-5-8-3-2-6-7-4
--7_
r----1-C---=L--
ij
I-
ii
r--
1 5
II--~-I
111 1
L--
I I
It-t--
I 1
With Indent
I--!
17
4-45.
I 1
"T
I
I
Mark
on
on
remove
Aligned
Drive Plate
Magneto Housing
Remove the
I~
i
HOUSING INDENT
I
___L--
opening
screw
marked
(shield-
ed
T"
a small screwdriver through the
opening and engage the painted rotor timing
groove. ~he painted lines on the distributor block and
finger will be found in approximate alignment. See figure 4-13. With a light force depress the screwdriver,
moving the rotor in a counterclockwise direction, as
viewedfromthe rear, sufficientlytoremove anybacklash while at the same time, rotate the magneto back
and forth in both directions untilthe breaker points
just begin to open, as indicated by the timing light.
4-47. Insert
marked
AC timing
manner as
out when
described
NOTE
magnetos
are
set to fire
together,
timing marks
are in alignment. At this point, both lights should go
on simultaneously. Tighten nuts to specified torque.
Disconnect the
switch,
accom-
so
the
plate.
Final
b.
screws
magneto.
timing light
Line
on
Distributor
Finger
Section 4
Ignition Sytlem
c.
Remove the
switch,
leads
b.
d.
the
move
flange
of the
the distributor
radially in
magneto and carefully reblock from the magneto.
not
wise to the
d. Replace
ed;
magneto
wise
point
the
the
between the
switch,
magneto
position while
and forth
secure
magneto.
pinched
plate.
outlet
forward in
Tighten
block in the
opening,
or
and
re-
screw
was re-
~roperly
quired,
or
timed to the
at
20
moved:
a.
4-8
Connect the
capacitor,
4-11.
05
Sec~ion 5
Accel~ory Hou~inq
SECTION
5.
ACCESSORY HOUSING
housing.
specifically called out tothe contrary, all
component parts will apply to all engines
except those with a housing incorporating dual magnetos in a single housing. These housings willbe identified as Dual Magneto Housings.
5-2.
(Where applicable)
See
Unless
references to
(Where applicable)
Remove the
on
Propeller GovernorDriven Gear (WhereAppliSee figure 5-3. Remove the propeller governor
oil line (12). Remove the adapter (10) from the mounting pad on lower right side of the accessory housing.
Remove retaining ring (9), washer (5) from shaft gear
and remove shaft gear (11) from adapter (10).
5-12.
DLSASSEMBLY
cable)
5-3.
The
one
OilPressure
nut
(whichever
is
applicable)
that
secure
it to the
housing,
5-5. Thermostatic
Valve and
Oil Pressure
Screen
same manner.
oilpressure
unit
See
as an
(8).
more
detail information
on
all models.
vacuum
(9),
dual
acces-
(12)
5-14. DualDrives
Vacuum Pump and Propeller Govfigure 5-5. Remove brace (2), vacuum
pump and propeller governor drive adapter (5), and
dual drive adapter (8). Remove accessory drive gear
See
5-1. This
Adapter.
figure
unit,
option, replaces either the oil
pressure screen housing or the thermostatic valve and
5-6.
er
ernor
usually installed
Removalfrom
is removedfrom the
parts
gears
vacuum
pump
are
If
engine
is
equipped
with "AN"
when
FuelPump Driven Gear, AN Type ONhere applicable) See figure 5-4. Removethe adapter (3) andgear
(5) from the mounting pad on the lower left side of the
accessory housing.
5-9.
pins,
(Where applicable)
Removethe
housing
and
housing
remove
5-1
o~
f:
3"
Fxo~ oe~D
____J
L---
1~
-r--
1
2
i
Or
lo
12
13
r$
6
5
"c
m
c~
2. Gaskets
7.
8.
Housing
11. Washer
12. Plunger
Spring
Plug
9. Bolt
Figure 5-1.
Oil Pressure
and Full
Screen, Oil Cooler Bypass Valve
10. Elbow
Impeller
22. Washer
Dill
4
6
o
~n (~a p
19
---19
22
18
8
8
17
O
8~
20
9
1. Crankcase
7.
Spring
h~J
11
,,R
0,
(2
14
21
"n
0;O
s+,
cn
c:
H
Z
8. Seat
9.
Sleeven
9.
Drive
Components
v,
gr
I"
it%
3vn
TP~
sdF
5
cs
34
~aL
12
5
c~"
m
cr,
P.
1. Vacuum Pump
2. Gasket
3. Oil Seal
4. Adapter
9.
5. Washer
6. Vacuum
7.
8.
Pump Driven
Pump
Fuel
Cover
Governor
Figure 5-3. Vacuum Pump and Propeller
Retaining Ring
Gear
Propeller
Section 5
Hou,ing
5-19. Turbo Scavenge Pump (Where applicable) See
or 5-11. Disassemble as shown in the il-
figure 5-10
lustration,
5-12. Disassemble
as
See
figure
CLEANING
allplugs
impeller
manner
5-22.
gines.
plugs,
Be
instructions
as
See
outlined in Section 3
5-26.
of this manual
Oil Pump
5-2. The
INSPECTION
same manner
re-
5-27. Oil
re-
Suction
(Where applicable)
Tube.
figure
pellers
lower
(7)
semble a gasket and the oil suction tube over the bolt
ends and assemble plain washers, lockwashers and
slotted nuts and tighten to 75 inch pounds torque. Secure
with cotter
pins.
plate.
1/4-20
screws
LI I
on
and
lock-
pQ 09
&1 8~8
1. Oil Seal
6.
2. Gasket
3. Fuel Drive
4. Pin
7. Fuel
5.
hex head
10 11
Insert
housing. As-
5-28.
REASSEMBLY
See
as
paragraph 5-25.
as
figure 5-7.
sure
body,
changeable.
general
keyed.
Oil pump bodies are made for both clockwise and counterclockwise rotation en-
pump
with the
manufactured
CAUTION
are
from
exceptions. The
with these
Adapter
Retaining Ring
Pump Idler
Gear
5-5
Sec~ion 5
Acce~sory Houling
~se
2
s80
~Q)
Q hlJ
~BIPPOP O
6
12
jLfi
2
esol8
ib
9
13
7. Washer
8. Dual Drive
i. Gasket
2. Brace
Adapter
Accessory Drive Gear
10. Dual Accessory Drive
9.
3. Cover
4. Oil Seal
Gear
Figure 5-5.
Vacuum
the shaft. Be
sure
in the tachometer
that
a new
on
Rotate the
oil
are
front of the
Apply
magneto. As s emble
in
1-3/4
adjacent
5-30. Vacuum Pump Drive. See figure 5-3. If the engine is equippedwith a vacuum pump drive, assemble
as
follows: Insert
a new
oil seal
(3)
into the
such
engine
1/4-20
and idler gear hub. Carefully fit the accessory housing in place on rear of crankcase, guiding
the housing first over the tachometer drive shaft and
coating
of
through holes
liberal
are
The two
the unit
5-29.
right magneto.
surfaces,
gearteeth
then
place
on
1/4-20
5-6
to the
locating
1/4-20
1-3/4 bdlts.
with ten
15/16
housing
in
Two of the
1/4-20
15/16
bolts
recess
grooved side
toward the
to the upper
right
side
adapter.
Place
a new acces-
Section 5
Houring
four
If the
engine is equippedwith
place
a cover over
vent entrance
the
is
engine
vacuum
pump
the
those
9~
7
5-32.
with
lows: Insert
side of the
sure
a new
hydraulic
towardthe
washer
equipped
unit
as
fol-
in the pump
assembly. Make
recess
adapter
grooved
side
adapter.
over
pump
is
Place
a new
1. Drive Shaft
2. Plug
3.
Body
5. Drive
Impeller
6.
Cotter Pin
7.
Idler Shaft
4. Driving Impeller
Drive
Assembly
cover.
B
4. Driving Impeller
5. Driven Impeller and Idler Shaft
6. Oil Pump Drive Shaft
1. Woodruff
Key
Plug
3. Oil Pump Body
2.
Figure 5-7.
Revised October 1974
Oil
Pump
Drive
Assembly (Sintered
Iron
Impellers)
5-7
BRACKET
O
3"
XI
AT THIS POINT
O~p
.io
DUAL DRIVE
ASSEMBLY
i"\f
)n-J
i-
jj
STD-1215
BOLT
SECURE DRIVE TO
HOUSING INITALLY
II
69320 CAPSCREW
.250 PLAIN WRSIER
THREE
PLACES
IIBII
SECTION"A"-"A"
Drive
Assembly
Vacuum
HYDRAULIC PUMP
li~
r,
PAD7
~ii"64
VACUUM PUMP
PAD
0)
~O
SECURE DRIVE TO
HOUSING INITIALLY
.f~, !o
~W
nT THIS POINT7
~,i
ASSEMBLYDUAL
I,rui
i--
-i
j
t~
-1:--
STD- 1215
BOLT---I~
j
i_~
DRIVE
o
o
AJ
11GJ~
"a/i
ACCESSORY
HOUSING----~1i
SECTION
"A"-"A"
Section 5
Acce~,ory Houling
5-33.
engine
recess
follows: Insert
a new
oil seal
(1)
screen
inthe pump side of the fuel pump adaptMake sure that the seal is inserted
assembly (3).
with the grooved
er
as
housing
under ends of
CAUTION
Brace must be
no
seatedproperly
so
there is
are
tightened.
5-34.
sory
housing.
on
Install the
acces-
vacuum
pumppad andpressure
vacuum
screen
housingflange.
requiredfor
seating.
i4
9
08"/
II
~9-9
10
C"--12
14
1.
~s13/>
8.
2. Dowel
3.
Hydraulic Pump
Hydraulic Pump
Drive Gear
9. Dowel
Adapter
Retaining Ring
7. Washer
Figure 5-10.
Revised October 1974
Turbo
Scavenge
and
10.
11.
12.
13.
Ring
Pump
Woodruff Key
14.
Oil Seal
Oil Seal
Gerotor
Pin
Hydraulic Pump
Drive
Assy. (0-540)
5-9
Sec~ion 5
Acces~ory Houting
5-40. Thermostatic Valve and Oil Pressure Screen
CAUTION
Housing.
Brace must be
no
seatedproperly
so
are
See
thermostatic valve in
there is
tightened.
housing on
the
screws or
one
nut
(whichever
is
applicable).
Pump (Diaphragm Type) See figure 5-3.
installing the diaphragm type fuel pump make
sure that the pump drive plunger is all the way up and
the cam of gear is on the low side. If the plunger is
5-36.
Fuel
5-41.
Before
case
at bottom of
plunger.
5-42. Oil Filter (Dual Magneto Housing) See figure
5-2. Assemble oil filter bypass valve spring (7), seat
(8)
5-38.
Oil
5-12.
on
the lower
5-39.
right side
of the accessory
detail information.
housing.
oilpressure screen housing and the opening is plugged when using either a thermostatic oil cooler bypass
valve and oilpressure screen assembly or oil filter
and adapter. Install plunger (12), spring (7), washer
(2) and plug (8).
Assemble
screen
housing on
the
screws or
the
in
one
nut
(whichever
is
applicable).
e~i9r
3
4:
43
1. Prop. Gov. Drive
2. Dowel
Adapter
4.Woodruff Key
5. Turbo
10
6. External
Ring
7. Washer
8. Prop. Gov. Drive Shaft Gear
9. Gerotor
10. Prop. Gov. Drive Shaft
Drive
Assembly (0-360)
Revised October 1974
ik~
6
;I
h3
;i
eaF1
16
:o~ObICL
10
(5
(I~p
14
Ir
n
00
s
13
12
o
z
15
tii_;
~I--
i. Tube
2. Hose
Assembly
Clamp
3. Hose
4. Fitting
5. Hell Coil
6. Cotter Pins
7.
8.
Union
9.
12. DriverImpellers
1.3. DrivingImpeller
14. Dowels
15. Oil Seals
18. Pump Housing Assembly
iii
i
B
Iff
t g
06
OVERHAUL
See)lan~
Cylinder,, Pi~ton,.
and Valva Train
SECTION 6.
CYLINDERS, PISTONS AND
VALVE TRAIN
reciprocating part,
is
nor-
mally grouped
the
the retainer.
intercylinder
cylinders.
Remove the
6-8. Deleted
6-9. Deleted
or
down
exhaust, basic
cylinders.
overhaul
procedures
baffle
exhaust
are
the
same
cylinder
for all
assemblies
except
steel,
cylinders
noted.
as
plated,
chrome
or
nitride
6-10.
CYLINDER ASSEMBLY
(AIl models)
Remove
6-11.
covers
and
VALVE
PARALLEL
0-235, 0-290-D,
-D2)
See
(Except-
CYLINDERS
Remove the
figure 6-1.
Plain steel
b.
Chrome
All grey
Orange paint
plated
fins
below
on cylinder
spark plug
c.
the
hole.
Nitride hardened
Blue
steel
below
6-12.
move
Green
when
customer
plain cylindei.s
applied
overhaul
to
en-
gines.
e..OaOinchoversize
plain cylinders
Yellow
moved untilthe
rocker shafts
move
when
customer
applied
overhaul
to
en-
gines.
are
used.
the
push
on
(14)
(12)
re-
rods
cannot be
these models
cylinder is removed.
Re-
Note
(13
or
17).
Re-
6-6.
covers
(31)
and
or
gaskets.
Pushvalve rockers shafts (20) outward to allow clearfor removal of valve rockers (22) and thrust wash-
ance
ers
NOTE
(l)through
valve
d..010inchoversize
to
(23).
remove
the detent
first
May, 1972
(14)
from end
of shroud
tubes;
also
(19)
and
remove
6-1
Sec~ion 6
Cylinder~, Pi,ton~,
and Valve Train
tool
ure
6-8.
CAUTION
8
It is
6.
i. Shroud Tube
2. Shroud Tube Spring
3. Shroud Tube Lockplate
4.
Rocker Box
7. Valve
Seat
Spring
Plain Nut
5. Valve Rocker
each tappet assembly be kept together during all overhaul operations, in order that
all component parts may be reassembled
with theri
and each
its
orig-
Parallel Valve
(A11Models.
6-14.
ploy pal-nuts
nuts
nor
or
lockwire
cylinder base
If
are
are
lockwired,
currently
hold down
nuts(
em-
II
pulled
falling
against the
Using
piston
and
from
remove
CAUTION
After the removalof
a cylinder andpistoa
connecting rod must be supported to
prevent damage to the rod and crankcase.
This is drone by supporting each connecting
rod with torque hold down plate ST-222,
rubber band (discarded cylinder base on
s eal rings) looped around the cylinder bas e
studs or using plates as shown in figure
the
6-2.
6-16.
successively
1-4-5-2-3-6
or
the
engines firing
order
1-3-2-4,
1-5-8-3-2-6-7-4.
CAUTION
Do not
or
making
6-2
the unit
inoperative.
Figure 6-2.
Two Methods of
Connecting
Supporting
Rods
Revised October 1974
3/8
30.
a7
8
9
10
cylinder base
31,
Nut, lockwasher,
32,
33.
34,
35.
36.
37,
Exhaust flan~e
nut
washer
Exhaust
flange gasket
key
Valve spring seat
Outer valve spring
Inner valve spring
Valve
II
37
inch
(0-235-0)
10
36
35
34
e~
B~-
GiFP
33
15
32
16
30
17
29
18
_
19
28
1,
Spark plug
insert
spring seat
spring seat
1/2 inch cylinder base nut
(0-290-D, -D2)
3/8 inch cylinder base nut
(0-29~-D,-D2)
2, Outer valve
3. Inner valve
4.
5.
(0-235-C,O-290-D)
adjusting screw
(0-235-0, 0-290-D)
Nut (0-235-0, 0-290-D)
19.
22.
Intake valve
23.
Rocker box
(0-290-D2f
20
18, Valve
20. Screw
Push rod
21
9. Intake valve
10. Shroud tube seal
12.
25i,2322IV~B
24, Valve
25,
cover
guide
gasket.
rocker bushing
P
O.~L
m
cs,
2
3
29.
30,
31.
32.
---------7
395
Hose and
~1
~i
36.
10
U~
Nipple
shaft
bushing
9
1
(VO-360, IVO-360j
rVO-360, n70-960)
clamp
L)rain tube
valves
11
12
13
I~
38
15
Iq
37--i~
a
)817
19
20
21
35
33
22
34
23
24
~25
gJr
17.
18,
19,
20.
21.
22,
Spacer
Springs
Loclq~late
Nut
plug)
28
23. Valve rocker bushing
24, Gasket
25, Rocker box cover (VO-360,
~7
NO-360)
31
Figure 6-4 Parallel~VaLve Cylinder Assembly (Except 0-235, 0-290-0, 0-290-D2)
30
29
~a
23.
b0_~-----
26.
cover
gasket
cover
Rocker shaft
bushing
7 __J
O
cover
e90s
II
~a
IBI~
13
15
(ID
(1
17
30
29
27-"
28
r
a
18
14
i~
19
20
21
22
26
1. Valve retaining keys
2. Outer valve spring seats
3.
4. Outer valve
spring
5.
Lower valve
6.
Hell-coil insert
7.
Valve
seats
(spark plug)
18.
10.
11.
Fin stabilizers
22.
9.
23
Push rod
~dt------ 24
I
Exhaust
(b
flange
Shroud tube
S~WI
25
C:
spring
Shroud tube
10. Shroud tube seal sleeve
20. Valve rocker shaft
guides
3/8 inch nuts
1/2 inch nuts
Cylinder hold-down plate
8.
Ln
springs
12.
13.
14.
15.
16.
17.
bushingaig
Valve rockers
Figure 6-5.
Angle
Valve
Cylinder Assembly
Down Exhaust
2(
22
23
cR
cn
,4
/8
79
12
jO
ii
13
~1
14
15
32
27.
Cylinder
28.
Intake valve
ring
nipple
is
zs---~
II
14
~Y3
28
~P--20
29
i. Vahe retaining keys
2. Outer valve spring seats
3.
Auxiliary
valve
springs
10.
11.
12,
13.
14.
Fin stabilizer
Intake valve seat
Push rod
Shroud tube oil seals
6.
7.
8.
9.
27
g$---2~
35-~8,
2 23
34---~;%
24
33
20
1
21
23
Figure 6-6. Angle
Valve
CI~
~as
~gg
B
5.
Section 6
Cylinderr, PirtonJ,
ond Valve Train
DLSASSEMBLY
6-18. CYL~DER. Place cylinder
holdingblock (64526-1,
or
-2),
over
the
cylinder
spring
assemble valve
of
rocker
CA UT ION
Figure
Do not drive the valves
through
the
Usingthepiston ringexpander(64523
the rings from all pistons. Remove
the rings in order, starting withthe top ring andworking down. Be careful not to scratch or score piston
when removing rings.
6-21.
or
6-8.
CAUTION
Keep plunger and cylinder of eachassembly together. They are very closely and
selectively fitted together during manufacture and are not interchangeable.
PISTONS.
64713),
CLEANING
remove
spring
mately
Plunger Assembly
guides.
end of
Specific
instructions follow:
in the proper
compartment
re-
of the clean-
CA UT ION
It is imperative that various parts of each
tappet assembly be kept together duringthe
overhauloperations, in order that all component parts may be reassembled with
their original mating parts and each completed assembly inserted in its original
location in
parts
new
are
the crankcase.
In the
intermixed, discard,
event
and install
assemblies.
INSPECTION
generalinstructions described
Specific instructions willbe found inthe
followingparagraphs, possible revisions will be found
in accordance with the
in Section m.
Section s
Cylinderl. Pizlon~,
and valva Train
(b)
provided
its depth
is
no
Physically damaged,
7. Camshaft
(a)
8.
exceed
6-9
Tappet body
9. Cylinder
10. Ball check valve
11. Plunger
12. Push rod
of
(b)
(c)
CVISUAL INSPECTION).
otherwise
studs.
0. 007
or
0. 012 oversize
studs).
or
for
Loose, cracked
replacement.
for
e.
and
or
that
(d)
(Replace
with 0.
scored valve
3/8
inch in
areas on
the
any
one
more
on
the push
than sixblended
In additionto the
above,
it is recommended
following
areas.
to the exhaust
cylinder.
(2)
port flange.
(2)
thantwoblended
more
on
of
The
area
spark plug
counterbore.
guides. (Mark
i. Cracked fins.
adjacent
nor
inserts.
concerned,
Fin
one
(a)
inches,
bent fins.
or
003,
f. Cooling fins. The following standards shall prevail insofar as acceptance or rejection of cylinder heads
are
square
more
No
damaged valve
d.
No
fins
Loose
c.
(Mark
3/8
Ex-
the
damaged
Loose
b.
for the
seats.
broken
depth.
Hydraulic Tappet
amine the
a.
deepening of
fin.
Diagram
CYLINDER HEAD
6-26.
the crac~.
i. Shroud Tube
Figure
2.
1/4
closer than
re-
one
one
11
is
quarter
inch radius. Minimum corner at top of
fin adjacent to the removed portion is
6-27.
CYLINDER
TION).
HEAD
@IMENSIONAL
overhaul)
guides
be
INSPEC-
guide tit
replaced
is
at
gage (ST-81).
Check the diameter and out-of-roundness of the guide
bore by checking with the gage at a minimum of two
with the flat
plug rejection
sure
to
use
"Cyl.
Head".
duce
aa.
Maximum removalis
one
no more
than
No burrs
mitted.
6-8
or
sharp edges
are
per-
Figure 6-10.
Seetion 6
Cylinder~,
ond Valve Train
(VISUAL INSPECTIONr.
CYLINDER BARREL
6-28.
athorough inspection of the cylinder bargeneral condition, make the following specific checks:
In additionto
OR SCRATCHES
IN THIS AREA ARE CAUSE
FOR REJECTION.
or
nicks be
Cylinder
b.
bent,
cracked
Check
c.
Skirt.
broken sldrt.
or
mounting flange
for
cracks,
nicks
or
warping.
sion.
Minor
1047.
(DIMENSIONAL
CYLINDER BARREL
6-29.
INSPEC-
TION).
Table of
a.
applicable
Limits):
Fit between
piston
of
skirt and
cylinder
b.
Maximum
c.
Maximum out-of-roundness
taper
cylinder (519).
walls
(5202
6-31.
(VLSUAL INSPECTION).
PISTON
Examine the
cavaties
or sur-
face distortion. The latter may be evidence of detonation, particularly if the piston has been in service for
relatively
ton
(522).
Valve Stems
short time.
must receive
d. Bore diameter
Inspect
hold down
(521).
to
pin
thorough
and grooves,
holes bosses.
ring lands
and
pis-
piston
NOTE
PISTON @IMENSIONAL INSPECTION). Make
following dimensional checks on each piston (the
numbers in parenthesis refer to the applicable ref-
6-32.
All measurements
involving cylinder
bar-
minimum
3
THIS PART OF PISTON
HAS LARGER DIAMETER
THAN RING LANDS,
STRAIGHT EDGE MUST
BE USED AS SHOWN.
the
erence
6-11 in order
clearance.
to
obtain
true
check
of
the side
(512).
FEELER GAGE
:-17
Clearance
c.
piston diameter
6-33.
OD of
STRAIGHT
EDGE/C
512,
of
Checking
Side Clearance
Piston
Ring
and
Table of
Limits).
piston
and
plugs
at
and check OD of
6-9
Sec~ion 6
Cylinderl,
ond Volve Train
the stem
reason
for not
tuo.tnartenep
facturer of the
TABLE VI-I
for
Valve
Part No.
or
at severaldifferent
positions with
flat
plug rejection
Min. Permissible
Edge
Engine
Series
Thickness
0-235, 0-290-
60037
6642 9
-11901
040 inch
67905
.050 inch
0-290-D2,0-320,
0-360, 10-360,
VO-360, 0-540
73938
.060 inch
0-290-D2, 0-320,
AIO-320, 10-320,
LIO-320, 0-340,
0-360, 10-360,
HO- 360,.HIO-360,
IVO-360, VO-360,
0-540, 10-540,
0-435-A
ment.
and clean to
cor-
must
TIG-540
not be released.
NOTE
73129
-13622
.075 inch
reused. Inconel
exhaust valves may be reused if they comply with requirements of the following in-
10-980, LIO-360,
AIO-360,IO-540,
TIO-540, LTIO-540,
67518
.085 inch
spection.
10-360, HIO-360,
TIO-360, 10-540,
72612
Exhaust
valves)
(except
valves
should
never
Inconel
exhaust
be
71953
73117
73876
6-37. Do not
reuse
way of valve
measures
10-720
on
stem diameter
shown in
as
figure
6-12.
6-38. Check runout of valve face.
See
figure 6-13.
Do not
re-
6-39.
See
limit
NOTE
edge of intake valve heads are generally formed as shown in figure 6-14. The
The
thickness "A"
an
can
measured with
means
plate,
6-10
opticalcomparator; however,
of
as
sufficient
it
can
be
accuracy by
dial indicator and a surface
shown in
figure 6-15.
~Y
Figure 6-14. Section Through Edge
of Valve
Section b
Cylinders, Pistons,
and Valve Train
STP~RTINb TO
I\OVPNCED
B4L)LY
SPPILL~
NOTE
Each
two
or
one
(figure 6-18)which is
Rockwellmarks
not
shown in
as
body
valves).
6-43. HYDRAULIC TAPPET BODIES. If for any reason a new camshaft is to be installed in the engine, or
the
cam
lobes
are
conditioned
are
also
as
shown
infigure
body
for
signs
of
with
tappet body
is
rejected
nose
because of
of the
power) must
HEAD
cam
the
tappet
part. Each
body using
surfaces, If ally
appreciable
amount of
plunger assembly)
rejection of the
(which
feather
entire
wear
has
or
oc-
seat
serves as a
chipped edge
(figure 6-20).
chipped edge
tappet assembly.
or
is
cause
The
for
the
through
use
a.
GRO~E
the
of the
Clean the
sandpaper
a
on
rejection of
for
the
ling,
cause
6-46. When
figure 6-17.
valves,
for
edge
grade
coating (figure 6-22).
spallobe
be made.
b.
the
2-GROOVE
UNDER CU7
fixture with
DOUBLE RIB
6-11
Section B
Cylinderl, Pi~tonl,
and Valve Train
ROCKWELL MARKS
to hold the
Tighten
assembly securely
on
in the
fixture.
6-53. Make
ger
assembly
visualinspection
of the
body
of the
plun-
for cracks.
CA UT ION
to the
CAUTION
When it has been determinedthat
body
tappet
method.
is
the same
clean solvent.
Various
hydraulic plunger assemblies are used in subject engines. (Consult Service Instruction No. 1011). These
assemblies
are
differentiatedby
a.
(Extra
Dip
of the engine check the P/N on the hydplunger assembly. Hydraulic plunger assemblies must be usedin sets and it is not permissible to
mix assemblies inthe same engine. It is recommended
the following procedure be followed at overhaul:
raulic
the
leaking check
manner:
fast leakdown
blies must be
disassembly
following
Hold the
and middle
CAUTION
c.
and if the
Allparts
bly
are
6-51. As the
new
hydraulic plunger
6-52.
ROUGH
assemblies
are
chipping of the
6-12
SMOOTH MACHINED
SHOULDER
re-
seat-
Line the
FEATHERED
EDGE
on
WORN
BODY
NEW
BODY
Seelion B
Cylinderl, PiEIonl.
ond Volve Troin
31(2
~L-.r
--L
_1_
5~I_L
MtI-r~ p~lg
-I ciL
E~
2
L~f
-i I ~f""
,*T~a n.ER
nl
i~--i
ii
-1 4
II
ri
DR
BRAZE
~TAP
qL -20
DEEP
jr
i I
--I__;
plunger does not bounce back but recollapsed, it is an indicationthat the ballcheck
valve is not seating properly. When this condition exists, the hydraulic plunger assembly is defective and
must be replaced.
d. When the
mains
or
6-57. DETECTION
OF MAGNETIZED
tizationwith
compass
or
If the
ths
FIBER
ICOPPER
slrF
*aTERlnL
Fixture
springs
on
plunger
as
of all
suitable
as-
the
and
Table of Limits.
MODIFICAT IONS
6-59. Several modifications have been made to
var-
No.
HYDRAULIC
parts of
assembly become magnetized the plunger
in a collapsed position. Check the parts
PLUNGER ASSEMBLIES.
COPPER
801,
Making Holding
exhaust valve
an
hydraulic
plunger assembly has proven to be defective, the valve itself must be replaced as
well as the hydraulic plunger assembly.
intake
for
C.R.S.
x2Bx2~
/Ifola, rA
IB X2t Y28
srocn
NOTE
When
COPPER
MtH.SCR.
F~HD.
DIA. X2
Oi-,w~
xIf
/t-20X1Z,
1280and 1302.
plunger
may remain
for magnesmall iron wire. In the event
6-60.
6-13
Section 6
Cylinderl, Piltonl,
and Valve Train
insert.
(64596-1)
Figure 6-22.
vance
Coating
were
plug
so
that the
clockwis e
6-63. A
tool
(64595)
in the
spark
top
counter-
insert may be installed by use of the inWithdraw the mandrel part of the
serting too1(64594).
tool
beyondthe
of the insert.
press forward slightly; this will engage the insert in
threadedend of sleeve. Continue to rotate the mandrel
tang
inch
bottoming tap
tightly by
boss,
the handle
hand, freeingthe
can
be
seen
By sliding
top of the mandrel, the end of the
projecting above the boss. The
new
.010
Surface to be Cleaned
of Ferrox
is available.
disappears from sight. When this posireached, the turning action should be stopped
and the tool withdrawn. The top of the insert will be
approximately one half turn from the face of the boss.
However, if it is not, the tool should be reassembled
tion is
and the
one
half turn
while
on
the
screw on
as a
so
Figure
6-14
6-23.
Chipped
Shoulder
Assembly
for Leaks
Revised
July, 1967
Sec~ion 6
Cylinders, Pir~onr,
and Valve Train
shown in
NOTE
replace intake or
inthe cylinder head mustbe cut .010,.020 or .030
oversize and the corresponding oversize
When it is necessary to
exhaust valve seats, the
recess
seat installed.
SEATS.
See
figure 6-26.
The ID of the valve guide is used as a piloting surface
for all valve seat reconditioning operations. Grind
valve seats, using suitable grinding equipment, to 30"
angle on intake valve seats and 45" angle on exhaust
on some
valve seats.
Grind to the
These seats
figure 6-26.
Proceed in the
dimensions
following
seats,
use a
called out
in
manner.
"C") by narrowing
the face
75" wheel.
son" type seat employed on all current subject engines. See figure 6-28 for sectionalviews of both seats.
(dimension "B").
The width of
sion"D".
6-70. If seat
wear
has
progressed to
narrowing
the
extent that
not
interchangeable.
on
ricate
6-74.
securely.
Fab-
secure
to
are
cylinder
to
figure 6-29.
temperature of 600"F,
and
to fixture.
in cold water.
cling to the sponge. Withbeing careful not to cock the seat. This
entire procedure should be performed as swiftly as
possible after removing the cylinder from the heal.
seat,
recess
in the
cylinder head. Compare the measurementwith the original manufactured diameter of the recess (see Table
of
wheel must be
replaced.
Limits)
installed.
11811
IIAll
__
45"
X)" 0
30"
45"
X)
0
X)
/IC~Y
15"
15"
75"
INTAKE
I,,,,
MODEL
0-290-D, 0-435-A
All angle valve head
cylinder
assemblies
2.
(INTAKE)
145/2.
155
"B"
1.
EXHAUST
(EXHAUST)
740/1.
750
"C"
(INTAKE)
.076/.
117
"D"
(EXHAUST)
.058/.
077
0-435-A
1.965/1.975
2.013/2.023
2.
334/2.
344
1.722/1.732
1.740/1.750
1.
816/1.
826
.032/.067
.076/.117
.091/.106
.058/.077
.074/.
.091/. 106
093
Section 6
Cylinders, Pi,lans,
and Valve Train
TABLE: VI-n:
VALVE SEAT REPLACEMENT TOOLS
VALVE SEAT RECESS CUTTER
ID Valve Seat Hole in
Cylinder
Head
Part No.
2.280-2.281
1.733-1.735
2.073-2.075
1.926-1.928
1.918-1.920
2.087-2.089
1.994-1.996
ST-51-1,-2,-3
ST-52-1,-2,-3
ST-53-1,-2,-3
ST-54-1,-2,-3
ST-56-1,-2,-3
ST-57-1,-2,-3
ST-58-1,-2,-3
Cylinder
Part No.
Head
ST-66,-1,-2,-3,-5
ST-67,-1,-2,-3,-5
ST-68,-1,-2,-3,-5
.5913-.5923
.6613-,6623
.6247-.6257
ST-66 is standard
ST-66 is standard
-1 Indicates .010 inch oversize
Part No.
1.870-2.060
1.474-1.730
ST-64
ST-65
64520
64696
Cylinder Heads
Cylinder Heads
ParallelValve
Angle
Valve
ST-62
ST-63
adapter
6-76.
up the
major
recess
REPLACE SEAT IF
11111
WHEEL PRODUCES
Is NARROWING
WHEEL
GR\ND\NG STEP
HERE
diameter.
6-77. In the event the seats are to be cut by hand, install the hand drive adapter over the special drive and
using a T" handle proceed to cutthe recesses as described in the
111111
VALVE SEAT
preceding paragraph.
PILOT
6- 78.
and
Heat
~II
secure
new
seat
for correct
cylinder
6-16
drift)
head
by tapping
recess
in the
GUIDE
Sec~ion 6
Cylinderl.
and Valve Train
guide.
From
guide
guide
the
hole
same
oversize
size
ALLISON TYPE
grindthe
Proceedto
valve seats
as
faces of the
described in
newly installed
6-69.
NOTE
Whenever
newvalve seat is
installed,
it
6-80.
valve
Using
soft #80
suitable
equivaremove
cylinderto 350"F. -400"F. for a minnew guide on the appropriate valve guide installation drift (See Table VI-III)
and insert the guide in the hole in the cylinder head.
Drive the guide to a firm seat with sharp hammer
blows on the end of the drift. Allow the cylinder to
cool. Ream thevalve guide with the appropriate valve
guide TD reamer and check the finished ID with the corresponding valve guide ID gage (See Table VI-m).
Heat the
one
while valve is
machine,
excessive
valve
guides
are
following paragraphs.
or
may be
(reference 533,
wear on
brought
Table of
Limits)
cylby
caused
support boss
following manner:
removed and
Damaged
Exces-
accomplished
VI-III)
6-86.
or
grit wheel,
Table
imum of
lent. Set refacer to 30" for intake valves and 45" for
exhaust valves.
guide
guidepuller (ST-49)
Screw the
over
valve
(3/4-16)
guide
nut of
(3/4-16).
inside of rocker
a.
to
NUTS
1/2" BAR
spotfacer (64862)
(2)I~
STOCK
Figure 6-29.
Revised October 1974
2"
2.5" DIA.
6-17
Section 6
Cylinderl,
Piltonb
TABLE VI-III
GAGE
REAMER
SIZE
Cylinder
5913/.
64571
64507
64509
64511
64639
Head
Standard
_,-____
.005 oversize
.010 oversize
.020 oversize
.030 oversize
64678-2
64678-3
on
bushing
(All Cylinders).
bushing using
the
cover
with
an
Remove
the outer
bushing
and inner
removal drift
(64814).
Standard
ST-89-5
.005 oversize
ST-90-5
ST-89-1
.010 oversize
ST-90-1
ST-89-2
.020 oversize
ST-90-2
;ST-89-3
.030 oversize
ST-90-3
ACCEPTABLE
INTAKE VALVE
6623
on
diameter drill.
64678-5
ST-89
6613/.
suitable fixture
64678-4
hole)
6257
to
6-90.
6247/.
cylinder
hole)
5923
EXHAUST VALVE
hole)
64940
Standard
64924
64928
64929
64930
.005 oversize
.010 oversize
.020 oversize
64924-1
64924-2
64924-3
64931
.030 oversize
64924-4
Valve Guide ID
64514
64514
64725
ST-26
64901
64927
64927
84684
64684
.4040/. 4050 exhaust valve
MSIRED (I MAX.ANGLE)
64726
.4360/. 4370 exhaust valve
ST-27
INTAKE VALVE
.4370/. 4380 exhaust valve
EXHAUST
64900
.4375/. 4385 exhaust valve
64925
.4985/. 4995 exhaust valve
(except ni-resist)IMAX.
.4985/. 4995 exhaust
(Ni-resist)
il;r~
Pilot diameter
ST-155
.4828/.4833
.4778/.4783
.4995/. 5005
VALVE
ST-113-1
ST-113-2
exhaust
(Ni- resist)
Pilot diameter
.4828/.4833
.4778/.4783
ST-143-1
ST-143-2
NOT ACCEPTABLE
REPLACEMENT FMTURE
INTP~KE VALVE
T/N
CYLINDER ASSEMBLY
64501
64644
64714
All
All
All
4-3/8"
EXHAUST VALVE
bore
REPLACEMENT DRIFT
64505
64505
64796
64923
6-18
.4360/. 4370,
.4370/. 4380, .4375/. 4385 ID
Valve guides with .4985/. 4995,
.4995/. 5005 ID
Not-Acceptable
Desired and
May,
1972
Section 6
Cylinderr,
and valve Train
shaft
standard
bushing
hole in
cyl-
plug
If the fit of
plug gage
in the hole is quite loose, it is evident thatthe bushing
that was removed was an oversize bushing. Use the
0. 005 oversize plug gage to determine what oversize
bushing should be used for replacement. When the proper size replacement bushing has been determined,
proceed to ream bushing hole in the cylinder head.
reamer
ream
of the rocker
NOTE
After
6-98.
rocker
(64838
Place the
Cylinders.
pilot of
the
ream
the
6-94.
(64826) through
the four
can
be
drift,
remove
the
bushing
6- 100. Using a suitable arbor press, install a new bushing in the valve rocker. Make sure the oil hole in the
bushingis alignedwith the oilhole in the valve rocker.
bushing
finish ID gage.
6-102.
RegrindingCylinder
Barrels.
Allunplated cyl-
diameter, taper or out-of-roundness, must be reground to .010 or .020 oversize. Nitrided cylinder
barrels employed on the O-360-B, -D and O-540-B
low compression engines may be ground to .010 oversize. Do not attempt to regrind a barrel on light weight
grinders such as block mounted automotive or similar
type machine.
in
NOTE
Insert the
Angle
rocker shaft
reamer
(64821
and
64822).
cylinder
ParallelValve
rocker shaft
bushings
thoroughly.
Cylinders.
in
After
Revised January,
1971
installing
Only
employed
on
the
engines listed in the above paragraph may be reground oversize. All other
series
reled
or
reconditioned
by
chrome
plating.
allowance)
point
of
greatestwear.
groundto the
barrels with
wear
Limits.
Check the
6-97.
If valve
head.
(60"C.
bushing
the
new
pilot
ID finish
1. Wheel
6- 19
Section 6
Cylinder~, Pi~tonl.
and Valve Train
a.
b.
Grain Size
c.
Grade -K
2A
and
54
e.
Vitrify
3-1/2
Diameter
a.
3-1/2
b.
per minute.
4 inchwheel
inchwheel
V92
b. Nitrided Barrels
shaft in
i. Wheel
by
lathe
rubber
or
pad
b.
Grain Size
c.
Grade-ii
d. Structure
2. Wheel
1C
cloth.
54
NOTE
6
Bond Treatment
f. Diameter
or
limited to
250 RPM
a.
are
Speed
Vitrify
process.
removal of
to 4 inches
minute.
e.
plating
2. Wheel Speed
3. Work
5 porous
Bond Treatment
d. Structure
f.
replating
Tag
V32
rocker
sembled in the
4 inches
it
was
removed at tear-down.
REASSEMBLY
Speed
minute.
3. Work
Speed
6-114.
250 RPM
pander,
6-106.
as
1181.
6- 107. In field service where one cylinder is worn beyond maximum limits, the worn cylinder and its opposite cylinder should be reground to the same oversize dimensions and oversize pistons and rings be
used to maintain proper dynamic balance.
one or
exor-
On chrome
cylinder
and 0-235
cylinder,
the scraper ring is installed with the scraper edge toward the top of the piston. All
other
cylinders, the scraper edge is installed toward the bottom of the piston.
6-115.
(All Pistons).
lying top up on
oilregulating ringequalizer
in the first groove above the piston pin hole. Assemble
the regulating ring over the equalizer with its gap 180"
opposite the equalizer gap. Compress the assembly
several times with the fingers to make sure the ring
lies free and loose in the groove. Both the equalizer
and the regulating ring are symmetrical and may be inStalled with either side upward.
the
workbench,
6,116.
installthe
in the
Installcompression rings
remaining top
top
of the
piston.
should
6-109. Reconditioning Nitrided Cylinder Barrels. Although only the series engines listed in paragraph 6- 102
may be ground oversize, other nitridedbarrels can be
reconditioned by chrome plating or in some cases by
re-barreling. Consult the latest edition of Service Inst1047 for information relative to reconditioning nitrided barrels,
ruction No.
6-110. Reconditioning Chrome Plated Barrels. Although it is notpractical to remove wear steps by regrinding, such barrels can be restored by a stripping
6-20
new
NOTE
the finished pass made. The wheel should then be allowed to run over the work four or five times. When
be fitted with
assemble the
der described in
setting up the job, make sure that the stops are arranged
to prevent the edge of the wheel from running past the
top of the barrel more than 1/8 of an inch. This protects the combustion chamber interior from damage.
6-117.
(O-235-C).
Invert the
piston
on
edge
toward the
1037
or
Division.
Sec~ion 6
Cylinderr,
and Valre Train
(All
6-118.
the
Uponcompletion
Pistons.
assemblyof
of
rings
straight edge as
340
fi~
figure
Cylinder.
Assembly
valve guides and valves with a pre-lubricant as described in paragraph 3- 39. Insert the intake and exhaust
valve intheir respective guides. The intake valve can
be identified by the fact that it is slightly larger than
cylinder
lower
outer and
valve
3),
and
quer)
ends of
dampener
or
~bl I
O
next to lower
and outer
LINE OF ENGINE
springs
or
HORIZONTALCENTER
NOTE
Assemble the
the
on
each valve
on
CJI I
the exhaust valve. Hold the ends of the valve stems and
Install
U/
See
of
the
PER CYLINDER
THICK X.50~70 IN. WIDEI
no
6-119.
place
REPD
block.
rSHIM
o
NOTE
Under
340
*r
lac-
spring
seats.
slight carbon in the piston pin bore of the pispiston pin or piston is to be installed,
select the pin to give a palm push fit at room tempAfter piston
erature of 15" to 20"0. (60" to 70"F.
Pin is in place and centrally located, insert a piston
Pin plug at each end of the piston pin.
nicks
6-120. Compress
the valve
springs
with
the valve
means
should be used.
are assem-
bled
are
Cylinders.
cylinder
See that
and
pis-
allpreservative
oil accumulation
ton assemblies
with
a new
installed.
oughly dried
or
If
NOTE
ton.
compressed
on
Immediately
prior to assembly of piston and cylinder to the engine,
space the rings correctly and apply a generous coating of the oil mixture described in paragraph 3-39.
Apply to the inside of the cylinder barrel and to piston
and rings working the mixture well around the rings
and into the grooves. Startingwith No. 1 cylinder, proshafts in their bores in the rocker box.
ceed to install
as
follows:
NOTE
6-122.
Rotate crankshaft
so
that No.
piston,
when
Assemble
which is
serted
prior
to
assembling cylinder
to
crankcase.
assure proper assembly of the crankcase
halves and to eliminate the possibility of subsequent
6-125. To
directed in Section
are
installed
as
described
6-21
Sec,ion d
Pi~tons
Cylinderl,
repeat steps
b and
c.
fins
cylinder
by filing
or
bur-
ring.
6-128. Install
some
in each
spark
assembly of cylinder to prevent entrance of foreign matter and at the same time to permit the engine to be turned easily by hand.
plug
hole after
6-129.
O~
Indtall
1/2 INCH
Sequence
Cylinder Base
of
Tightening
CAUTION
Nuts
Be
6- 12 6. When all
initially installed
onthe crankcase as described inparagraph 6-124, begin tightening all cylinder base nuts as described below,
using the proper cylinder base nut wrenches and handle
in conj!mction with a suitable torque indicator. T orque
wrenches should employ the flexible beam design hydraulic principle or a dial indicator with rack and
pinion.
cylinders
have been
NOTE
dry.
Wash any
oilout of these
6-130. Assemble
new
push
rod shroud
tubes;
combination of lubricants.
O-290-D,
outer
on
then assemble
tering
seals,
cen-
tube
firmly
springs (2),
(where applicable)
figure 6-31.
Tighten 1/2 inch or 7/16 inch holddown nuts
pounds (25 foot pounds) torque.
(l)through
end
Thread Lube.
b.
that there is
inder
installingcylinder hold-downnuts,
lubricate crankcase through stud hreads
with any one of the following lubricants, or
sure
body
Before
a.
3/8 INCH
Figure 6-32.
concave
with
to
in the crankcase.
Place
spacer,
two
6-132. AngleValveCylinders. SeefigureG-5. Assemble shroud tube spring (17) over the inner ends of the
two shroud tubes (18) so that the detent notches in the
spring are approximately 90" removed from detents
tubes. Place shroud tube washers (15), as many
necessary to bring minimum overlap between the
Spring and detent lugs to 1/8 inch, over end of each
tube and insert tube ends through oil seals in crankc"se. Hold both push rod shroud tubes with detent at
inner end at unlocked position and insert the outer end
of tubes in cylinder head rocker box. See that all rubber seals (14) are inserted squarely and then turn each
shroudtube 90" thus locking the tubes by engaging the
on
300 inch
as
tighten
the
to 300 inch
is
optional.
loaded
e.
As
finalcheck,
hold
thetorquewrench
may be
presumed
to be
tightened to
correct
oneach
it
turn,
torque.
and
f.
6-22
barrel.
If .010 clearance is
not
obtained,
push
rocker
arm
and
secure
hole,
insert
bther
stalling exhaust
6-4)
cylinder
or
6-32.
spring.
over
protrudes equally
from both
outside bosses.
Revised October 1974
Seclian 6
Cylinderr,
and Valva Train
6-135.
Angle
Valve
Cylinder.
Before installing exhaust valve rockplace special cap (32, figure 6-6) over the exhaust
valve stem. Slide rocker shaft back into position. Repeat with the other rocker arm and thrust washer. If
clearance between the valve rocker and cylinder head
cannot be brought within limits (See Table of Limits)
by the use of standard valve rocker thrust washers,
clean up the worn valve rocker support boss as described in paragraph 6-8 7 and use any two of the selective fit undersize washers to bring clearance within
er
(O-235-C,
6-137.
O-290-D.
Set
following
tappet
clearance
on
manner:
limits
different due to
of valves. Be
rockers
assembled.
are
on
numbers 2 and 4
are
sure
b.
of the
compression stroke.
Adjust
closed.
each for
on one
piston is
0.007/0.
009
zero
side.
at TDC
now
be
clearance.
c.
at
cylinders
angle
correctly
Set tappets
a.
CA UT ION
"B" for
numbers
d.
Tappet
engine
However,
FIN N0.28
FIN N027
FIN NO.IB
0.
006/0. 012
is
acceptable.
6-138. At
completion of
cylinder,
recheck clearance
on
each
FINNO.IT
~FIN
NOTE
NO. 16
Noll
NoIO
was
33e
,,I
3.69
-I
1
-I
I
No.l
N0.2
N0.14
mount-
6-139. Installation of
(Angle
Valve
fected fin
N0.13
cover
thoroughly to remove
foreign matter.
areas
grease, dirt
6-140.
Cylinder
Cylinders). Clean
Apply
or
all traces of
other
Dow
fin stabilizers and press surfaces together in the locations described in figures 6-33 and 6-34.
NOTE
Because of
two widths
tone approximately.63
31 inch) may
one approximately
of fin stabilisers
inch and
be encountered. See
Dotted lines call
Angle
Head
narrow
Up Exhaust
stabilizers.
figures
stabilizers,
6-23
Seccion a
Cyliderl. Pi~tonl,
ond Volve T~ain
d.
Proceed to
ON
IIOE
e.
Use
cloth
dipped
in thinner to clean
paint from
accidentally ac-
6-142. Intercylinder
intercylinder baffles
,j
.aslulm
--I
Angle Head
Down Exhaust
6-141.
This
paragraph
is intended
(Where applicable.
Baffles.
an
"S"
All
type
hooked
over
enough to
comes
above
be turned and
and the
NOTE
the
a.
on up exhaust cylinder assemplaced above and between the cylThe retainer is placed below and
The baffles
blies
are
inders.
fastened in the
same manner
as
described
above.
b. Mask off the following parts of the cylinder: Masking tape, corks, plugs, metal covers, etc, are acceptable
for masking purposes.
PERSTEP-D"
plied
paint will
be green with
yellow-
is
CAUTION
It is
the
one
Tinsley
satisfactory method. If
type equipment is not available, use a
micrometer to
measure
the thickness of
SPRAY
AREA PER
STEP-C"
repainted.
6-24
1971
07
Section 7
Crankcase, Cronkrhoft,
and
Reciprocating
Ports
SECTION VII
ring
face of the
rear
7-9.
(22)
figure
7- 5.
camshafts with
separate
gears,
remove
the
breather slinger..(l9), camshaft gear (14), and tachometer shaft spacer (18) by removing the 4 hex head
(21)
bolts
and
the camshaft.
the
assembly
to
sur-
Hydro
cover
Control
applicable.)
remove
the
cover
and valve
body.
7- 8. Crankcases that are doweled at the thru- studs (#2
saddle on 4 cylinder engines, #2 and 3 saddles on 6
3 and4 saddles on 8 cylinder
cylinder engines and#a
engines) must be separated by the use of pressure
in the
housing at the
same
time
supporting
(8)
housing.
(12).
7-7.
opening
from the
remove
Where
the
together.
on
Propeller
side of
the idler
7-10.
(16)
(14)
tappet
corresponding cylinder is located
nearest the front of the crankcase, while
in the right crankcase half the intake tappetis nearest the rear of the crankcase.
for its
of the crankcase
ploying
January, 1971
as
shown
7-11. Crankcase
Remove allthreaded plugs to facilitate cleaning. Remove and discardthe rubber oil seals
encircling the studs. (Doweledcrankcases do not em-
re-
7- 13.
(6
and 8
cylinder
engines using camshaft with separate gears). See figure 7-5. Remove the governor drive gear (2) by removingthe two externalretaining rings (1) that secure
it to the camshaft.
7-14. Crankshaft
With the crankshaft properly supported at front and rear main bearings, remove the
nuts securing the rod caps to the connecting rod. Remove the rods by tapping on the rod bolts with a soft
hammer. Discard the bearing inserts, bolts and nuts.
Reassemble each cap with its corresponding rod. Rods
and caps are not interchangeable.
7-15.
the
To
remove
lockplate (24)
and
from the
rear
obviously damaged.
7-1
Section 7
Crankcase, Crankshaft,
and
Reciprocating
Parts
te678I bd L
11
o
15
1314I
as~12
16~
24
17~
21 20 19
i.
2.
18
Lifting Strap
(Field Conversion)
4.
Ball
5. Spring
6. Washer
7. Spacer
8. Gasket
15.
Spring
Pin
Assy.
(Non- adjustable)
24. Oil Relief Valve
Assy.
(Adjustable)
Revised January,
1971
OVERHAUL MANUAL
Section 1
Crankcale, Cronklhoft,
end Reciprocoting Port,
CAUTION
All crankpin journal sludge tubes must be
removed from the crankshaft; otherwise
accumulated sludge loosened during clean-
CLEANING
from
they
are
Counterweights
See
and
reciprocating
general in3. When cleaning the
all crankpin and main
crankcase,
parts
are
structions outlined
crankshaft
7-20. All
in Section
NOTE
Do not
All
same
location
sludge tubes (where appliThe solvent will loosen but not reaccumulated sludge. This loose
is certain eitherto form a stoppage
the crankshaft
they occupied on the crankshaft before disassembly. For example, the retaining
washers used with the counterweights are
selectively fitted to the washer seats in the
counterweights during manufacture. It is
cable).
move
sludge
in the
7-18.
nearest
through and
oil
passage,
cause a
or
to wash
bearing failure.
merse
Piston
the
cable).
7-19.
Sludge Tubes (6
and 8
cylinder engines
where
removing either six or eight cylinder engine sludge tubes use slide hammer puller
applicable).
-Lii
When
(P/N 64782)
64547 for
six
with
tubes.
Revised January,
1971
I/
i. Dowel
2. Thrust Washer
3. Idler Gear Bushings
4. Idler Gear Shaft
5. Gasket
8.
OVERHAUL MANUAL
CRANKCASE, CRANKSHAJi"I, AND RECiPROCATING PARTS
SECTION 7
-3
s
i. Gasket
2. Thrust Washer
5. Gasket
3. Cover
6, Hex head
7, Woodruff Key
8.
9.
Plug
and 8
Cylinder Engines)
7-27. Grankcase
R\ISPECTION
paragraphs
Inspect
(Visual Inspection).
Check
carefully for
and
cause
engine damage.
cause
of severe
7-26.
Fretting by itself
damage
the fretting action does change the size of the bearing
saddles sufficiently to cause loose thru-studs and undersize
main bearing bores. If not detected during overhaul,
excessively tight crankshaft bearing fits will result with
eventual
7-4
engine failure.
followin
7-24. Crankcase
The
(Dimensional Inspection).
7-28. Crankshaft
7-23.
overhaul.
on
describe dimensional
7-29.
I
i plate and dial indicator measure the run-out at center ma
I bearings. If this total indicator reading exceeds t
I dimensions given in Reference 505 the shaft must not
I reused. The crsnkshaft flange run-out may be checked
be
rejected.
CAUTION
Any attempt
to
straighten
Revised June 19
Section
Crankcare, Cronkshoft,
ond
clearances in the
Reference 502.
scribed
7-33. Crankcase
lowing inspection on
accomplished unless
in figure 7-11.
Bearing Clearance.
the engines listed below
thru-studs
0- 320- B Serie s
7-31. Camshaft
0-
(DimensionalInspection).
Support the
camshaft in Vee blocks at its front and rear bearing
journals and check the run-out at the center bearing
location. See reference 539, Table of Limits. Slight
bending operations are permissible on the camshaft
providing careful magnetic inspection follows such procedures.
360-A,
-C Series
0-540 Series
of the center
shown
prior to 3815- 39
prior to 405-30
prior to 3042-36
prior to 2790-40
main
figures
7- 36.
section.
16 18 17
$C
9
~(crI
35----s
25
14
12
18 19 20
15li- 21ia~
13
~"a,
must be
as
marked
Port~
The fol-
15
are
Engines
Engines
Engines
Engines
0- 340 Series
all surfaces of the camshaft for cracks, scoring, galling, corrosion, pitting or other damage; be particu-
Reciprocoting
Main
22
23
QC~"_ 24
25
26
22
,rli
31
33
10 11 30 29 28
32
I. Retaining Rings
12.
13. Camshaft
Screw
24. Washer
3. Woodruff Key
25.
15.
26.
Crankshaft Gear
4. Camshaft (Integral
5. Tappet Socket
Gear)
Stepped Dowel
Pin
23.
28.
19.
Breather
9.
20.
L;ockplate
6.
Roller
Slinger
Lockplate
10. Washer
32.
33.
January,
1971
7-5
Sec~ion 7
Crankcare, Crankshaf~,
Port~
Recipracating
and
,iIQ
ip~Le
~-9
to
r,i
~sll
13
in the counter-
out-of-round
on
gage, ST-73.
and 0. 7505 inch. Out- of- round should not exceed 0. 0005
inch.
2.
3.
4.
5.
6.
7.
9.
10.
11.
12.
13.
14.
15.
Lockplate
Breather
Slinger
Spacer
Tachometer Shaft
Camshaft Gear
Dowel
Pin
Camshaft
Gear
Pin
7- 43.
Spacer
Retaining Ring
Piston
sent Avco
(Prop. Governor
on Crankcase)
Camshaft
Drive
Integral
Tachometer Shaft
8. Camshaft
be set with
(4 Cylinder Engines)
ton
following
a.
manner:
Use SAE
temperature
of 65"
to 90"F.
inspecting O- 540 models, the above inspecprocedure must be performed on both intermediate
bearing saddles.
7- 37. When
tion
(Dimensional Inspection).
7-38. ConnectingRods
card all
nuts
connecting rod
are
bore in
to be used
large
Check bore in
bolts and
nuts;
assembly.
on
Dis-
of the nozzle
at 50 psi.
bolts and
Check condition of
new
b. Direct
Connecting
See
figure
bearing
holes in
connecting
rod.
Be
sure
that bearing
spectively)
and
place
(6)
gage
arm
(5)
on
arbor
(3).
Set
gage arm to exact distance between arbors and lock the adjusting screw with nut (7).
adjusting
screw
on
Then
(3),
same.
See
Limits.
7-40.
7-9.
Connecting
Using the
Rod
same
Squareness
gage that
was
Check. See
used in the
figure
paral-
connecting rod, place ends of arbor on paralCheckclearance at points (2) where arbors
rest on parallel blocks, using a feeler gage. For exact
squareness or zerotwist, no clearancewill exist at the
designated points. See reference 567, Table of Limits.
in
place
in
lel blocks.
7-6
1971
See~ian 7
Crankcote,
and
Reciprocoting
Specific
7-45.
identified
the
flange
as a
suffixto the
In addition to
part number.
the code symbols the letters RN are stamped as a suffix to the serial number indicating the shaft has been
renitrided. The code symbols are, M03MP (main and
II
(main
undersize)
crankpin journals
bearing journals 0. 003 inch undersize) M03P (crankpin bearing journals 0. 003 inch undersize). If the maxiM03M
0. 003 inch
limits
service
mum
are
(Reference
exceeded
501or
Limits)
502, Table
of
~I
Do not allow
time
RPM at any
2.
NOTE
4. Arbor
surface is polished to
.006 undersize all corresponding
Note that if
or
003
one
faces mustbe
polished
to
same
size.
areas
NOTE
If
sult in
cracks and
can
ultimately
dere-
broken crankshaft.
7-46. If it is necessary to make a standard shaft journal surface more than 0. 003 inch undersize or a renitrided 0. 003 inch undersize more than 0. 006 inch
ground to undersize
and renitrided. Standard shafts may be ground to 0. 006
undersize,
or
ties and
wheel
nitriding.
one
undersize all
Sleeve)
sur-
nonuniformity of grinding tools. The possibility exists wherein the grinding wheel
will cut through the nitrided surfaces on
one or more of the journal radii causing
velop into fatigue
Pin
Pol-
(Piston
great degree
of skill.
properly
or
dressed
equivalent)
must
ground finish maintained duringthe complete opThis procedure must be followed to eliminate
possibility of grinding cracks. After grinding, the
crankshaft must be carefully inspected by the magnetic
particle method. If any cracks or checks are found, the
shaft must be rejected,
final
eration.
Revised January,
1971
7-47. Crankshaft
Straightening Flange. Maximum
permissible flange run-out is 0. 018 inch TIR. If the
flange run- out exceeds 0. 018 inch the crankshaft must
be rejected. If the flange run-out is less than 0. 018
inch the flange may be straightened as described in
the following paragraphs.
7-7
Section 7
OVIRHAUL MANUAL-AVCO LYCOMING DIRECT DRIVE AIRCRAFT ENGINES
Crankcase, Crank~ha*,
and Reciprocating Porl~
7- 49.
dures
e
are
area
of the
crankshaft.
1. Remove
propeller flange bushings from crankflange and note the locations of long and short
bushings replacement. Do not scribe on shaft. Use
Avco Lycoming Special Tool ST-115 to remove
flange bushings.
shaft
aS%i
2.
Strip
cadmium
plate
from
2. Check Points
1. Parallel Blocks
gallon of water).
3. Set up crankshaft in
ter
an
external
grinder and
cen-
carefully.
CAUTION
Extreme
any
care
No.
tween the
must be exercised
during
to avoid dam-
straightening operation
remove
54
slinger
to the crank-
shaft gear mounting surface. These nitrided surfaces are glass hard and will
crack if shaft is bent, dropped or handled
carelessly.
straightening operations,
inspected by the magnetic
particle method paying particular.ttention to the bearing surfaces and the fillet areas at the base of the
flange.
then cadmium
maximum
thickness,
should be
proper
only
permitted
(0.
area
be-
age to the nitrided surfaces of the crankshaft. The nitrided surfaces extend from
propeller flange
010 inch
u/s diameter).
NOTE
The grinding wheel, on the corner toward
the propeller flange must be dressed to
toward oil
fectly.
Do not
to touch the
5. A No.
finish of
54 or 60 grinding
approximately 8 to
wheel will
10 microns.
produce
The
sur-
face roughness of the oil seal area should not exceed 10 microns before polishingwith crocus cloth.
to extend
TABLE 7-1
Min. Width
Engine Model
of
Flange
290-D
0. 190 inch
0. 260 inch
290-D2
0. 260 inch
320
0. 260 inch
235
0. 260 inch
320
0. 370 inch
360
0. 370 inch
0-360
HO- 360
IO- 360
0. 370 inch
0. 370 inch
0-360
0. 370 inch
IO- 360
0. 370 inch
(Except O-540-G)
540-C
0-540 (Except
O-
IO-540-K, -M,
540-K, -M, -N, -R
O- 540- A
O-540-C
0- 720
7-8
_?
0. 260 inch
O- 320
540
-N and
-R)
0. 370 inch
0. 430 inch
0. 370 inch
0. 430 inch
0. 430 inch
0. 370 inch
0. 370 inch
January, 1971
kction 1
CroclLcor, Cranlrloi~
OVERHAUL MANUAL
aJ
the
flange
so
when the
embrittlement.
for the
No. ST-115.
by
magnetic
rorh
inch radius.
12. Examine
method.
Ilcipr#oti0
particle
0\
/O
O~L[O
Oa;o
oOd
OoQ
CYLINDER
I h
i II
N0.4
CYLINDER
Q~h
~O
X~
o o
January, 1971
7-9
OVERHAUL MANUAL
Section 7
Crankcase. Crankshaft.
and
Reciprocating Parts
DIAMETER
(MUST RUN TRUE WITH FRONT
TABLE 7-2
Hole Size
Reamer No.
.9369/.9377
.9420/.9425
.9445/.9450
.9470/.9475
.9495/.9500
.9520/.9525
None
64874
ST-210
WITHIN.OO3)
PERIPHERY OF CHAMPER
64875
ST-211
64876
\3~n"
lug
to proper
size.DISTANCE
puller to the crankshaft in the same mandescribed in Step 1 except that the large puller
bushing is used instead of small puller bushing. Place the
correct size crankshaft bushing on the puller bolt, bet-
4. Assemble the
ONLY
ner as
Figure
Straightening
Bent
Flange
CAUTION
The inside diameter of these bushings is finished at the factory and no further machining of the
bushing is necessary. Caution must be exercised when installing the bushings so that this
finished ID is not damaged. Because of possible damage to the crankshaft, never, under any
circumstances, remove or install the roller
bushings by use of a drift.
5. After the
Consult the
latest edition of Servie Instruction No. 1143 for information
relative to rebushing counterweights and subsequent
7-51.
inspection.
2. Use
I
I
ing procedure:
CAUTION
7-10
I
I
I
I
I
OVERMAUL MANUAL
Section 7
Crankcase. Crankshaft.
and Reciprocating Parts
steps. Do
size
1
I
I
I
the threads
are
by running
not
attempt
to
reuse a
crankshaft with
an over-
pilot diameter.
a.
After
machine
the
pilot
Also,
deep
.06R undercut
as
shown.
b. Chrome
CAUTION
Use extreme
care
tap.
c.
After
plating,
by baking
at
I
1
AFTER GRINDING
CHAMFER 450 x .03
MACHINE TO THIS
DIA. BEFORE
PLATING. PLATE
DIA. ONLY. GRIND
DIA. TO
AFTER PLATING.
.06R
o
o"
.09 MAX.:
reading.
CAUTION
The
PLATING
NOT PERMIT
TED IN THESE HOLES
I
I
quies repair other than specified in CAUTION following paragraph 7-53, the crankshaft should first he
measured~as shown in Figure 7-12G. If the crankshaft
measures more
reading
to
rear
main
e.
in
Chamfer
edge
Figure 7-121\.
of
pilot
diameter 45"
.03
as
shown
Figure 7-12A.
CAUTION
If the dowel must be removed, it is very important to do so without damaging the hole in the
crankshaft. A satisfactory method consists of
drilling a 1/8 in. dia. hole through the center of
V~U II
STD-1065 DOWEL IS
DRIVEN TO LOCATE
SHOULDER OF DOWEL
.010/.020 IN. BELOW
SURFACE.
the dowel; then fill the hole with oil and insert
a piece of 1/8 in. dia. drill rod in the hole. Strike
Hydraulic
hamo,
pilot diameter
of the counterbore
on
the
damage.
I
I
7-10A
OVERHAUL MANUAL
SECTION 7
DIRECT DRIVE
4.
oversize,
ream
required
as
for installation of
or
an
are
DOWEL
eziSSELOH
STD-2078 DOWEL IS
DRIVEN TO LOCATE
END OF DOWEL .160
IN. ABOVE COUNTERBORE
SURFACE OF CRANKSHAFT.
Code
Diameter of
Diameter of
Dowel
on
Dowel "A"
Dowel Hole
Part No.
Dowel
STD-1065
in Crankshaft
(Firr. 7-12D~
None
.3095/.3100
.3085/.3095
STD-1065-P02
P02
.3115/.3120
.3105/.3115
STD-1065-P05
P05
.3145/.3150
.3135/.3145
STD-1065-P10
P10
.3195/.3200
.3185/.3195
STD-1065-P15
P15
.3245/.3250
.3235/.3245
None
.3760/.3765
.3750/.3760
STD-2078-P02
P02
.3780/.3785
.3770/.3780
STD-2078-P05
P05
.3810/.3815
.3800/.3810
STD-2078-P10
P10
.3860/.3865
.3850/.3860
STD-2078-P15
P15
.3910/.3915
.3900/.3910
STD-2078
CAUTION
i.2505
.........II............/
"A"
DIA.
to
being reassembled
gear
STD-1065 DOWEL
that
has
configuration
counterbore
on
been
the
crankshaft,
or a new
manufactured
to
this
modifying
pilot flange.
.so
.3765
and
. . . . . . .r. . . . . . . . .
11
pilot flange
reused. The
DIA.
original
2.1250/2.1255 dimension of
flash
"A"
..........r.........
I
STD-2078 DOWEL
Figure
7-10B
New
Crankshaft
I Superseded
Crankshaft
Gear
Gear
Lockplate
Bolt
Dowel
Part No.
Part No.
Part No.
Part No.
Part No.
13819646
13919647
61155
LW-18639
STD-2213
STD-1065
67514
LW-18638
STD-2209
(5/16
13819648
76786
LW-18638
STD-2209
dia.
13819649
LW-10284
LW-10332
ANS-14A
STD-2078
(3/8 in.
in.
dia.
OVERHAUL MANUAL
Section
Crankcase, Crankshaft,
and
Reciprocating Parts
Ring Gear. The latest edition of Service Instruction No. 1141 contains all the information necessary to
accomplish the replacement of the starter ring gear.
7-54. Starter
CAUTION
tion to be
7-55. Crankcase
performed
on
the
Sup-
DOWEL HOLE
600
~Q:
Q-
7
.78
EDGES OF GROUND
SURFACES WITH A
HAND STONE.
.758 3 PLACES
EOUALLY SPACED
50
WITHIN
.06 R
"aT
t
1~
.78
Lb717i7~
P/N 13819649
.94
L
P/N 13319648
.06
.,gR
Rj
tC
1.31
.94
.02
P/N 13819646
1
rIt_Ilf
.56-
P/N 13819647
Configuration
7-10C
OVERHAUL MANUAL
8eotlon 7
Crankceae, Crenkshaft,
and
Reciprocating Parts
5M6" Bolt
Head Must Be
Identified As
Shown.
NOTE
Attaching
Bolt:
Do Not Reuse
Q
Note: In Some Engines A Tang
Will Be Found Instead Of A Slot
At This Location. It Should Be
Lockplete:
Do Not Reuse
AssembleWith Threads
Clean And Dry Of Al\
Foreign Substances,
ToAdding Lubricant.
CI
Prior
Gear:
Crankshaft:
Threads By
Check Condition Of
In At-
Screwing
taching
bore-During Assembly
(Sae Textl.
13.962 INCHES
6 CYLINDER
21.094 INCHES
8 CYLINDER
28.226 INCHES
-I-
THRUST
FACE
SURFACE
MINIMUM DIMENSION
CAUTION
pilot.
GVERHAUL MANUAL
kctiol I
Cronkcau, Cronllhoft,
and
6. Assemble
finish
ream
to the
preceding
proceed to
again paying attention
84907).
a
3/4 inch counterbore (P/N 64904) and
standard tap handle to resize the oil seal counterbore hole. Exercise caution so as not to go deeper
than the present depth. See figure 7-10.
8. Use
WHEELR~R.so R.RbMOS
vrEEL FOR .IS R. RIWVS
-I
_,--11------~
10. Assemble
P07)
MCEED
new
body
fit thru-studs
lief
valve).
and
-C Series
0-540 Series
1. With the crankcase
1.
Apply
threads of
Surface
assembled
directed in
remove the
as
figure
liberal
a
cyl-
coating
standard
cutting edge
of
(P/N 64905)
reamer
(P/N
64902).
4. Assemble the universal
inch electric drill
(P/N 64908)
motor, the
to
or
oil
re-
otherwise
heavy grease
to the
hand
tap.
CAUTION
Do not rotate
because the
5. 75 inches above
special piloted
scored
1/2-20 bottoming
the
of
The
inch
7-11.
badly
replace the
72698-
9/16
(Non-adjustable
If the sleeve is
damaged, remove
ing manner.
0-360-S
(P/N
crankcase.
same
0-320-B Series
0- 340 Series
Parl~
Rlciproco~lng
to universal and
--\\r
reamer
COUNTERWEIGHT
ROLLER BUSHING
beyond
the sleeve.
COUNTERWEIGHT EAR
ON CRANKSHAFT
1/2
to the universaland proceed to ream 0. 547 inch through thrustud holes from the even cylinder number side.
Continue reaming until the reamer reaches the
collar. Make sure the drilland reamerhas stopped
reamer
_I
-r
I
III
O
_L
_7CAUTION
A liberal amount of kerosene must be
con-
January, 1971
OVERHAUL MANUAL
Section 7
Crankcastl, Crankehaft,
and Reclpmcs~ing Parts
2. Draw the
a
~d
LEVER
particular
new
foreign matter,
or
HYDRAULIC ~LVE
C(WER
~L at sEnL
Ilrr
remove
Figure
crankshaft (see figure 7-17) with the convex side toward the
front, Be sure the plug fits firmly against the shoulder provided for it on the inside diameter of the crankshaft.
7-63.
peller,
(adjustable). The
latest edi-
lion of Service Instruction No. 1172 contains the information relative to replacing the non-a(ljustable oil pressure relief
valves assembly with the adjustable oil
assembly if required.
7-58. Crcmkcase Fretting. Consult the latest edition of Service Instruction No. 1112 for information relative to inspection and repair of crankcases damaged by fretting.
plug is installed
NOTE
Some crankshaft employ a 1-1/4 inch plug. This
size plug cannot be replaced in the field. The
crankshaft must be returned to Textron ~Lycoming for repair.
7-59. Crankcase Fretting. The latest edition of Service Instruction No. 1123 contains all the requirements necessary
to modify the crankcase to prevent fretting.
7-60. Crankshaft Idler Gear Shaft Recess. Damaged or worn
idler gear shaft recesses in the crankcase can be repaired
as described in Service Instruction No. 1197
REASSEMBLY
7-61. C~nkshaft Sludge Tube Assembly CWhere applicable),
the crankshaft in a nearly vertical position and install new sludge tubes. Place a new sludge tube on the applicable drift, P/N 64547 for six and eight cylinder engines
and P/N 64548 for four cylinder engines, and drive sludge
tube to its correct depth. See figure 7-17 for four cylinder
CAUTION
7-15.
bushings.
Support
and
NOTE
tap lightly around the pilot flange of the gear and listen
for sharp solid sounds from the hammer blows that
would indicate that the gear is seated against the
crankshaft. As
check
on
sur-
OVERHAUL MANUAL
Section 7
Crankcase, Crankshaft,
and Reciprocating Parts
7-66.
Counterweight Assembly. When assembling
counterweights which have previously been installed on the
engine, use the identifying marks, made on the various parts
during disassembly, to enable matching each washer with the
proper seat on the counterweight from which it was removed.
Install washer (10) and retaining ring (11) on one side of the
counterweight (8), place the counterweight on its proper ear
on the crankshaft, insert the roller (9) and secure the assembly
by installing the washer and retaining ring on the second
7-12 A/B
Section 7
Crankca,e,
and
TO
Reciprocating
Part~
TO
ASSEMBLE DOWELED CRANKCASES
CRANI(CASE
SEPARATED.
Installation of Bolts
on
Thru-Studs
WnSHER,PINO
STUDS
BOLT
NUT
PLATE
BOLT
MIT
WASHER
PLATE
Step
2.
Step 2. Right
Side of Crankcase
Showing
Installation of Plate
January,
1971
Showing
Step 3. Left
Side of Crankcase
of Doweled Crankcases
Section 7
Clronkcose,
and
Reciproco~ing
Ports
-C( ~tllA"
-----e
OPERATION ONLY
MODE L
0-235,
DIMENSION "A"
DIMENSION "B"
0. 20 inch
0-290
0. 20 inch
0-320, 0-340
0. 20 inch
0. 20 inch
0-360
0. 25 inch
0. 31 inch
to Drive
are
in-
Sludge
Tubes
and the
order
stamped
edge
properly.
Make
of the
ring.
counterweight
on
the crank-
the
7-67.
rods
are
marked
at
7-69. There
7-71.
7-68.
tion of
so
that all
on
suitable
are
support
and
recess of the camshaft gear. Assemble the breather slinger (19) and secure assembly to the camshaft gear with lockplate (20)
and hex head screw (21).
7- 72.
(a)
screw.
and O- 290
on
(2)
crankpins
(b) (0-235, 0-290) The tachometer shaft is installed in the accessory housing. Assemble the
tachometer drive pin (15) in the camshaft. Assemble the camshaft gear (14) over the stepped
dowel (12) and secure to the camshaft with lock-
service rod
with
and 0-290
manu-
tS".
the bench
key (3),
Secue
classification.
are
placed by
(toward
letter
nut assemblies
NOTE
Connecting
assembly
on
sump).
ruff
of
ring.
Revised
January, 1971
Section 1
Crankco,e,
and
upward. Place
and
on
rear
Reciproco~ing
Parts
new
main
2.
ing
Insert the idler gear shaft (4) through the openin the housing. Note that a Woodruff key is used
in the shaft
employed on six and eight cylinder engines whereas the shaft used on applicable four cylinder engines is pinned to the housing.
NOTE
The front main
Use
rear
pencil
to
trace,
on
the assembled
4. Assemble gasket
bearing, both
parting
crankcase
7-75.
the
flanges and the bearing. Also make a vertical reference mark on both the bearing and the crankcase at
any convenient point along the line of intersection,
thus locating the bearing both radially and axially.
These marks are necessary to insure proper seating
of the bearing halves on the two locating dowels when
the crankshaft is placed in position in the crankcase.
Assemble
rear
1.
Insertthe
2. Place
lockplate (28)
7-78.
in the
flange.
Con-
Catalog.
on
suitable sup-
and bench.
accomplished
the
in
7- 74. Propeller Governor Drive (Located on left crankcase half). See figures 7-3 and 7-4. This drive asassembled. This is
over
7-77.
are
of the
the
suit Parts
sembly
plug.
NOTE
(5)
following
manner.
the
half
on
an
oil seal
a new
oil
(BEARING END~
January, 1971
to Drive
Sludge
Tubes
(Six
and
Section 7
Cronkcole, Clanklhaft,
and
Recipracating
Part~
WASHER
slinger,
sible to the
rear
of crankcase.
necessary to
far as pos-
as
c r anks haft
and
c rankc as e.
right
ASSEMBLE
CIRCLIP
WITH SYARP EDGEOF
Apply
7-84.
to the outside
No.
1125.
Counterweight
Lowerthe right half of the crankcase so that the
align properly with the left half. If necessary,
tapthe right half gently with a soft hammerto facilitate
assembly. However, no difficulty will be encountered
if the two halves are kept parallel while the right is
being lowered onto the left. After the cases are together, tap the right half with a soft hammer to seat
it securely all around.
7-85.
studs
NOTE
Oil seal
rings
dies that
dies
on
are
are
doweled
nor
at center
sad-
cylinder
are
fl-
not
NOTE
Crankcases that
NOTE
If
a new or
used,
7-80.
as
new
tappet
directed in
position
in the
are
can
only
be
7-86. Installall crankcase fastenings. Consult the applicable Parts Catalog for correct attaching parts.
7-87. In order to insure uniform loading on
bearings, it is necessaryto tighten the studs
in the following sequence.
the main
andbolts
so
that the three oil transfer holes will be upperplaced in the left crank-
\EDGE OF CIRCLIP
case
permitting the even numprotrude through their respective cylinder mounting pads. Using the reference marks made
previously, adjust the front main be aring so that the
halves are seated squarely on the locating dowels.
into the left crankcase half
bered rods to
7-82. See figure 7-24. If either the crankcase or crankshaft has been replaced, the crankshaft end clearance
must be checked. When crankshaft is located in the
left crankcase half, push the crankshaft forward as
far
as
LASSEMBLE CIRCLIPSWiT~iGnP
POSITIONED AS SHOWN
the front
and crankshaft
shoulder.
(Point "A").
7-16
c ranks
If clearance
Figure 7-20.
Location of
Section 7
Crankca,e,
and
alent)
at
(ST-222
or
equiv-
Reciprocating
Port~
cylinder pads.
2No
pounds.
NOTE
0-320
and
0-360
cylinder flange
wide
7)
(6)
(B)
crankcase.
6T-n
TIGHTEN CRB~KCASE
THRU
FASTENINGS
7-90.
Figure 7-22.
0-235
series
inch
inch
or
oclockposition
on
right hand
engine.
bearing (4,
6, figure 7-23)
NOTE
to 300
pounds.
Crankshaft: oil seal may have either a flat
surface OD and held in place by retaining
1/4
Tightening Sequence
at front main
at the 1:00
split located
pounds.
Crankcase
7-91. Torque
IN SE(IUENCE INDICATED
NOTE
thru-bolts and
(9
inch nuts at
crankcase
parting face
to
75
inch
crankcase.
pounds,
or a
raised
lip
on
changeable.
7-93. Torque 3/8 inch nut (10, figure 7-21; 13, figure
7-22 or 16, figure 7-23) at camshaft bearing to 300
inch
withNo. 20 Pliobond
pounds.
the seal
the
7-94.
remaining 1/4
pounds.
ing
at the
the seal
No.
or on
2ELo TIGHTEN
ON LEFT SIDE
(8
I. D. of
9)
match-
or a
raised
lip
on
crankcase.
changeable.
Control
7-97.
Hydro
where
applicable).
valve
See
should be
cover
Valve
valve
6)
(5)
(7
body,
valve
7-98. Generator
M
OTHRU~IN
SEQUENCE INDICATED
plicable)
cover
or
on
the valve
cover.
Install
(where
ap-
7-17
Sec~ion 7
Crankcase,
Reciproca~ing Pores
and
5TH
13
5
3Ro TIGHTEN ON
LEFT SIDE
10
11
6LH
over
etched
ring
on
correctly
on
to assure proper
the ring gear,
Crankshaft
(4 cylinder engines).
marks in
meter gear is marked at one place withthe etched circles ontwo adjacent teeth and at another place a single
tooth is marked. The
Idler Gears
Place the crankshaft idler gear
7-99.
places withtiming
at
one
place
larger
in two
places
with
on one
tooth
teeth of the
on
between gears.
(6 cylinder engines).
7-18
It will be
2-8
mark
making sure
larger
on
adjacent
idler gears.
(8 cylinder engines).
places
Sec~ionl
Crankco~e, Cronk~haft,
ond
Par~l
Reciprocoting
teeth. The camshaft is marked with smalletched circles on two adjacent teeth and the crankshaft gear is
marked at one location with one circle. The single
BI
oi~ I
I \/i
~h,
(LLI
the idler
shaft, meshing
on
on
the
the
are
teeth.
marked with
The
single
an
etched circle
on
a
two
adjacent
circle
on
the
smaller diameter idler gear surface must mesh between the two marked teeth on the magneto gear.
7-19
08
OVERHAUL
Sctlon 8
Oil Sump ond
Fwl Induction
SECTION 8.
OIL $UMP AND FUEL
8-1. General. To accomodate the number of engine
models, covered inthfs manual, a number of oilsump
configurations are employed. Basically all oil sumps
are similar and overhaul procedures will apply to all
mode~j unless specifically called out to the contrary.
8-2. Various carburetors and fuel injectors are emplayed on the engine models covered in this manual.
No attempt will be made to describe their overhaul.
Overhaulinformation for these trade accessories may
be obtained from their respective manufacturers,
played.
One method
DLSASSEMBLY
8-4. Intake
same
Engines
pipes matched in length and diameter.
Carburetor or FuelInjector. Remove the carburetor or fuel injector from either the air inlet housing or from the mounting pad on the sump. Remove
the air inlet housing oninstallations employing same.
Carburetor or fuel injector mounting pads may be incorporated on either the bottom, front or rear of the
8-5.
oil sump.
8-6. Oil Suction Screen. See figure 8-1
oilsuctior! screenhousing maybe found
the sump.
and oil suction
o~ locations
on
and remove
gasket
at any number
Unscrew the hex head plug
induction
3-8.
the sump.
inlet
lievised
May, 1972
pipe
extensions and
clamps
remove
that
secure
the intake
the extensions.
periphery
the
CLEAN~G
8-11.
Oil Sump
Clean the sump according to the
instructions contained in Section 3. Clean the
oil passages with solvent and a suitable brush and
blow out with compressed air. Do not clean the oil
suction screens until they have been inspected for
general
metal
particles.
accor-
(Simmonds).
8-15. InjectorNozzles
orifices
use a
probe
stream of
To cleannozzle
air. Do not
of any kind to clean nozzle orifices.
use a
dry compressed
8-18. InjectorNozzles
(Bendix). Remove the nozzle
and submerge itin cleaningsolvent (Stoddard Solvent,
Methyl Ethyl Ketone or equivalent). Remove nozzle
from solvent, and dry with clean, dry compressed air.
Under normal conditions, the shield and screen are
NOT removedfrom the nozzle assembly. However, if
either the shield or screen are removed from the noztie, both must be thoroughly cleaned prior to reassembly and the shield must have a tight.tit on body
when installed.
NOTE
screen.
8-7. Induction
8-3.
Atno time is
itpermissible
tool such
as a
to use
an
asharp
air bleed
nozzle.
INSPECTION
8-17. Inspect the sump according to the
structions contained in Section 3.
general
in-
OVERC1AUL
kc~on a
OilSump
ond
Fud Induction
3---gP
Be12
QI
Q)
5
9
PP
"O
i.
2.
3.
4.
5.
6.
Intake Pipe
Gasket
7.
8.
9.
10.
11.
12.
Flange Gasket
Flange
Oil Suction Screen
Gasket
Plug
Gasket
Throttle
Casket
Hose
Body
Elbow
Clamps
Hose
ting inspection,
8-20. Bendix
deformation,
inspection procedures
530 fuel injectors,
8-2
are
applicable
The
following
to Simmonds
8-22.
and
PumpAssembly Inspectmountingsurfaces
fastenings for security. Check for leakage, cracks or
other damage to pump housing. Check pump fittings
and lines connectedto pump for cracks or other damage. Check mixture controllever for damage andwea.r.
Inspect linkage connected to mixture control lever .lor
damage and/or
wear.
for
8-24. Nozzle
Assembg.
damage or leakage. Inspect installed nozzles for security of mounting. Make sure fuel lines are r,onnectRevised
May,
1913
OVERHAUL
Section 8
Oil
Sump
and
Fuel Induction
operation
matched set
and
or
a.
system are
stamped "A", "B"
"A"
280 to 284
it with
ing
NOTE
are
"C".
Fuel
chisel
new
connection
tighten the
sufficiently to
per minute at 9. 8
or
punch.
Installation.
are:
cc
on
swaging
tool
Place
(64781)
screw
provided. Begin to
tool, stopping every couple of turns to expand the rollers by tightening the screw one or two
fullturns. When the groove in t~e connection is fully
swaged in the groove in the sump, ehis willbe evidenced by the increased resistance of the screw) collapse the rollers and withdraw the swaging tool.
seated
on
rotate the
b.
"B"
276 to 280
cc
per minute at 9. 8
"C"
272 to 276
cc
per minute at 9. 8
Only
sary to
Service Bulletins
All
repair
and
297A, 306,
8-29. Fuel
Injectors
procedures
,~7
All
repair
replacement
conjunction with
and
~S--- 2
aa
Adapter
1. Intake Pipe
5.
2. Flange Gasket
3. Gasket
4. "0" Ring Seal
7. Gasket
8.
Plug
May, 1972
Parts
Group
8-3
OVERHAUL
Section 8
OilSump
end
Fuel Induction
~7
iCS3
i
12
15
"Y
12
I--\
he
13
~pp"
1
9.
10.
11.
12.
13.
14.
15.
16.
1. Annular Gaskets
Oil Sump Baffle
14 x.62
Plug, 7/8
2.
3.
4.
5.
6.
7.
8.
Hose
Clamps
Flange Gaskets
Intake Pipe Flanges
Intake Pipes
Hose
"0"
Ring
Gaskets
Pipe Connection
Oil Suction Screen
20 x.62
Plug 1. 00
Intake
proper
the manufacturers
publications.
Consult Avco
Ly-
torque.
bulletins.
REASSEMBLY
8-4
(10-540
applicable).
housing
Revised May,
1972
OVERHAUL
Sec~ion B
Sump ond
Fuel Induc~ion
1--h9
12
f
O
10
ii 1
43
11
5------0
4
7. Helicoil
1. Gaskets
2. Intake Pipe Flange
3. Intake Pipes
4. 1 Inch Plug
8. Induction Housing
9. OilSeal
5. Gasket
6. Oil Suction Screen
Induction
(8)
See
figure
to the bottom
Induction
System (10-720)
housing
the induction
of the sump.
to the induction
InductionHousing (IO-720-B). Assemble the inpipe extensions in the induction housing and secure with clamps and studs. Assemble the induction
8-33.
take
Revised
May, 1972
housing.
8-5
OVERHAUL
Sec~ion 8
OilSump
ond
Fud Indudion
bly
and throttle
body
same.
These units
are
injecnotinterchang-
eable.
cure
the
over
connection
are
in-
the
fuel
pounds).
8-36. Intake Pipes. See figure 8-3. Slide a flange
over each intake pipe (8). Assemble either hose
(7)
(4)
clamps (5) or "O" rings (9) over end of inpipe and install in sump or induction housing.
Place a new gasket (6) over the intake port and seand hose
take
8-6
to fuel
to
clamping
Revised
May, 1972
09
Section 3
Test Procedure
SECTION 9.
TEST
PROCEDURE
overhaul,
means
completion
of
Also,
Avco
repaired,
test cell
following
instruments should be
tachometer,
fuel flow
for
ment and
engine
test
engines after
more
test
detaillist of cell
able,
it is
permissible
to mount the
engine
providit~g
the
observed.
following requirements
club,
not
are
flight propeller,
is
used.
used, plus
any additional instruments that may be deemed necessary by the operator. 0" to 600"F. temperature gage,
counter
run-in of
equipment,
equipschematic of oil supply systetn
SSP1169,
recommends that
Consult
overhaul.
moved
9-3.
Lycomit~g
at this time
that
NOTE
it is recommended that
shroud is installed.
3. The airframe gages may not be used. All necessary calibrated gages shallbe installed indep-
THROTTLE OPEN
RICH
83"
\o
IDLE SPEED
ADJUSTMENT
IDLE MIXTURE
ADJUSTMENT
_1P~
TH?OTTLE
CLOSED
CUT OFF
IDLE SPEED
ADJUSTMENT
76"30
THROTTLE
OUTLET
.4375-20 UNFATHD
GLOSED-~72
FULL RICH
FUEL INLET
.5625-18 UNF 3ATHD
IDLE MIXTURE
ADJUSTMENT
THROTTLE OPEN
MA-4-5
RSA-5ADI
THROTTLE CLOSED -1
~70"
IDLE SPEED
ADJUSTMENT
FUEL INLET
.250-18 NPT
MIXTURE
ADJUSTMENT
K~
LFUEL
INLET
.250-18 NPT
FULL RICH
60"
~IDLE CUTOFF
PSH-SBD
9-1
CD
TABLE 9-1
ENGINE RUN-TN TEST LIM~S
Fuel Pressure
psi- atinlet
to carb.
Fuel-Minimum
Octane
or
Maximum Oil
Oil Press.
Consumption
Operating-
Temp.
Temp.
Max. Cyl.
HeadTemp.
Bayonet
Idle
"F.
"F.
Location "F.
RPM
psi
Rating
Xu,
OilIn
Oi10utlet*
FullThrottle
Engine Speed
injector
AviationGrade
-C2B.-E
2-5
80/87
0.9
.50
75-85
25
165-230
190-210
500
2800
O-235-F.-G.-J
O-235-C2C. -H2C
2-5
100/130
80/87
0.9
.50
75-85
25
165-230
190-210
500
2800
0. 9
.50
75-851 251165-2301
190-210
O-290-D
2-5
80/87
80/87
91/96
80/87
91/96
91/96
100/130
100/130
91/96
91/96
1.0
.56
75-85
25
165-230
190-210
500
1.2
.67
75-85
25
165-230
190-210
500
2600
2700
i. 2
.67
75-85
25
165-230
190-210
500
2 700
1.2
.67
75-85
25
165-230
190-210
500
1.2
1.2
.67
75-85
25
165-230
190-210
500
.67
75-85
25
165-230
190-210
500
500
2-5
91/96
13-18
2-5
91/96
80/87
14-45
100/130
18-28
91/96
IO-360-B1A
-2-+2
Lbs.
Hr.
Qt.
Normal
Hr.
o-235-cl,-cl~,-czn
2-5
D2
O-320-A.-E
O- 32 O-B,-~
2-5
2-5
IO-320-A.-E
IO-320-B,-D
18-28
18-28
LIO-320-B
18-28
IO-320-C
18-28
_
LIO-320-C
18-28
AIO-320-A,-B,-C
18-28
0-340-A
2-5
1.2
.67
75-85
25
165-230
1.2
1.2
1.3
.67
75-85
25
165-230
.67
75-85
25
165-230
72
75-85
25
165-230
190-210
190-210
190-210
190-210
i. 4
1.4
.78
75-85
25
165-230
78
75-85
25
165-230
1.4
78
75-85
25
.83
75-85
.78
.78
.78
500
2600
C
2700
2700
2700
500
2700
2700
500
2700
500
2700
190-210
500
2700
190-210
500
2700
165-230
190-210
500
25
165-230
190-210
75-85
25
165-230
190-210
500
2700
75-85
25
165-230
190-210
500
2700
75-85
25
165-230
190-210
500
2700
9
r
O-360-A,-C(except-AlC,
-C2B and -C2D
0-360-A1C,-C2B, -C2D
O-360-B.-D
IO-360-
-C.-D
IO-360-F
18-28
AIO-360
14-45
LIO-360-C
14-45
91/96
100/130
100/130
100/130
HO- 360-A
2-5
91/96
1.5
i. 4
1.4
1.4
1.5
i. 5
1.4
HO-360-B
13-15
91/96
14-45
100/130
91/96
11i0-360-
-C
HIO-360-B
14-45
KIO-360-D1A
i
1
TIG-360-A
14-45
23-27
0
o
25
165-230
190-210
500
2700
25
165-230
190-210
500
2700
.78
75-85
25
165-230
190-210
500
2700
i. 4
.78
75-85
25
165-230
190-210
500
2700
i. 5
.83
75-85
25
165-230
190-210
475
2900
1.5
1.5
.83
75-85125
165-230
190-210
500
2900
.83
75-85
25
165-230
190-210
475
3200**
i. 5
1.8
.83
70-80
25
2575
75-85
25
190-210
190-210
475
1.0
165-230
165-230
500
2575
1.0
75-85
25
165-230
190-210
500
2575
75-85
25
165-230
190-210
500
2700
251
165-230
190-210
475
2575
75-85
25
165-230
190-210
500
2575
75-85
25
165-2301
2700
25
165-230
190-210
190-210
500
75-85
475
2700
87
1.8
2-5.5
91/96
1.4
IO-540-A,-B,EE,G,-P
7~L-18-28
18-28
-R
18-28
18-28
TIO
37-39
18-28
LTIO-540-A
TIG, LTIO-540-C,-E
37-39
TIO
LTIO-540-J,-N,_F
37-39
TIG.
LTIO-540-H
IOt
37-39
-D
during
24-28
oil
consumption
pressure.
IP
75-85
2-5.5
O-540-E,-G,-H
91/96
91/96
100/130
100/130
100/130
100/130
100/130
100/130
2700
75-85
2-5. 5
1.8
1. 4
.78
i. 6
.78
1
Z
G)
a
a
A
a
1. 8
1. 6
1.8
75-85
25
165-230
190-210
475
2575
i. 8
1.0
i. 6
r
G)
75-85
25
165-230
190-210
475
2575
1.8
1.0
75-75
25
165-230
190-210
500
2575
1.8
1. 6
75-85
25
165-230
190-210
475
2575
i. 8
1.0
75-85
25
165-230
190-210
500
2575
3. 9
1. 7
75-85
25
165-230
190-210
475
2650
run.
2700
.83
O-540-B
IO-540-D, -N,
100/130
100/130
91/96
500
.83
O-540-A.-D
IO-540-C. -J
(D
For oil
Hg.
manifold
V,
can
run
dry
tering capability
turbocharger
fil-
set to 15
no
lubrication
system.
9-7.
ner.
into the fuel inlet connection until fuel flows from the
fuel outlet. Close the throttle and move the mixture
control to "idle cut-off".
sembly
of engine is
with the
same
forcing 35 psi oil thru one main gallery until oil flows
from the opposite gallery with the front end of the gal-
lery
open.
throttle and to
the oil
temperatures
some
method of
maintaining
specified
limits dur-
within the
until oil
9-9.
Be
move
sure
the cables
applicable cooling
shroud, test cluband adapter. SeeSection 11. Be cer-
rt
50. See
Table 9-1.
"off"
are
no
freely,
interference eldsts
or
cause
specifications.
See Table
9- 1.
following procedure.
9- 11.
with
as-
9- 8. It is desirable to have
Section O
Teec Procedure
all).
equipped with
a
remote
or
Injector
position.
installed
carburetor orSimmonds
at least
type
a(2).
Float
d(l).
representative
fuel pump.
Set throttle at
Turn
starter.
TABLE 9-2
RECOMMENDED RUN-IN SCHEDULE
LOAD
RPM
1200
1500
1800
2000
2200
2400
Normal Rated*
Normal Rated*
Prop.
Prop.
Prop.
Prop.
Prop.
Prop.
Prop.
Prop.
TIME
(MINUTES)
RE MARKS
Load
10
Load
10
Load
10
Check
Load
Load
10
10
Load
10
Load
15
Load
60
magneto drop-off.
magneto or 35
magnetos.
Oil
on
either
RPM between
Consumption
Run.
1972
9-3
Sec~ion 3
Tett Procedure
9-23.
MIXTURE~GTMEM7
can
Non-adjustable
though
be controlled
under the
cap
as
Al-
adjustable,
by
required (maximum
of
three)
to in-
uses
SPEED
io
closeo
Adjustable Oil
Relief Valve
The
adjustable
oil
pressure relief valve enables the operator to maintain engine oil pressure within the specified limits (see
,830
Table
9-1).
d(2).
Turn combination
to decrease
HA-6
magneto-starter
switch to
"start".
e(l).
mixture control
When engine fires,
move
to "Full Rich" on pressure carburetor or
Bendix fuel injectors.
smoothly
e(2).
Leave float
injectors
type
in "full rich".
Move
f(2).
to "both".
CAUTION
If oil pressure is not indicated within ten
seconds, stop engine anddetermine cause.
9-19. Operate engine at approximately 1000 RPM untila minimum oilin temperature of 140" F. is obtained.
Check magneto drop-off and general operation of the
or
to "both".
tion
justment. Close the throttle, engine should idle at approximately 600 RPM (turbocharged engines, appro~mately 1000 RPM). If the RPM increases appreciably
after a change in the idle mixture adjustment during
the
f(l).
magneto swit~h
continuing
run.
9-26.
than 50 RPM while "leaning out" indicates an excessively rich mixture. An immediate decrease in RPM
(if
not
preceded by
momentary increase)
indicates
Check this
9-20.
Complete the
run
Table 9- 1.
closed.
can
All three
ment
ly.
clockwise until
screw
an
brief
Subject enadjustable or a
description, of
2. Idle Air
is not obtained
follows.
Revised
January, 1970
Sec~ion 9
TeP~ Procedure
Idleoir
distributor
bleed
toclean
Fuel filler
Throttle slop
screw
idle cut-off
position
an
adjustment
bleed
counter-clockwise,
screw
if
adjustment
until
more
clockwise.
screw
check results in
than 10
RPM).
Make
adjustments
(never
pick-up
time an adjustment is
of five
Each
by the
as
9-30.
Upon completion
of the
Refill the engine with a 1 to 1 mixture of MILType 1, and Bayol "D" or equivalent.
9-31.
vative oil.
9-32.
steps proceed
9-33.
adjustment,
factory
Spraythe exhaustportandvalve
Spray
or
each
cylinder
of
turn at
as
determined in
of
turn
ounces
with
an
more
b.
counter-clockwise.
check
than 10
adjustment
nut
airless
clockwise
1/6
of
available,
ture trap
turn.
9- 35.
resistant
turn
mixture is
AN4062-11.
idle
(2)
be
Repeat 1/6
until proper
two
200"F. to 220"F.
locknut
a
with MIL-
cylinder.
conventionalspray
lean, unloosen
Spray approximately
In the event
adjustments
the
spray gun
model 24A-8395
NOTE
RPM).
adjustment nut
1/6
and turn
i.
cylinder
and checkmixture.
until
Type
turn
step 2,
oil,
of each
9-34.
time.
a.
equivalent) through
C-6529
pre- set and normally not requiring adjustment. If, however, adjustmentis necessary
L-6529,
Remove top
full of
is
Linkage.
CAUTION
speed
first two
follows.
This is
idle
If proper idle
cannot be obtained
proper
than
more
until
obtained.
An increase of
10 RPM indicates
required direction
with
obtained.
If the
Revised January,
1971
sears
are
section O
Telt Procedure
cylinder
TABLE 9-3
location and
LOAD
1200
9- 38. Exhaust
with suitable
The
should be closed
turbine outlet
on
turbo-
be covered.
9-40.
sur-
cor-
Although
the
corrosion under
mended that the
above
favorable
it
is
recom-
be
lowing
9-6
TIME
2400
Prop. Load
Prop. Load
Prop. Load
Normal Rated
1800
(MINUTES)
5
5
5
15
position.
9-43.
Pressure
Carburetors
and
Fuel
Injectors
emptied of all
residual fuel and flushed with oil, MIL-O-6081, Grade
1010. Injectors will have approximately one (1) ounce
poured into inlet under gravity head. The injector will
be rockedto cover all interior surfaces. Injectorswith
fluoro- silicone diaphragms and seals (no cure date) do
not require flushing. Carburetors shall have the oil
supplied to the inlet port at a pressure of from 5 to 8
psi. Mixture controls shall be at full rich during the
flushing operation. Under no circumstances shall the
regulator air chambers, air passages, or automatic
mixture control be flushedwith oil; these must be kept
dry at alltimes. Drain excess oil and install plugs or
caps. Lock the throttle in the closed position.
Carburetors and fuel
injectors
shall be
Revised
January, 1971
10
~ZIAVCO
BERVICE
LYCOMING
TABLE
OF
LIMITS
ANP
VALUE
TOROUE
NOTICE
The basic Table of
Limits, SSP2070 (including SSP2070-1, SSP2070-2, SSP2070-3 and SSP2070-3A) has been completely
as SSP1776. It is now made up of the following four parts, each part contains five sections.
PART I
PART n
PART III:
GEARED ENGINES
PART IV
VERTICAL ENGINES
(Including
(Excluding
VO and
VO and
IVO360)
IVO-360)
SECTION I
500 SERIES
CRANKCASE, CRANKSHAFT
SECTION 1I
800 SERIES
CYLINDERS
SECTION III
700 SERIES
GEAR TRAIN
SECTION IV
800 SERIES
BACKLASH
SECTION V
900 SERIES
CAMSHAFT
(GEAR TRAIN)
TORQUE AND SPRINGS
This publication supersedes and replaces the previous publications SSP2070, SSP2070-1, SSP2070-2, SSP2070-3 and
SSP2070-3A; it is not to be used in conjunction with them. To make sure that SSP1776 will receive the attention of
maintenance personnel, a complete set of pages for the book is sent to all registered owners of Overhaul Manuals. These
recipients should remove all previous Table of Limits material from the Overhaul Manual and discard.
Additional
copies
Limits, bound
in
plastic
cover,
are
available
as
Reference numbers in the Table of Limits vary from previous Table of Limits therefore, the current
are listed. The shaded columns contain the old reference numbers.
~6
well
as
the old
numbers
SSP1776
Indicates cut-off date for data retrieved
Apri130,1919*
prior
to
publication.
INTRODUCTION
SERVICE TABLE OF LIMITS
This Table or Ilmi$ Is provided to serve as a guide to all service and maintenance personnel engaged in the repair and
overhaul of Avco Lycoming Aircrait Engines. Much of the material herein contained is subject to revision; thereiore, if any
doubt exists rearding a specific limit or the incorporation of limits shown, an inquiry should be addressed to the Avco
The numbers In the first column headed "Ref." are shown as a reierence number
to locate the area described in the "Nomenclature" column. This number will be
found in a diagram at the end of each section indicating a typical section where
(Ist column)
the Limit is
Indicates the old reference number. There are no diagrams in this manual for
these numbers. These numbers are only to be found in previous publications.
Chart
applicable.
The letter or letter and number in this column are used m symbols to designate
models to which the specific limits is applicable. A list of the letter or
letter and number and the engine to which they reler is shown below.
(3rd column)
engine
Nomenclature
Dimensions
(=learance
(4th column)
615
(501
(?th
8tb
columns)
columns)
adjacent columns
The dimensions shown in column 5 are the minimum and maximum dimensions
for the part as manufactured. The dimensions shown in column 6 indicate the
limit that must not be exceeded. Unless it can be restored to serviceable size, any
part that exceeds this dimension must not be rebuilt into an engine.
Like thi! dimensions shown in the 501 and 601 columns, the clearance represents
the fit between the two mating surfaces as controlled during manufacture and as
a limit for permissible wear. Clearances may sometimes be found to disagree
with limits for mating parts; for example, maximum diameter of cylinder minus
minimum diameter of piston exceeds limit for piston and barrel clearance. In
specified
In some instances, where a parts revision has caused a dimensional or tolerance change, the
been deleted from the list; provided compliance with the change is not mandatory.
superseded dimenional
date has
alphabet and numbers are used as symbols throughout the Table of Limits to represent specific
to desig~ate engine models. ~etters in parenthesis refer to dimensional characteristics; letters (or
combinations of letters and numbers) without parenthesis indicate engine models. They are listed below with their separate
Z~tters of the
interpretations and
definitions.
(A)
adjusted,
(B)
are
or
Side clearance
on
piston rings
piston.
measured at the bottom of the
(D)
(11)
(L)
(T)
(WD)
or
are
(rod
and main
piston
shirt at
bearing journals)
to be minus
interference fit.
light
mating
Introduction
typical of the referenced limit or fit described in the Table and in no instance are these
illustrations intended to represent a specific part or engine model unless specified. Also, the terms used to designate cylinder,
piston and ring materials such as "nitride, chrome, half-wedge" are more fully explained in the latest edition of Service
The illustrations shown
am
PART I
(Including
0-235
55
Al
0235F, G, K,
56
0-290
IVO-360)
CHART
MODELS
CHART
VO and
-L
MODELS
IO, LIO-360-A,
IO, LIO-360-A,
(Angle Valve)
(IO, LIO-360-C1E6
IO-36O-A1D6)
0290-D2
57
HIO-360-D
0-435-A
58
KIO360-B
ED
0-320-H
59
HIO-360-C, -E
S1O
HIO-360A
B1
G
G1
(76 Series)
O, IO, LIO, AEIO-320
O, 10-920 With Gov. at Front
(0320E1F, -E1J, -D1F IO-320-D1B)
G2
AIO-320
0-340
VO, IVO360
O, IO, LIO, HIO, LHIO, TO, TIG,
T1
T2
AEIO-360
T3
(Angle Valve)
IO-540-K, aiI, -S; TIG, LTIO-540-A,
F, J, N, -R (Large Mains Angle
S1
TO-360
52
AIO-36O
53
TIG-360
T4
Valve)
TIO-540-C, E, G,
54
AF
10-720
(0360-A1H, -A1LD)
BE
NOTE: In "Chart"
column,
number
appearing after
letter shows
exception
IIRV ICE
TABLE
OP
LIMITO
Rti.
Rsf.
Chut
Nnmenckture
Dfmcmdon~
Mfr.
New
Old
Min.
a
Mx.
Cbuenes
I Mh.
ae3v.
I
I
i:i:i:i:i:i:i:l BDG-J-S-T-Y-BD-BE-AF
BGJ-S-T-Y-AF
I:lilili:~i:Il B-D-G-J-ST-YBD-BE
88-810
.0015L
.0060L
Main
.0011L
~W14 IL
(E)
2.3745
Main)
(E)
2.6245
ZFZF
(E)
2.6245
3.62155
(E)
Crankct~e
2.566
meter
G**J-ST-Y
(E)
Bearing Journal
500 I:iSti~:i:l A-B-B1-D-C*-BD-BE
.0050L
2.3735
.00soL
Main
(2-3/8
T1-T3-AF
Wu.
.0025L
~5G
aerv.
I
I Mu.
500
I Min.
Mx.
2.567
2.5685
meter
Wall
T1-T3-AF
meter
Bearing) (25/8
T1-T3-AF
in.
2.6890
2.816
1 -2~.817
Main)
2.8185
meters
S1-TAF
2.9375
2.9390
2,816
ing) (2-5/8
2.817
2.8185
2.566
2.567
2.5685
meter
G**J-ST-Y
2.9365
in.
Main)
Bearing) (2-3/8
in.
Wall
Main)
~9bitl
ALL
A-BD-G-JS-T-Y-BD
.0050L
in.)
SSP1776
2.1235
(E)
11
gPRIRV ICI
TAILB
OC
LIMIT8
Rel.
Rei.
Chut
CRANKCASE, CRANKSHAFT,
I
CAMSHAFT
Nnmeneklure
Dlmendone
Mfr.
New
Old
Cburncsl
Min.
I Ht~.
Bsrv.
M.
Mx.
501
ST-AF
AB-D-GJS-T-Y-BD-BE
2.2485
in.)
2.250
Min.
gerv.
Mu.
Mx.
(E)
Connecting
Rod Bearing
Bore Diameter (2-1/8 in.)
(Measured At Axis 300 on
2.2870
Each Side)
ST-AF
tSB~iil
Connecting
Rod Bearing
Bore Diameter (2-1/4 in.)
(Measured At Axis 300 on
Each Side)
ALL
Connecting
Rod
2.4205
2.4210
Side Clearance
.004L
.016L
503
ALL
Connecting
Rod
Alignment
.010 in 10 Inches
504
ALL
Connecting
Rod
Twist
.012 in 10 Inches
505
Ili:5ff~ril
I
4 CYLINDER
6 CYLINDER
8 CYLINDER
.002
.002
.005
.0075
.003
.0045
1 .002
.002
.005
.0075
.003
.0045
.003
.0045
.002
.002
.003
.0045
.003
.0045
.003
.0045
.005
.0075
ALL
End
"/~g3BI:l
ALL
.026L
ThrustCrankcaseFacl!Crankshaft Against
~2
(A)
OF
IILPRV ICE
Lll\nlTs
Ref.
Ref.
Chart
CRANKSHAFT, CAMSHAFT
Dimenaiona
Nomancktun
Clcarancel
Mtr.
Ne~m
Old
Min.
Sarv.
Min.
serv.
Max.
Max.
MPI
Max.
508
I:t~ S!: : : :
509
ALL
ALL
Crankshaft
Run-Out
Starter
Prop. Flange
.002
Gear and Support
Ring
i
AB-D-G-J-ST-Y-AF
ED-BE
511
AB-D-G-J-S-T-Y-AF
Crankshaft
Crankshaft
Timing Gear
Tappet Body
and
.005
.014T
.U22T
(A)
.0005T
.0010L
(A)
and Crankcase
.004L
BDBE
.0010L
~030L
A-B
O.D. of
.004L
Tappet
.6229
B1-D-G-J-S-T-Y-AF
iIi
O.D. of Tappet
.7169
.7r77
ED-BE
A-B
B1-D-G-J-ST-Y-AF
ED-BE
O.D. of
.8740
Tappet
.8745
.8737
.6250
.6263
.6266
.7187
.7200
.7203
LD.
Tappet
.8755
Bore in
.8773
512
Iliisg~
B1-D-G-J-ST-Y
513
:j~60:I
::.:::i:I:i
B1D-GJ-ST-Y
S7-S1-AF
514
_::.~1
~LL
.87 76
.0010L
S7-S1-AF
.7166
Body
.0067L
Chilled
.0010L
.002L
I005L
Tappet Socket
(Hyperbolic)
and
.0087L
.002L
Body
~wa
.002L
ALL
.002L
Illlliiliil
1009L
Camshaft Run-Out at Center
Bearing Journal
~LLA
illlllllll!
Al Models
Using
Counterweights
517
All Models
Using
Counterweights
Counterweight
.006
and001
Roller
End
.007L
IU25L
Counterweight
I.D. of
.038L
.003 L
and Crankshaft
Side Clearance*
~m3IJ
.017L
.0002L
O.D.
(A)
Counterweight
.7485
.7512
Bushing
SSP1776
.000
~TT
Clearance
~j 17~5:
.015L
(A)
Counterweight
All Models
521
CounteMreight Bushing
Using
i: .aa~ll
liilliliilil Counterweigh$
520
.009L
.006L
515
516
.007L
1-3
IRV)CP
TAILI
OC
L(~IITI
Ref.
Chut
Ref.
Nonunckturce
Dhneluiona
Hit.
New
Old
Hex.
624
525
San.
MLo.
MI.
Mu.
aetv.
I
Mu.
ALL
""I
IMin.
(AS APPLICABLE)
I;:
1. : : :D
Thrust
Shaft
]iiiljifil~i
Thrust
003T
Bearing
(A)
.027 Tilt
Tilt
ti~
526
5g6i:~ D
5211:: j _j_j
Crankshaft Run-Out
Incation
Rear Cone
Crankshaft Run-Out
Location
Front Cone
.003
528
Beuingl
f~f
.0045L
_itf
a
O
C)
=I=
c>
r\
o
O
\O
CZ
THRUST FACE
507
(CRANKSHAFT AGAINST
THRUST FACE)
.007
1-4
5)(
e,ERV ICE
TABLE
OF
LIMIT8
511
51
bi
J1
1-!.13
fj:;
--C 522
524
8nI
~rcS
527
526
525-/
\o
0-435-A
1-5
515
IIIRV ICE
OF
IAILE
LINIITIB
Raf.
Ncn
Rai.
Cbut
Dimsndon
Nomsnckturs
Old
Min.
San.
Mx.
Max.
soo
ALL
Connecting
Rod
Rod and
of
Rod
601
Connecting
Bushing
Clauanaaa
Mtr.
Min.
San.
Mu.
Mu.
BushineTo Be
BurnisLd in Place
Connecting
Bushing
S-T-Y-AFBE
RotrBearing
iiiiiiiiiii
Centers
and
.0025L
Piston
603
ALL
.0018L
ALL
ALL
jlliljiiii
604
i8f3::I:I
~ -DB-FAT-SJG-A
AGJS-T-AFBD-
Plug
.002L
fjijjijljil BE
605
B-D-GJ-S-T-Y-AF
.005L
Plug (Optional)
G-J-ST-Y-AF
B-D
Piug
Plug
B-D
.000
.004L
.0025L
(Chrome)
G-JST-Y-AF-BDBE
Wedge
Piston
A-B-DGJ-S-T-Y-AFED-BE
SSP1776
LA
Ring
and Piston
(Chrome)
Full
Wedge
Wedge
.0025L
IRSVSt
.008L(B)
.0025L
~D65L
.008L(B)
.000
.004L
.006L(B)
.000
.004 L
.006L(B)
Side
Clearance
Half
606
.008L(B)
Wedge
606
Full
.006L(B)
Side
.006L(B)
1-6
8 ERV I O E
OF
TABLE
LIIIlIITE
Ref.
Caut
Nomenclature
Dfmsndolu
Cleclr~ncs
Mf~.
Old
NetR
Min.
Ckav.
Min.
Berv.
Man.
Mu.
Ml.
606
notRing
siP)mot oB(
607;i:il ALL
and Piston
Man.
Side
.Clearance
.003L
.0055L
.020
.047
(Straight Barrels)
ALL
.045
.067
(Choke Barrels)
ALL
Piston
.015
~7556
(All Barrels)
piston
Ring
Engine
and Piston
Ring gap
is measured at
top limit
of
ring
.047
.015
~3b
Application
.007L(B)
Ring gap
at
top of travel
.047
must not be
travel.
Cylinder
Barrel
Max.
Clearance
ine
Letter
Piston Number
61147, 73851
608 :;422:
609 52tl:
610
ii
i3la
13
LW11621.L
lrs
69841,69958,70396
69958
73196. 74059. 75413
69337
G,S,T
J,S,Y,T
71594,72967,74530c,
ED
750891
LW-15357"
S,T,AF
LW- 13396+
Type of
Maximum
Surface
Diameter
Top
Bottom
Type of Piston
4.3470
4.3555
Cast-Round
4.3470
4.3555
4.3290
4.8290
4.8290
5.0790
5.0790
4.3605
4.8620
4.8620
5.1090
5.1090
CastCam
Cast-Cam
Cast-Cam
Cast-Cam
F
P-C
P
P-C-N
P-C
5.0790
5.0790
5.1090
5.1090
Cast-Gem
Cast-Cam
5.0790
790
5.1090
5.1090
Cast-Cam
Round
PistonSkirt
Cyl.
4.3795
4.3195
4.3805
4.8805
4.8805
.021L
.021L
.018L
.018L
.018L
5.1305
.018L
5.1305
.018L
P-C-N
N
5.1305
5.1305
.018L
.018L
N-C
N
5.1305
5.1
.018L
.018L
NOTES:
To find the average diameter of cylinder in an area 4" above
bottom of barrel: First, measure diameter at right angles
from plane in which valves are located. Second, measure
diameter through the plane in which valves are located. Add
I:i:.:i:i:i:11 both diameters; this sum, divided by 2, represents the average
diameterof thecylinder.
=High Compression.
find
the
C=chrome
SSP1776
average
an area
1-7
SERV ICE
TABLE
OF
LIMITS
Ref.
Raf.
Chut
Nomenclature
Dimeadonl
Mfi.
Old
Nen
Min.
9snl.
Max.
It
Max.
Cylinder
Cylinder
81-82-83-85-86-87S9-S10-T2T3-AF
Cylinder
611
B-D-GJS-T-Y-BD-BE
Cbuuncca
Mfr.
Min.
Scrv.
Max.
Max.
.0065T
.010T
(A)
.0045T
.008T
(A)
.0075T
.OllT
(A)
.0070T
.0105T
(A)
.0065T
.010T
(A)
.~01T
TD025T
(A)
2.0025
2.004
B-D-GJ-S-T-YBDBE
S1-S2-S3-S5S6-S7S9-S10-T2-T3AF
1.7395
1.741
1.9355
1.994
1.733
1.735
Cylinder
B-D-GJS-TY-BD-BE
Cylinder
at
I -7S6 5-3S2 1
:!:1:1:1:1: S9-S10-T2-T3-AF
A
612
Cylinder
C~linder
2.0965
2.0975
A1-B-D
1.9265
1.928
B1-C-J-S-T-Y-BDBE
2.0815
2.083
81-82-83-85-86-87S9-S10T2-T3-AF
2.2885
2.087
Cylinder Head
2.089
1.918
Cylinder Head
11920
B1-G-J-S-T-YBDBE
2.073
Cylinder Head
2.075
81-82-83-85-86-87S9-S10-T2-T3-AF
Cylinder
2.280
2.282
ALL
AB-D-GJ
SSP1776
B-DG-J-S-T-YAF-BDBE
A1-B-D
613
1.926
Cylinder
Head
li:jliljljlj
tlilllllll
Head
18
BEBV ICE
TABLE
OF
L(MITB
Ref.
Ref.
Mil.
Mfr.
New
Old
Min.
Selv.
Min.
Serv.
Max.
Max.
Max.
Max.
613iirj~
.6267
.6272
GJ-S-T-AFBDBE
.6633
.6638
S1
.6953
.6958
A-B-DJ
.5913
;6257
TF625
~i;9a5
ijiijijiji
ilillllil
IIIIIIII1I
G-J-S-T-AF-BD
iilitlfiit
S1
ALL
Illlltiiii
liiiilliii
tillliilil
.6247
.6613
.6933
.0010T
.D025T
Cylinder
ili.ilj~il
ALL
A-B-D
A1-G-J-ST-BD-BE
.5933
.5938
.5913
.5923
.0020L
.0038L
.0040L
.o06oL
S1-S2-S3-S5-S6-T2TS-AF
S7-S9-S10
(A)
(A)
0035L
Ilillliililj
Clearancea
Dimendona
Nomenclature
Chart
LWSSt
(A)
.0037L
.0050t
(A)
.0035L
.0055L
(A)
iiilil~ili
Helicopter~
liiitiilif
iiiiiilii
.4012
-4020
4320
.4333
G-J-Y
4332
.4340
G-J-S-T-BD-BE
T;m~5
7hsB~
A-B-D
lilili:ili S1-S2-S3-S5-S6-S7il:l~i:il
S9S10~T2-T9-AF
.4935
.4955
is
f.4937
.4915 is
e only to inconel
nimonic valves.
lilllilili
SSP1776
.4915
1-9
or
I)LRV ICE
TAILI
OF
LlnnlTs
Chut
Ref.
Ref.
No~nckturs
Min.
Nea I Old
Berv.
Mx.
Min.
Berv.
Mu.
~IP.
M~.
615
Cburnca~
DtmePdonl
A-B-D
.4370
.4380
GJ-S-T-BD-BE
.4985
81-82-83-85-86T2-T3-AF
.4995
.5005
87-89-810
Helicopter)
.5000
T56m
1/2 inch diameter exhaust valves may have exhaust valve guides that are .003 in. over the maximum inside
diameter
anytime up to 300 hours of service. After 30[1 hours of service, inside diameter of exhaust valve
guide may Increase .001 m. during each 100 hours of ooeration up to the recommended overhaul time for the
engine or not to exceed .015 inch over the basic I.D. See latestedition of Service Instruction No. 1009 for
recom;nended overhaul time.
li~it,
ALL
616
ALL
0010L
.006L
4022
.4010
ALL
ale
liiiiltlt
617
ALL
618
I,-
.4040
.4050~
A-B
Solid
G-D-J-S-T-Y-AFED-BE
Dry Tappet
.005L
.006
.012
Tappet Clearance
(After Engine in Run)
.028
aearance
619
1 : : : :
6181
619
iiSSBjll
fi~3%lil
8SP1776
&DJ-S-T-Y
.0025L
Rocker Bushing
Valve Heads)
(Parallel
S1-S2-S3S5-S6S7S9S10-T2-T3AF
.6246
(No Bushings)
.6261
BD-GJ-S-TY
Heads)
1-10
.6270
.6270
.0001L
.0013L
.0025L
.0001L
.0013L
.0025L
IERV ICE
PART 1
TABLe
OF
LIMIT8
SECTION II CYLINDERS
Rai.
CLelnnce~
Dimendon~
NomenclPture
Chut
Ref.
Mtr.
New
Min.
Old
Serv.
Mx.
620
S1-S2-S3-S5S6S7-S9-S10-T2T3-AF
ALL
ALL
.6246
.6261
Serv.
Mix.
.6270
.0007L
.0017L
.004 L
.6252
.6270
Bushing
iiiii.siiiiil ALL
a
Malt.
Max.
619
IMin.
.624
.6231
B~I
Valve Rocker
Valve Rocker
623
624
Ittria~ iii
Bushing
Bushing Must Be
Burnished In Place
and
Bushing
(A)
.016L
.7380
.7388
ALL
A-B-D-G-J-Y-S-T
.005L
1013L
81-82-83-85-86S7-S9-S10-T2TI-AF
;020L
A-BJ
.002L
.0005T
.0025T
625 I:ieP~:i:l A
.705
T725
.705
ALL EXCEPT
0-235
.765
.785
ALL
ALL
(Parallel
Heads)
.914
.954
SSP1776
.0022T
1(K)38T
1-11
.024L
(A)
IIRV(CE
TABIE
OF
LIMIT8
825
45
611
607
~I:::
608
\--OPTIONA
600
u,~
1-12
QIERV ICE
TABLE
OF
LlnnlTs
0-235 TYPE
i /-624
621~
/-623
620
623
621
620
619
Cylinder,
SSP1776
Components
OF
PAOLF
OERV ICE
L1MITI
Old
Ne~
Cbnnccl
Dimcndonl
Nnrnanoiaturt
Chart
Ref.
Ref.
OIL PUMP
Mir.
Min.
Serv.
Min.
Serv.
Mx.
MPX
Max.
700
701
li
ALL
:EiOlt
A-B-D-G-J-S-TAF
.0010L
.0025L
.004L
.0015L
.0030L
.006L
.0015L
Oil
Oil
Pump
and Oil
.006L
Accessory Case
ED-BE
Iltllllill
ST-AF
Clearance
A-BD-GJ-S-T-YAF
:~42
704
.0010L
and
.004L
(DUAL MAGNETO)
ED-BE
:I
Crankcase
702
703
Oil
ED-BE
ALL(Except ED-BE)
Oil
.015L
End
.050L
.017L
Llearsnce
as76
.002L
Oil
Pump Impeller
.0035L
.0075L
Diameter
Impellers
AS APPLICABLE
AS APPLICABLE
AS APPLICABLE
ED-BE
1111111111
Width of Oil
Shaft
AF
.;..i:.
ED-BE
SSP1776
Width of Oil
A-BDGJ-S-T-YAF
A-BD-G-J-S-T-Y-
liltlliliiiil
Width of Oil
Oil Pump
Shaft
S-T-AF
iiiiiiiiiP
707
Width of Oil
~DUAL MAGNETO)
8~58
ijiijji~jj
Impeller
Side
Pump Impellers
Pump Impellers
Pump Impellers
Pump Impellers
.622
.624
.621
.747
.749
.746
199~
.997
.994
.0045L
.005L
.003L
.005L
.006L
.622
.620
BDBE
Ij
Oil Pump
Clearance
.009L
.OOZL
Side
Clearance
ED-BE
.()4?L
.00sL
Clearance
Oil Pump
Clearance
.065L
Oil
Impeller
and Idler
.004L
Oil Pump
Shaft
(DUAL MAGNETO)
.001T
(A)
Impeller
and Idler
.002T
.004T
(A)
.0005L
.0020L
.003 L
.0010L
.0025L
.003L
.0000
.0015T
(A)
Oil
Pump Body
S-T-AF
.0010L
and Oil
AB-D-G-J-S-T-YAF
Oil
.0010L
.00251~
.0035L
BDBE
.0010L
10025L
.0035L
1-14
IIEF~V Ice
rAeLe
of
Linnirs
NonwneIature
Chut
Ref.
SCAVENGE PUMP
Cburncel
Dtmendonu
Mh.
Min.
Old
Min.
a
Mar.
708
709
C2S2
Iftli~f&liG2-S2 "
Scavenge Pump
.0010L
and
~aant
End Clearance
.007L
Tbiit
Diameter aearance
Side Clearance
1.498
Idler Shaft
716
Gerotor Pump
Clearance
S3-T4-AF
18Pi~ S3-T4-AF
iifiiiiliif (WIDEDECK)
il)jiiliii~ (WIDE
iiii~iii
T4
Side
.0015L
.003L
.0055L
and
(DUALMAGNETO)
J-S-T-AF
720
721
723
:1:.:i:i:i:
.0105L
.0395L
.0445L
FUEL PUMP
.005L
.005L
.0020L
.0035L
.0065L
S-T-AF
(DUAL MAGNETO)
and Crankcase
.0020L
.0035L
.0065L
S-T-AF
AN Fuel
Shaft
.001L
.003L
.005L
Crankcase
.0020L
.0035L
.0065L
.0020L
.0035L
.0065L
ST-AF
(DUAL MAGNETO)
ST-AF
(DUAL MAGNETO)
SSP1776
(AJ
(DUAL MAGNETO)
S-T-AF
CiS~
.004L
.OP1SL
End Clearance
DECK)
End Clearance
719
.0005L
L
Pump Housing
.004L
.0035L
Adapter
Gerotor
:i:il S3-T4-AF
718
Rotor
(A)
.0010L
(WIDE DECK)
iiiiiiiiiii ONIDEDECK)
717
.OOSOL
.0025L
ii S3rT4-AF
94~8
.004L
~T51F
sim
S3-T4-AF
ii
.0010L
~0025L
.0000
C2-S2
.oosL
1.495
i5~4Kii
T~65C
Width of Impellers
G2S2
712
.014L
.003L
713
.004L
.060L
710
ii.iiiiiiii
Mu.
Mu.
Max.
Pump Idler
Gear and
1-15
TA~LE
IIRVICE
OC
LIMITI
Ret.
New
(CONT.)
Old
Mtr.
Mfr.
Min.
8erv.
Min.
Max.
Max.
724
End
End
End
End
End
(DUAL MAGNETO)
A-B
i
I.:::
J-S-Y
T-AF
Qililililiiils
i~tjljliiiiiiJ(DUAL MAGNETO)
.i..
725
tt~8iil
.058L
.005L
.055L
.007L
.037L
.052L
.020L
.040L
Clearance
.015L
,038L
.046L
Qearance
W5L
.055L
T-AF
T-AF
(DUALMAGNETO)
.03 8L
Pump
Adapter
728
iijijj~iiiil(NARROW DECK)
:67~t
OI7IDE DECK)
BDBE
G1-GP-ST-AF
ED
732
G1-OP-S-T-AF
Ilililiiftf
SSP1776
ED-BE
.045L
.004L
.035L
.044L
.OS1L
.091L
.035L
.073L
.OS3L
Ij
.024 L
.069t
TAF
End
Clearance
AN Fuel
STAF-Y
727RPO::ilS
731
.003L
.043L
.030t
and
730
Max.
.~iOL
(DUAL MAGNETO)
729
Serv.
Mix.
~tiS:
T-AF
726
Qeunce~
Dirnendona
Nomancktun
Ch~t
Rsf.
FUEL PUMP
GOVERNOR
.079L
.07 5L
HYDRAULIC PUMP
.0010X,
.0025L
.004L
.004 L
.0010L
.0025L
.004 L
.0005L
.0025L
.004 L
~abZn;
CrankcaseFront
.0010L
.004L
.004 L
End
End
.021L
.0045L
.021L
Clearance
1-16
IIBAVICE
TABLE
OF
LINIIT8
Rat.
Rat.
New
Old
Chut
GOVERNOR
HYDRAULIC PUMP
Nomendnture
(CONT.)
Dimendonl
hlrr.
a
Serv.
Min.
I)crv.
Max.
Max.
Max.
c-J-s
"if rF~
Adapter
.0010L
T0125L
c.s
.0010L
(DUAL MAGNETO)
Housing
GJS
End
End
liiif!iii~i
G-S
(DUAL MAGNETO)
:?~21:1TAF
735
Hydraulic Pump
Adapter
~Sdraulic Pump
Gear
-YTS-JGB-A
.039L
TACHOMETER
and
.0010L
.0025L
.004 t
Vacuum
and
.0010L
.0025L
.006L
,010L
.057L
.075L
.003L
.020L
.030L
.000
.067L
.075L
.012L
.044L
.055L
.017L
.039L
.050L
.0015L
.0035L
.006L
7381iiISSaIj
A-B-GJ-S-T-AF
(DUAL MAGNETO)
TAF
(DUAL MAGNETO)
1625.:1
Pump Gear
Accessory Housing
End
End
End
End
End
Y-BA
Adapter
,,,~iriiiiiliii
D-G-J-S-T-AF
740
.0010L
Adapter
.0050L
.0065L
.0015L
Accessory Housing
.0035L
.006L
G-J-S
Vacuum
(DUAL DRIVE)
Adapter
.0010L
.0025L
.004 L
1784:1 G-JS
SSP1776
.007L
.03 2L
(DUAL MAGNETO)
tl.i1584::I
q/ il
VACUUM
.076L
.0045L
ST-AF
End
.010L
.066L
AF
iiiill
737
End
Clearance
1311
.004L
lump Dp,
(DUAL MAGNETO)
.004L
.0010L
and
uearance
T-ar
.044L
.001DL
.OD25E-
Acees~ory Housing
.034 L
.002L
Gear and
T-AF
.002L
.024L
,037L
(DUALMAGNETO)
-~III
.005L
.005L
T-AF
i~
I:
Max.
(DUAL DRZVE)
Pump
Gear and
1-17
End
gPe
.017L
.027L
bERV ICE
OF
TABLE
LIMITE
Ret.
IC~t.
Chut
VACUUM
TACHOMETER (CONT.)
Nornenolature
Dirnendona
Mir.
Nea
Old
Cleueneea
Mtr.
Min.
8erv.
Mix.
8erv.
i
Mu.
M.
742
1~i791ti:
743
GJ-S
(DUAL DRIVE)
GJS
.0030L
Idler Gear
End Clearance
.021L
(DUAL DRIVE)
ijlsPiil
""1~Pi
.060L
c-J-s
(DUAL DRIVE)
Adapter
GJ-S
(DUAL DRIVE)
Hydraulic Pump
Adapter
GJ-S
Propeller Governor
SECTION III GEAR TRAIN SECTION
~fl
146
Gear and
.0013L
L
.005L
or
Hydraulic
.000
Magneto Bearing
and Gear
.0005T
.0005L
Magneto Bearing
and Gear
.00a8T
.0005L
74787~::I
Magneto Bearing
87
87
and Crankcase
Drive
Bearing
Magneto Bearing
Magneto Bearing
and
and Gear
and
Adapter
I!~Sjl
ST-AF
ii:jlii:iij
(DUAL MAGNETO)
751tii~l?i
liiiiliiiilj (DUAL MAGNETO)
S-T-AF
Magneto
752
Magneto
750
753
AF
756
751
j:rr~s7:1Y
i :j i iji
758
8SP1776
Magneto
Clearance
.0006T
.0008T
(A)
.0001T
10T
(A)
.000
12L
.0015L
.0010L
L
.083 L
001L
.005L
.001L
Magneto Shaft
Magneto Case
.001L
Magneto
Gear and
.005L
.005L
and
.001L
L
.0075
001L
and
.003L
.073L
Shaft
ED-BE
.0002T
(A)
Magneto
Adapter
749
.074 L
ililjli jl
748
.005L
.0013L
ejC~fE.IT
.005L
yros ec Aylbmes A
Support
.015
0005L
.0015L
5
1-18
.005L
.005L
.0035L
.0055L
C)BiRV ICE
TAIIILeS
OF
LIMITLI
Ref.
Ref.
Chart
Nomsnckt~e
New
Old
Cblnncel
Dlmendone
Mfr.
Min.
Ssrv.
Mar.
Min.
Serv.
Mar.
Mar.
Mar.
Mfr.
.0015L
.0035L
.0055L
and Crankcase
.0025T
.0045T
(A)
759fi"
.0020T
10(735T
(A)
760
.001L,
.0028L
.0005T
.0025T
.0010L
.0025L
.005L
.003L
.005L
.010L
.000
.0059L
.080L
Magneto
Gear and
Bushing
(DUAL MAGNETO)
70951iiiiIi~ifiliiiilBD,
BE
Bushing -Magneto
761
762
763
764
73:16
Drive
End
Clearance
7#
712
7#)113
4 CYL-DUAL MAG
6 CYL-DUAL MAG
106
~7
O
0-320-H O LO-360-E
STANDARD TYPE
Oil
SSP1776
Pumps
1-19
.005L
(A)
O BRV I OE
TABILIE
OF
LIMITE)
718
717
715
716
7157
~-717
,716
719
715
709
/-716 /-713
r768
-h
IICVn
711
_v
712
120
713
IIRV ICI
7ABLk
OF
LIMITI
720
721
721
721
AC FUEL PUMP
(ouat Ma(S~
o-
AC FUEL PUMP
74 CYLJ
724
726
AC FUEL PUMP(GCYL)
726
aN FUEL
Fuel
SSP1776
PU~AP14CYL)
Pumps
1-21
IIERV ICE
TAICILPE
OF
LIMIT8
729
131
731
8 (WIDE DECK)
0-320-H 0,L0-360-E
728
131
732
131
Front Governor
8881716
1-22
S ERV I CE
TABLE
OF
LIMITS
723
736
735
723-~
rR5
724
723
733
734
REAR
(4 CYL.)
(STANDARD)
(DUAL MAG.)
732
Hydraulic Pumps
1-23
IIlRRVlCe
OP
lAllILlll
L(NI1I1E~
I"
739
I I
!I
Is
"739
~jf
7Je
TACHOMETER DRIVE
731
VACUUMPUMP 8 TACHOMETER
r740
741
738
737
~,1
115
114
VACUUM PUMP
OR (VACUUM PUMP
Tachometer
SSP1176
Drives,
Vacuum and
1-24
Hydraulic Pumps
HYD PUMP)
IPeRVICe
IABLEE
OP
LIMITb
7,1
:I
ylh
0-43M
ICCESSORI~SG?
6 CYLINDER
Y/1
~--Y*D)ILTO
HIO-360-D TYPE
8 CYLINDER
0-320-H O LO-360-E
158
il/
r!
ri-r(T
1Xi(
sCYL.(S~LN-ZI BS4~N-1227)
151
4 CYL. DUAL
MAG.
WAL
Ice
TPILIS
Llhll)TB
CIP
ENG1NES
CT DR\VE
pART 1 DIRE
TRAIN
QECTIOfJ IIIGEAR
r.,
rr.*
ukir,~
uo.
(V0-36~
Acces~ory DiYes:
126
SSP1776
Mapt~etos
PCIIRV Ice
TAisiie
of
LIMITS
100
759
760
GENERATOR DRIVE
0-435-A
161
763
i~3
3
BENDIX DRIVE
0-435-A
1-27
IERVIOE
OF
TABLE
LIIMITE
Rei.
Ref.
Chut
Nornenclature
Dimendonll
Mfr.
Old
New
Serv.
Min.
Serv.
Max.
Max.
Max.
A-BCJS-TY-AF
800
eol
I:ji i i i i i
BD-BE
803
I
804
.004
.015
.006
Itiax~ittl
A-B-G-JS-T-YAF
ie~:2:
805
A-BGJ-ST-AF
i
ED-BE
Drive
Pump
.004
~15
808
Be-Be
I;~lill ABD-G-J-S-TED-BE
iijjjijjijj
sos
~ FA-TS
(DUAL MAGNETO)
8101~8X
811
812
.004
Idler
.015
.020
.004
7015
.020
.006
Backlash
Magneto
Magneto
.020
.W6
.008
Oil Pump
Backlash
~mz
rf188:
Propeller Governor
Hydraulic Pump Backlash
G-J-S
Camshaft and
(DUAL DRIVE)
or
rJi)3iill
G-JS
titiriliri
(DUALDRIVE)
(DUALDRIvE)
816
s.Jc(DUAL DRIVE)
ST-AF
als
SSP1776
S-TAF
Governor or Hydraulic
and Idler- Backlash
vacuum
Pump
Pump
and Idler
.020
.020
.012
.002
.015
.004
.ozo
.0013
~bbiS
.004
.015
mo
.020
.004
7015
,C)15
.ozo
.004
~T15
Backlash
1-28
.020
.008
Impellers
GJ-S
.014
.020
813
,,i
:::I:::::
.020
Magneto
it tfil l~.i,
.020
.004
1015
Gear- Backlash
so?
.020
.ozo
Backlash
A-B-G-J-S-T-Y-AF
Max.
Pump
~ZSJti:IY
802
Mtr.
Min.
.020
.004
.020
.004
.ozo
~IRVICICS
~ABLI%
QF
tlMITs
Noms~c*Rps
Naw
Dhnsndon
O~d
a
Mix.
iij~jiiiii
(DUALMADMETO)
I:~
Ctnnol
amnr,
i;;;;;.
SllN.
Mr.
Mu.
Mu.
.004
7RS
004
Idler- Bscklash
821$il~5:i:1 G-J-S
.ozo
i::i:::::
.020
(Rear Governor)
822
:::q~::
cr-cz-s2S4-ssT-AF
004
.ozo
Governor)
G1-02-52-54-$6T-AF
823
824
ED-BE
:I:
825I"
D
.015
tfaTiming
hsknarChsalkcaB Gear snd
Coupling Spline
i"
tj~ifl D
830
L~WBill
1..;~i:
83z
.003
.020
CamshaEe Gear
828 li:158f~
aal
.Ot5
.004
~mF;
827
829
.004
820
.ozo
.020
.001
RT65
.0075
.004
7ars
Sbii;
.ozo
.004
.ozo
.015
Backlash
s
.020
Iniector Pump
Gear-~njeBacklash
ctorPump
.004
~UTf;
.020
IBRVICB
lAOLF
OF
LINIITEJ;
CRANKSHAFTI
OP GOVERNOR
OIL PUMP
ECCENTRIC
TACHOMETER
IDLER
MAGNE~O_r
CRANKSHAFT
~CAMSHAFTAT REAR
CAMSHAFT AT FRONT
CRANKSH
IDLER
jl/CLPROPGOV
FRONT GOVERNOR
TACHOMETER
CAMSHAF T
VACUUM PUMP
CRANKSHAFT IDLER
ANKSHAFT
ECCENTRIC
r~--
IWAGNETOAC
MAGNETO
FUEL, PUMP
O1L
PUMPCRANKSHAf~ IDLER
rC--PROP GOVERNOR
VACUUM PUMP
IDLER
~--CRANKSHAFT IDLER
CRANKSHAFT
rsta
\t
~L----FUEL
PUMP IDLER
PROP GOVERNOR OR
HYDRAULIC PUMP
CAMSHAFT
AN FUEL PUMP OPTION
0-360
Backlash
SSP1776
(Accessory Drives)
TAILI%
I)BRVICE
OF
VACUUM
PUMPCAMSHAFT?_
,~,2J
FUEL PUMP
812
CRANKSHAFT
CRANKSHAFT
ACCESSORY DRIVESHAFT
GEAR
YI
111
~-ell
MAGNETO DRIVEN
VO,
ET
IVO-360
CAMSHAFT GEAR
Af FRONT
CAMSHAFT
CAMSHAFT
VACUUM
PROP GOVERNOR
TACHOM ETER
7;
OIL PUMP
jsr"~./
B,
CRANKSHAFT
808
MAGNETO
0-320-H, 0, LO-3010-E
ALL VIEWS SHOWN FROM REAR OF ENGINE
Backlash
(Accessclry Drivesj
IFIV ICI
OF
LIMITI)
GOVERNOR
CAMSHAFT (FRONT)
IDLERCAMsHAFT
(REAR)
TACHOMETER
VACUUM PUMP
CRP~NKSHBFT IDLER---,
CRANKSHAFT
ECCENTRIC
OIL PUMP
CRANKSHAFT IDLER
MAGNETO
AC FUEL PUMP
~fj
AN FUEL PUMP
PUMP
\8~8/
FUEL PUMP IDLER
PROP GOVERNOR
CAMSHAFT
(FRONT)
823
TACHOMETER
IDLER
1 i J-CAMSHAFT
(REAR)
VACUUM
PUMP
CRANKSHAFT IDLER
ECCENTRIC
MAGNETO
CRANKSHAFT
PN FUEL PUMP IDLER
i i
AC FUEL PUMP
j.~l--HYDRAULIC
0-540 a 10-720
ALL VIEWS FROM REAR OF
Backlash
1SSP1776
ENGINE
(Accessory Drives)
1-32
PUMP
IDLER
OBRVICE
TABLe
OF
LIMITs
~I1C
~1
STARTER DRIVE
~R CP
0-435-A
ACCESSORY HOUSING
i ldr
0-435-A
_B
o
I
i.
MIIGNETO DRIVE
0-435-A
Backlash
(Accessory Drives)
IIERVICB
OF
TABLI
LIMIT8
SECTIOd
TCsi.
nor.
V SPECIAL
TORQUE REQUIREMENTS
Thread
Chart
Size
Torque Limits
Nornenalature
Old
Nen
900
Rod Nuts
480 in.lbs.
Nuts
A-B-DGY-ST-BD-BE
3/8-24
Connecting
3/824
Connecting Rod
81-83-85-86-87-89TS-AF
3/82A
2.255
2.256
901
liIl BDBE
9/16-18
Oh
902
ED-BE
5/16-24
3/8-24
170
120
170
ii~jtji ALL(ASAPPLICABLE)
803
(EXCEPT 87)
Pump
Shaft Nut
150 in.lbs.
Magneto
1/2-20
87
904
liiilli~tiil
10-32
ALL
305
ALL
906
-:-:i:/ ALL
1/4-20
15 in. Ibs.
50 in.lbs.
6116-18
18MM
Spark Rugs
t LLA
1/8-27 NPT
C:ss~ia
ALL
5/8-32
Alternator
Pulley
910
ALL
1/4-28
Alternator
sat
ALL
10-32
Alternator
Auxiliary
912
ALL
5/16-24
913
ALL
ALL
907 E
we
909
iSgOl:i~
96 in. Ibs.
tight)
(AS APPLICABLE)
1/16-27
NPT
Piston
450 in.lbs.
Nut
85 in.lbs.
30 in. tbs.
Terminal Nut
24 in. Ibs.
Nozzle in Crankcase
Cooling
I:ia#ii
iiiiiliii
Y-S-T-AF
1/8-27 N~T
Injector Nozzle
in
Cylinder
60 in. Ibs.
Head
ALL
(AS APPLICABLE)
ALL(AS APPLICABLE)
3/4-16
13/16-16
Oil Filter
(AC
Can and
ALL
(AS APPLICABLE)
3/4-16
Converter Stud
916
ALL
(AS APPLICABLE)
3/4-18 MPT
Carburetor Drain
917
ALL
(AS APPLICABLE)
1.0014
Oil Cooler
918
ALL
(AS APPLICABLE)
i8qfi
SSP1776
1/4-12
1-34
Plug
Bypass
Valve
PJERV ICE
O)r
1"ABLE
llMIT8
Ref.
Now
016
Hose
20 in. Ibs.
jIliillllill~
927
I.Ii:I:l:
10 in. Ibs.
Hose Clamps
Exhaust V-Band
ST
921
ii
920
Torque Limits
Nomenclature
Size
ALL
919
922
Thread
Chart
Coupling Size
Avco
in.
in.
3.69 in.
3.
I~pe
5
83
83225
MVT6
9197-2
5369M
1
Torque
5
85
85
-12093-4
LW-12093-5
LW-120936
LW25-3
L; -1
LW14
T-BoIt Split
Locknut
Torque In. tbs.
Vendor
Part No.
Lyeoming
Part No.
Tube QD
.75 in.
00 in.
In. Lbs.
75
75
70
7
ALL
~urbocharger Model
V-Clamp Part
No.
VClamp
No.
In.
.50 in.
TC-6-15
301E10-2""
In. L
40-80
6.00in.
in.
7.75 in.
400500-600
00-685
400500-775
TH08A60"
Torque
Diameter
s.AiResearch turbocharger.
Rajay turbocharger.
See latest edition of Service Instruction No. 1238 for
assembly procedure.
Thread
Chart
Size
Torque LMitS
Nomenclature
1/2-20
ED
114
1/213
96
929
ST-AF
Iriitii~I:
Al
7/16
B-DBD-BE-JGY-
1/2
Cylinder
Nuts
S-T-AF
Hold Down and Crankcase
Instruction No. 1029.
Cylinder
Procedures
IIEFIV ICE
C)le
TAIILLE
L(MIT8
(CONT.)
net. I net.
Thread
New
930
Old
I:ii8qiSllil
3/8
ALL
titftliiliitl
931kjij jiii;~ A
Torpue Limitl
Nomenclature
S~
Chart
9116
(Diaphragm
225
LoelringNut(Vllve Adjusting
450 in. Ibs.
Screw)
i8PiB~iil AI,L
Exhaust ~I:ansitions
5/16-18
ilifillii:i
1;1 j~S
Ctart
NomencLat~re
AEDGS-ST-YED-BE
Outer Valve
Springs
(Parallel)
AvcoLYc.l
Wire
Part No.
Die.
8SP1776
Mfr.
Min.
Max.
Serv.
Max.
76994
LW-11800 1.177
1.30 in.
112 Ib.
122 Ib.
65427
.162
1.30 in.
82 Ib.
89 Ib.
79 Ib. min.
68326
.177
1.46 in.
103 Ib.
Illlb.
(Parallel)
S1-S2-S3S5S6S7-S9-S10-T2-T3
(Angle)
81-82-83-85-86-
Outer Valve
S7-S9-S10-T2-T3
(Angle)
LW-11796 1.182
1.43 in.
116 Ib.
13A Ib.
A-B-D-GJS-T-YBD-BIE
Auxilliary Valve
Spring (Parallel)
65567
LW-11795 1.135
1.17 in.
611b.
671b.
58 Ib. min.
.142
1.33 in.
75 Ib.
83 Ib.
72 Ib. min.
2.18
2.16
.054
.063
.054
1.90
2.12
1.054
.059
1.30
1.47
1.30
1.30
1.44
.0465
Spring
Magneto Coupling
Spring
Outer Valve
Springs
Springs
Springs
IAuxilliary Valve
Spring (Angle)
68328
LW-11797
61084
703
None
None
LW-11713
White
A-B-G-J-S-TYAF
Oil Cooler
Free
Length
BDBE
Oil Filter
8.5 Ib.
17.8 Ib.
1
7.11b.
6.4 Ib.
10.79 Ib.
9.5 Ib.
19.4 Ib.
7.8 Ib.
7.11b.
11.921b.
8.3 Ib.
18.0 Ib.
1 6.9 Ib.
6.2 Ib.
1.94 in.
6.50 Ib.
7.25 Ib.
16.4115. znin
.047
1.00 in.
3.05 Ib.
3.55 Ib.
.091
.603 in.
20 Ib.
22 Ib.
391b. nrin.
in.
in.
in.
in.
in.
min
min
min
min
110.5lb.min
Bypass
Spring
~.:801:i
Length
Mfr.
Outer Valve
ellow
955
Comp.j
A-B-I)-G-J-S-T-Y-
aL%
At
ED-BE
954
COMP. LOAD
Length
~9-S10T2T3-AF
tilisREIll
SECTION V SPRINGS
S1.-S2-S3-S5-S6-S7-
953
Studs
(Driving Torque)
j?so
Exhaust TIansitions
3/8-16
i:f
._.....
Studs
(Driving Torque)
ALL
Bypass
1-36
STANDARD
UNLESS
bolts to be
OF
TABLE
dEWVICE
LIMITIE)
TORQUE
LISTED
OTHERWISE
supplied by propeller
or
airframe manufacturer.
TABLE II
TABLE I
PIPE PLUGS
thread
In.Lb.
Thread
900
1320
1800
3240
1
1
9116
96
204
5116
3/8
7116
THIN NUTS
17
3
50
360
600
(112
Torqu
Torque
Torpue
In,Lb. Ft,Lb.
3/4
DIA OF
BOLTJ
i/2
Thread
Ft,Lb,
In. L
1116-27 NPT
75
110
150
270
4
4
8
11
16
23
31
27 NPT
18 NPT
18 NPT
-14 NPT
4-)4 NPT
1-11 1 12 NPT
1
1
3
1
LISTED TORQUE
TABLE IV
TABLE IrI
FLEXIBLE HOSE
OR TUBE F17TINGS
ANGLE OF TURN
Aluminum
Asbestos
Asbestos
670
670
1350
1350
10
1 800
1
12
1
270"
16
18
2700
27
3
3
28
Th read
(-3) 3/16
-4) 1/4
3/8-24
7/16-20
5/16
(-6) 3/8
112-20
9/16-18
314-16
7/8-14
-5
-8
1350
1350
.lo
1
5(8
In.
135
1
1
TABLE V
NOTE
Install all crush type gaskets except the self centering
type, with the unbroken surface against the flange of
the plug or part being tightened against the seal. ~m
the part until the sealing surfaces are in contact and
then tighten to the angle of turn listed for the
appropriate
To
Tube Site
thread size.
Specified,
STUDS
Threads
1/4-20
Torque
In, Lb s.
5/16-18
15
25
3/8-16
50
IIRV Ice
TAorlee
or
Llnn~Ts
Ii
TORQUE REQUIREMENTS
ft 1 M
ADJUSTABLE
,,,_
902
SSP1776
1-38
918
907
IIRVICE
TABLIL!
OF
LIMITs
REQUIREMENTS
i
I
au*
lili
Engine
8881776
139
dE4lft~lCIES
PlkBlbl
TS~QCTE
909
gg
911-
~912
..1
_.__._._
.._
--I--~
---"f:
E;ngine
1-98
OBRVICE
TAsL1BE
OF
LIMIII
455