O235l2c Ovh
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Approved by F.A.A.
Sixth Printing
December 1974 Part No. 60294-7
LYCOIIIIIIIIG
A Textron Company
652 Oliver Street
Williamsport, PA 17701 U.S.A.
SECTION 7 OVERHAUL MANUAL LYCOMING AIRCRAFT ENGINES
CRANKCASE, CRANKSHAFT AND RECIPROCATING PARTS DIRECT DRIVE
TECHNICAL PUBLICATION
REVISION
REVISION NO. PUBLICATION PUBLICATION NO. PUBLICATION DATE
The page(s) in this revision replace, add to, or delete current pages of the publication indicated above.
PREVIOUS REVISION CURRENT REVISION
April 1966 July 2011
53, 56; 85 710D
July 1967
58; 61 thru 618, 623, deleted pages 625 thru 632
April 1968
42 thru 48
December 1968
Section 11 replaced Special Tool Catalog
January 1970
i, ii, deleted pages iv and v; 11, 12, deleted pages 13; 21
thru 26, deleted pages 27 thru 212; 31 thru 35; 41; 91,
92, 94, deleted page 97; 101 thru 1036, deleted pages
1037 thru 1047
January 1971
i, ii; 619 thru 624; 71 thru 719; 93, 95, 96
May 1972
Added page 27; 31, 35; 51 thru 511, deleted pages 512,
513, 514; 61, 617, 618, 622, 623; 81 thru 86, deleted
pages 87, 88; 93
October 1973
i, ii, iii; 11; 33, 34, 35; 41, 43 thru 48; 51, 55, 56, 57,
59, 510; 62, 67, 610, 611, 612, 613, 617, 620, 621,
622, 623; 74, 716, 717, 718, 719; 91, 92
February 1992
i
June 1993
710, added pages 710A, 710B, 710C, 710D, 712, 712A/B
June 1996
i
June 1999
74
June 2002
710B
January 2007
i, ii, iii, added page iv; 11, 12, 13; 74, added pages 74A,
74B; 75, 716, added pages 716A, 716B
September 2007
715, 716, 716A, 716B
July 2008
715, 716A
October 2010
715, 714
©2011 by Avco Corporation. All Rights Reserved
Lycoming Engines is a division of Avco Corporation
710D Revised July 2011
OVERHAUL MANUAL - LYCOMING DIRECT DRIVE AIRCRAFT ENGINES
THIS OVERHAUL MANUAL, THE ENGINE OPERATOR'S MANUAL, AND ALL APPLICABLE
SERVICE BULLETINS AND INSTRUCTIONS ARE ISSUED IN COMPLIANCE WITH F.A.R 21.50,
AND SHALL BE USED BY MAINTENANCE PERSONNEL WHEN PERFORMING ACTIONS
SPECIFIED IN F.A.R 43.13.
For a period of three (3) years new and revised pages for this manual will be furnished to owners who fill
lout the registration card and return it to Lycoming. Registered owners of this manual will be notified of any
changes in revision policy or cost of revisions.
Service Bulletins, Service Instructions and Service Letters are available from all Lycoming Distributors or
Ifrom the factory by SUbscription. Consult the latest revision to Lycoming Service Letter No. Ll14.
Lycoming also publishes an Index of Service Bulletins, Instructions and Letters that lists all Bulletins,
Instructions and Letters in alphabetical order by title and top as well as a list of Bulletins, Instructions and
Letters applicable to each engine series. Consult the Service Publication Section of the latest revision to
Service Letter No. L114 for the current part number of the index.
SPECIAL NOTE
The illustrations, pictures and drawings shown in this publication are typical of the suhject
matter they portray; in no instance are they to be interpreted as examples of (lll)' specific
engine, equipment or part thereof
TABLE OF CONTENTS
SECTION 1
INTRODUCTION
I
I-I. This manual contains the necessary information for the
overhaul of the Lycoming horizontally installed direct drive
engines. Unless otherwise noted, all information and data in
I Therefore, it is required that the parts catalogs be used with
the manual, when reassembling the engine.
the manual will apply equally to all models; those portions I 1-5. The following procedure must be followed if warranty
of the text applying to anyone particular model or series parts are to be returned to the factory. You may obtain from,
will be so identified. but preferably have your distributor complete, the applicable
I warranty form. This form must include the engine models
1-2. The main portion of the text is divided into sections and serial numbers, number of hours in service, the reason
corresponding to the basic engine components. Additional for the parts being returned and any other pertinent facts
sections are provided for general description, general concerning the parts.
overhaul, cleaning, inspection procedures, preservation and
storage information, along with other items of a non-specific I 1-6. In this manual all references to locations of various
nature. components will be designated when viewing the engine
1-3. The tools required for overhauling the engines
(excluding the ordinary mechanic's tools found in most
overhaul shops) are listed in SSP-384, the Special Service
I from the rear (anti-propeller). The propeller end is
considered the front and the accessory drive end the rear.
The oil sump is considered the bottom. Cylinders are
Tools publication. Inspection gages are also listed in the numbered from front to rear with odd numbered cylinders
same publication. Any special information required on the right side. (The most forward cylinder is always
concerning tools may be obtained by writing to the Service designated the Number 1 cylinder.)
Department, Lycoming Engines, 652 Oliver Street,
Williamsport, Pennsylvania, 17701. When requesting 1-7. The direction of rotation of the crankshaft as viewed
information concerning any of these tools, refer to the tool from the rear, is clockwise on all models with the following
by name and part number and not merely by name. exception. The direction of rotation of the crankshaft, as
viewed from the rear is counterclockwise on all models with
1-4. Parts Catalogs for specific models, may be ordered I the letter L in the model prefix. (Example - LTIO-540-J.)
from the department listed in paragraph 1-3. Because this All references to direction of rotation of the various
manual covers the entire series of engines, it is almost accessory drives are viewed facing the accessory drive
I impossible to call out attaching parts for specific models. mounting pad.
NOTE
In addition to this manual and subsequent revisions, additional overhaul and repair information is
published in the form of Service Bulletins and Service Instructions. The information contained in these
Service Bulletins and Service Instructions is an integral part of, and is to be used in conjunction with,
the il~rormation contained in this overhaul manual. When received, these publications should be
inserted in the rear of this manual or maintained in a separate file for ready reference.
SECTION 2.
GENERAL DESCRIPTION
2-1. The engines covered in this manual are direct 2-4. Avco Lycoming incorporates a color code painted
drive, four, six and eight cylinder, horizontally op- on cylinder heads designating differences in the cyl-
posed, air cooled models. inder barrels and spark plug lengths. It is essential
that personnel be familiar with this code as described
2-2. CYLINDERS. The cylinders are of air cooled con- in the latest edition of Service Instruction No. 1181.
struction with the major parts, head and barrel, screw-
ed and shrunk together. The heads are made from an 2- 5. Damage will result with the use of incorrect pis-
aluminum alloy casting with a fully machined com- ton rings or spark plug lengths. The latest edition of
bustion chamber. Valve guides and valve seats are Service Instruction No. 1037 lists the approved piston,
shrunk into machined recesses in the head. Rocker piston ring and cylinder assemblies for all models
shaft bearing supports are cast integrally with the head while the latest edition of Service Instruction No. 1042
along with the housings to form the rocker boxes for lists the approved spark plugs. Consult these publi-
both exhaust and intake valve rockers. cations for correct application to your particular in-
stallation.
2- 3. The cylinder barrels are machined from a chrome
nickel molybdenum steel forging with deep integral 2- 6. VALVE OPERATING MEC HANISM. A convention-
cooling fins. The interior of the barrels are ground and al camshaft is located above and parallelto the crank-
honed to a specified finish. shaft. The camshaft actuates tappets which operate the
Example:
PREFIX
I
TID 541
,
Description of Engine Model Code
DISPLACEMENT
EIB4D
\
SUFFIX
L- Lefthand Engine Rotation 000* E- Power Section a Rating
Cubic in.
T - Turbocharged I - Nose Section
V- Vertical Helicopter B - Accessory Section
H-Horizontal Helicopter 4 -Counterweight Application
A- Aerobatic o-Dual Magneto
* Note: (DO/) '~"lndicates integral
I - Fuel Injected accessory drive
o-Opposed Cylinder
Figure 2-1. Description of Engine Model Code
NOTE
CAMSHAFT
BEARING NO. I
NO.1 MAIN
BEARING
(
I
I
I
~PROP GOVERNOR OIL TAPPETS VACUUM PUMP
DRIVE
I
I
RIGHT BANK
VACUUM PUMP Q D PRESSURE
l~~~~!!.f=
SUCTION SCREEN
OIL SUMP
draulic lifter cylinder outward. This action forces the 2-10. CRANKSHAFT COUNTERWEIGHTS. A system
ball check valve onto its seat; thus, the body of oil of dynamic counterweights, to eliminate torsional vi-
trapped in the pressure chamber acts as a cushion. bration, is provided on all six and eight cylinder and
During the interval when the engine valve is off its some four cylinder engines. Consult the latest edition
seat, a predetermined leakage occurs between plunger of Service Instruction No. 1012 for proper combination
and cylinder bore which compensates for any expansion and location on the crankshaft.
or contraction occurring in the valve train. Immedia-
tely after the engine valve closes, the amount of oil re- 2-11. ACCESSORY HOUSING. The accessory housing
quired to fill the pressure chamber flows in from the is machined from an aluminum alloy casting and is
supply chamber, thereby preparing for another cycle fastened to the rear of the crankcase and the top of
of operation. the oil sump. Accessories are mounted on machined
pads located on the rear of the housing.
2-8. CRANKCASE. The crankcase assembly consists
of two reinforced aluminum alloy castings divided at 2-12. CONNECTING RODS. The connecting rods are
the centerline of the engine and fastened together by made in the form of "H" sections from alloy steel
a series of studs, bolts and nuts. The mating surfaces forgings. They have replaceable bearing inserts in
of the two castings are joined without the use of a gas- the crankshaft ends and split type bronze bushings in the
ket, and the main bearing bores are machined for the piston ends. The bearing caps on the crankshaft end
use of precision type main bearing inserts. The crank- of the rods are retained by two bolts through each cap
case forms the bearings for the camshaft. secured by a crimp nut.
SPLASH OIL TO
PISTONS,PISTON PINS,
CAMS, ETC --'----H---+--
CRANKPIN -H---+---r
PRESSURE OIL
TAPPETS , - - - - - - - j H y D . PUMP
RIGHT BANK Q' AND DRIVE
SPLASH OIL TO ROCKER ~ PUSH RODS "AN"FUEL PUMP
ARMS VALVE STEMS, ETC.---i ROCKER ARM AND DRI'v'En VACUUM PUMP
Y
1
DRAIN'OI~ TO SUMP
AND DRIVE
\ BUSHINGS
THRU OIL DRAIN TUBES ~h-~-'-----" PRES. SCREEN I
OIL PUMP
:;-!.:-_-_-_-_-L'I]
I~::::==::=~i
SUCTION SCREEN
OIL COOLER
OIL SUMP
Far Side _ _ oJ
Oil Return
Figure 2- 5. Schematic Oil System - Alo- 320 and AlO- 360
pressure wet sump lubrication system. See figures 2-15. COOLING SYSTE M. These engines are designed
2-3 and 2-4 for diagrams of typical four and six cyl- to be cooled by air pressure built up on one side of the
inder lubrication systems. See figure 2- 5 for sche- cylinder and discharged, with accompanying pressure
matic of the oil system of the AlO series. drop, through the cylinder fins.
Cam
Magneto Gear
No. of teeth 13
Ratio 1:1
Figure 2-6. Gear Train Diagram - 0-235, 0-290-D and 0-290-D2 Series
Magneto Gear
Ratio 1:1
Fuel Pump
Idler Gear----l
2-16. INDUCTION SYSTEM (Engines Employing Car- The position of the exhaust bypass valve estab-
buretors). Subject engines may be equipped with either lishes the amount of supercharging delivered to the
a float type or pressure type carburetor. Particularly engine. Increasing oil pressure closes the valve and
good distribution of the fuel-air mixture to each cyl- increases power. Decreasing oil pressure opens the
inder is obtained through the center zone induction valve and decreases power.
system, which is integral with the oil sump and is sub-
merged in oil, insuring a more uniform vaporization
of fuel and aiding in cooling the oilin the sump. From The density controller regulates the oil pressure
the riser the fuel-air mixture is distributed to each to the bypass valve while the engine is operating at
cylinder by individual intake pipes. wide open throttle and limits manifold pressure below
critical altitude.
2-17. INDUCTION SYSTEM (Engines Employing Fuel
Injectors). The fuel injection system schedules fuel The differential pressure controller regulates the
flow in proportion to airflow and vaporization takes oil pressure to the bypass valve while the engine is
place at the intake ports. In addition, on the TIO- 360 operating at part throttle settings below critical alti-
and TIO- 540 series, a turbocharger furnished as an tude.
integral part of the engine provides constant air den-
sity to the fuel injector inlet from sea level to critical 2-19. IGNITION SYSTEM. Dual ignition is furnished
altitude. for all subject engines. Several combinations of mag-
netos and various ignition harnesses are employed.
2-18. TURBOCHARGER CONTROLS. The turbocharger Consult the applicable parts catalog for your particular
control system consists of three components, namely, installation. Consult the latest edition of Service In-
the exhaust bypass valve (waste gate), the density con- struction No. 1042 for a list of Avco Lycoming ap-
troller and the differential pressure controller. proved spark plugs.
Magneto Gear
No. of Teeth 13
Rotio 1:1
Fuel Pump Drive Shaft Gear- (ANType) Hydraulic Pump Driven Gear
No. of Teeth /3 No. of Teeth 10
Rotio 1:1 Ratio 1.30:1
Figure 2-10. Gear Train Diagram - Typical 4 Cylinder (Dual Magneto Housing)
Eccentric - - - _ u
Figure 2-11. Gear Train Diagram - Typical 6 Cylinder (Dual Magneto Housing)
SECTION 3.
GENERAL OVERHAUL
PROCEDURES
3-1. This manual will describe in separate sections furnace oil (38-40 specific gravity) or a suitable com-
the complete major overhaul procedures for each in- mercial solvent such as Varsol or Perm-A-Chlor.
dividual portion of the engine, thus dividing the manual Operators are warned against the use of solvents with
for all practical purposes, into a series of individual which they are unfamiliar, since there are many pro-
handbooks dealing in turn with each component part. ducts on the market which are injurious to aluminum
Since there are various overhaul practices and in- and magnesium. Extreme care must be exercised if
structions of a non-specific nature, which apply equally any water- mixed degreasing solutions containing caus-
to all basic engine components, these general instruc- tic compounds or soap are used. Such compounds,
tions will be grouped together and described in this in addition to being potentially dangerous to aluminum
section, thus avoiding repetition. and magnesium, may become impregnated in the pores
of the metal and cause oil foaming when the engine is
3-2. No attempt shall be made to inc.lude overhau~pro returned to service. When using water- mixed solutions
cedures for the various trade accessories. These ac- therefore, it is imperative that the parts be completely
cessories are covered in overhaul manuals published and thoroughly rinsed in clean boiling water after de-
by their respective manufacturer. Only such assembly greasing. Regardless of the method and type of solu-
and disassembly as required by engine installation will tion used, coat and spray allparts with lubricating oil
be covered. immediately 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 3-10. REMOVAL OF HARD CARBON. While the de-
and drain the oil from the engine. greasing solution will remove dirt, grease and soft
carbon, deposits of hard carbon will almost invariably
3-4. Attach the engine lifting cable to the engine and remain on many interior surfaces. To facilitate re-
remove from the airframe. moval, these deposits must first be loosened by im-
mersion in a tank containing a decarbonizing solution
3-5. Place the skid (ST-278) in the overhaul stand (ST- (usually heated). A great variety of commercial de-
162). Attach the engine overhaul adapter (ST-165) to carbonizing agents are available, including such pro-
the propeller flange and mount the assembly on the en- ducts as Gunk, Penetrol, Carbrax, Super-Chemaco,
gine mounting ring. Gerlach No. 70, and many others. DecarbOnizers,
like the degreasing solutions previously mentioned,
3-6. Place the overhaul stand and skid into position fall generally into two catagories, water-soluble and
and lower the engine to the stand and remove lifting hydrocarbons, and the same caution concerning the
cable. The engine is now in a position to be disassem- use of water-soluble d egreasers is applicable to water-
bled. Specific disassembly instructions are contained soluble decarbonizers.
in the applicable section for each component.
CAUTION
3-7. Inasmuch as visual inspection should be made
while disassembling and immediately after disassem- Extreme caution should be exercised when
bly, all individual parts ShOll.'d be laid out in an or- using a decarbonizing solution on magne-
derly manner as they are removed from the engine. sium castings. It is recommended that the
No cleaning operation should be performed until this use of heated solutions be avoided unless
initial visual inspection has been completed. All loose the operator is thoroughly familiar with
studs, cracked cooling fins, loose or damaged fittings, the particular solution being used. In ad-
and the like, should be carefully noted and tagged to dition, the operator is strongly advised
prevent their being overlooked during regular inspec- against immerSing steel and magnesium
tion. parts in the same decarbonizing tank, be-
cause this practice often results in damage
CLEANING to the magnesium parts from corrosion.
3-8. It is imperative to clean all engine parts thor-
oughly to facilitate inspection. Two processes are in- 3-11. Decarbonizing will usually loosen most of the
volvedin cleaning engine parts; degreasingto remove hard carbon deposits remaining after degreasing; the
dirt and sludge (soft carbon) and the removal of hard complete removal of all hard carbon, however, gen-
carbon by decarbonizing, brushing or scraping and erally requires brushing, scraping or grit-blasting.
grit-blasting. All of these ope rations demand care on the part of the
mechanic to avoid damage to machined surfaces. In
3-9. DE GREASING. Degreasing is accomplished by particular, wire brushes and metal scrapers must
immersing or spraying the part in solution of white never be used on any bearing or contact surface.
Revised May, 1972 3-1
Section 3 OVERHAUL MANUAL. LYCOMING DIRECT DRIVE AIRCRAFT ENGINES
General Overhaul Procedures
3-12. When grit- blasting parts do not use sand or any bearing surfaces in the engine will do no harm and
metallic abrasives. It is recommended instead that should not be considered cause for rejection of the
mildly abrasive organic substances such as rice, part, provided it falls within the clearances set forth
baked wheat, plastic pellets, or crushed walnut shells in the Table of Limits. Even though the part may come
be used. All machined surfaces must, of course, be within specified limits it should not be reassembled
adequately masked and all openings tightly plugged into the engine unless inspection shows it to be free of
before blasting. The one exception to this is the valve other serious defects. Ball bearings should be ex-
seats, which may be left unprotected when blasting the amined visually and by feel for roughness, flat spots,
cylinder head combustion chamber. It is often ad- flaking or pitting of races and for scoring on the out-
vantageous to grit blast the seats, since this will cut side of the races. All journal surfaces should be
the glaze which tends to form (particularly on the ex- checked for galling, scores, misalignment and out- of-
haust valve seat) thus facilitating subsequent valve seat round condition. Shafts, pins etc. should be checked
reconditioning. Under no circumstances should the pis- for straightness. This may be done in most cases by
ton ring grooves be grit blasted. If necessary, soak using vee blockS and a dial indicator.
the piston in petroleum solvent and scrape with a
wooden scraper. When grit-blasting housings, plug all 3-21. GEARS. All gears should be examined for evi-
drilled oil passages with rubber plugs or other suit- dence of pitting and excessive wear. These conditions
able material to prevent the entrances of foreign are of particular importance when they occur on the
matter. involute of the teeth; deep pit marks in this area are
sufficient cause to reject the gear. Bearing surfaces
3-13. The decarbonizing solution will generally re- of all gears should be free from deep scratches. How-
move most of the enamel from exterior surfaces. All ever, minor abrasions may be dressed out with a fine
remaining enamel should be removed by grit- blasting abraSive cloth.
particularly in the crevices between cylinder cooling
fins. 3- 22. CORROSION ON STRESSED AREAS. Pitted sur-
faces in highly stressed areas resulting from corrosion
3-14. At the conclusion of cleaning operations, rinse can cause ultimate failure of the part. The following
the parts in petroleum solvent, dry and remove any areas should be carefully examined for evidence of such
loose particles by air- blasting. Apply a liberal coating corrosion; interior surfaces of piston pins, the fillets
of preservative oil to all surfaces. at the edges of crankshaft main and crankpin journal
surfaces, and thrust bearing races. If pitting exists
INSPECTION on any of the surfaces mentioned to the extent that it
cannot be removed by polishing with crocus cloth or
3-15. The inspection of engine parts during overhaul other mild abrasive, the part must be rejected.
is divided into three catagories, visual, structural
and dimensional. The first two deal with the structural 3-23. SCREWED FITTINGS. Screwed fittings (any
defects in parts while the third is concerned with the parts such as threaded fastenings or plugs) should be
size, shape and fit. inspected for condition of threads. Badly worn or
mutilated threads must not be tolerated; the parts
3-16. Visual inspection should precede all other in- should be rejected. However, small defects such as
spection procedures. Do not clean any parts prior to slight nicks or burrs may be dressed out with a small
visual inspection, since indications of dangerous op- file, fine abrasive cloth, or stone. If the part appears
erating condition can often be detected from the resid- to be distorted, badly galled, or mutilated by over-
ual deposits found in some particular recess of the tightening, or from the use of improper tools, it must
engine. be replaced with a new one.
3-17. Structural failures can be determined by sev- 3-24. MAGNETIC INSPECTION. All ferro-magnetic
eral different methods depending on the part involved. steel parts should be inspected by the magnetic particle
The following are a few of the methods employed: mag- method. The successful detection of structural failure
netic particle, dye penetrant, penetrant, x- ray and by magnetic inspection demands skill and experience on
various electronic methods. the part of operating personnel. It must be remem-
bered that almost any fabricated steel part will show
3-18. Dimensional inspections should be carried out in indications of some kind, and it is important that the
accordance with the measurements and tolerances as operator exercise good judgment in evaluating the in-
called out in the Table of Limits (Section 10). dications. Too rigid an interpretation may result in
the rejection of a sound part, while on the other hand,
3-19. It is recommended that an inspection and over- a part showing a dangerous indication may be returned
haul form, containing a list of all engine components, to service as a result of a too casual diagnosis. In
be utilized when disassembling an engine. This form general, areas of stress concentration must be watched
should be prepared so that all inspection and over- closely for fatigue cracks. These areas include such
haul procedures can be checked off and remarks noted. locations as keyways, gear teeth, splines, roots of
This will also assure that no part is inadvertenly over- threads, small holes and fillets.
looked.
3-25. Proper judgment must also be used in deter-
3-20. BEARING SURFACES. All bearing surfaces mining the amount of current (amperage) applied; too
should be examined for scoring, galling and wear. Con- little current will not sufficiently magnetize the part,
siderable scratching and light scoring of aluminum while too heavy an application will permanently dam-
age the part by overheating and burning thin areas ad- rinse. After which the part is immersed for 45 min-
jacent to the electrodes. Again, skill and experience utes in a hot dichromate solution (3/4 lb. of sodium
on the part of the operator are of the utmost import- dichromate to one gallon of water at 180°F. to 200°F.,
ance. Consult the latest edition of Service Instruction quantity as required). The part should be then washed
No. 1285 for proper amperage. thoroughly in cold running water, dipped in hot water
and dried in an air blast. Immediately thereafter the
3-26. CORROSION-PREVENTION. Upon completion of part should be painted with a prime coat and engine
inspection, coat all steel parts with preservative oil. enamel in the same manner as prescribed for alumi-
num parts.
REPAIR AND REPLACEMENT
3-31. Shroud Tubes. Shroud tubes should be thoroughly
3-27. DAMAGED PARTS. Abnormal damage such as cleaned and dipped in zinc chromate primer thinned to
burrs, nicks, scratches, scoring, or galling should be spraying consistency. After the primer is dried the
removed with a fine oil stone, crocus cloth, or any shroud tube should be painted on the outside with en-
similar abrasive substance. Following any repairs of gine enamel.
this type, the part should be carefully cleaned in order
to be certain that all abrasive has been removed and 3-32. All paint applied in the foregoing operations
then checked with its mating part to assure that the should preferably be sprayed; however, if it is neces-
clearances are not excessive. Flanged surfaces that saryto use a brush, care should be exercised to avoid
are bent, warped, or nicked may be repaired by lap- an accumulation of pockets of paint.
ping to a true surface on a surface plate. Again the
part should be cleaned to be certain that all abrasive 3-33. REPLACEMENT OF STUDS. Any studs which
has been removed. Defective threads can sometimes are bent, broken, damaged or loose, must be replaced.
be repaired with a suitable die or tap. Small nicks can The method of removing studs depends on the type of
be removed satisfactorily with Swiss pattern files or stud and manner in which it is broken. The procedure
small, edged stones, pipe tapped threads should not for removing and replacing studs is as follows:
be tapped deeper in order to clean them up, because
this practice will invariably result in an oversized a. If there is sufficient thread area available on
tapped hole. If scratches or galling are removed from stud, use a collet grip tool consisting of a tapered
a bearing surface of a journal it should be buffed to a collet that threads onto stud and a housing that slips
high finish. Generally it is impossible to repair cracks; over the collet. Tighten bolt on top of the housing and
however, welding operations may be performed in draw collet into housing to lock puller on the stud with
some parts of housings, providing the area is not a a tight grip.
stressed section of the part. For example, almost any
area of a rocker box may be welded, but no part ofthe b. If the collet type tool cannot be used, drill a
cylinder head except the fins may be welded. small hole into the stud. Employ a pilot bushing to
guide drill into center of stud when stud is broken be-
3-28. PAINTED PARTS. Parts requiring use of paint neath the surface of the crankcase. Redrill the hole
for protection or appearance should be painted in ac- to enlarge it to accomodate the proper size extractor.
cordance with the following recommendations using Using the extractor, remove the stud.
material from the following list of approved materials.
Thinner - Toluene or equivalent (AMS3180 or equiva- c. After studs have been removed, check for size
lent Federal Spec. TT-T-548). Primer - Zinc chro- and condition of threads in stud holes to determine
mate (AMS3110 or equivalent MIL-P-8585). Enamel - whether oversize studs must be used for replacement.
Phthalate resin type (AMS3125C or equivalent MIL- Coat threads of studs with thread lubricant, Specifica-
E-7729). tion JAN-A-669, and drive stud to correct depth by
using a suitable stud driver.
NOTE
3-34. CORROSION-PREVENTION. At the conclusion
All machined bosses should be masked of all repair operations and subsequent inspection,
before painting. Do not paint areas under coat all steel parts with preservative oil.
hold down nuts where torque is required.
REASSEMBLY
3-29. Aluminum and Steel Parts. Parts shall be clean-
ed and degreased prior to painting. Apply one coat sinc 3-35. CORROSION-PREVENTION. Prior to assembly
chromate primer, thinned with approximately two parts of subassemblies, all parts should be cleaned to re-
toluene, and air dry. Apply one coat of enamel and move all traces of preservative oil and accumulated
bake at 250°F, to 300°F, for one-half hour. Enamel foreign matter. During assembly, Cover all steel parts
may be allowed to air dry but an inferior finish will with a heavy coat of preservative oil. This mixture
result. Parts from which paint has not been removed should be used on all machined surfaces, especially
may be repainted omitting the primer coat. on bearing surfaces, cylinder bores and piston rings.
The practice of using plain lubricating oil during as-
3-30. Magnesium Parts. Magnesium parts should be sembly is not recommended.
cleaned thoroughly with a dichromate treatment prior
to painting. T his treatment consists of cleaning all 3-36. PRE-LUBRICATION OF PARTS PRIOR TO AS-
traces of oil and grease from the part by using a neu- SEMBLY. Many premature failure of parts have been
tral, non-corrosive degreasing medium followed by a traced directly to improper pre-lubrication at engine
c. Visually, and by feel, determine if the edges of and gaskets throughout the engine. For complete re-
the mating gears are even. If the edge of one gear pro- placement sets of seals and gaskets available for these
trudes beyond the edge of the other, remove shims engines, consult applicable parts catalog.
from the protruding gear and add shims of equal thick-
ness to the other gear to achieve pitch alignment ofthe 3-48. ARBITRARY REPLACEMENT OF PARTS. Itis
gears. recommended that certain parts throughout the engine
be replaced at normal overhaul regardless of their
NOTE apparent condition. Consult the latest edition of Service
Bulletin No. 240 for information on the replacing of
It is possible to perform step (c) prior to parts at overhaul. Included among these are the fol-
step (b); that is, pitch alignment can be lowing:
corrected before adjustment for backlash
is made provided these precepts are ob- All engine oil hose
served. The removal or addition of an equal All oil seals
amount of shim material from both gear All gaskets
mountings will change backlash but not All circlips, lockplates and retaining rings
pitch alignment. The removal or addition Piston rings
of shim material from one gear only will All exhaust valves (except Inconel alloy valves)
change backlash and pitch alignment and All exhaust valve retaining keys
the removal of shim material from one Crankshaft sludge tubes (where applicable)
gear with the addition of an equal amount Cylinder fin stabilizers
of shim material to the other gear will All bearing inserts (main and connecting rods)
change pitch alignment but not backlash. Magneto drive cushions
Stressed bolts and fastenings
3-45. It is strongly recommended that all overhaul Camshaft gear attaching bolts
facilities adapt a firm policy of checking pitch align- Connecting rod bolts and nuts
ment of bevel gears at the same time backlash is ad- Crankshaft flange bolts
justed during engine overhaul. Damaged Ignition cables
All laminated shims
3-46. TABLE OF LIMITS. The table of limits SSP- Crankshaft counterweight bushings
2070 should be consulted whenever it is desired to de-
termine the backlash and end clearance of gears, the
clearance between mating machined parts, the clear- 3-49. FUEL SUPPLY LINES (Fuel Injected Engines)
ance between moving parts which are in close contact The fuel supply lines to the nozzles can become damag-
with each other and the torque limits for various nuts, ed and will leak if not properly installed and clamped
screws and fastenings. at the correct locations. Consult Service Bulletins
Nos. 335 and 342 for inspection procedures, config-
3-47. OIL SEALS AND GASKETS. When building up uration of lines and location of clamps, and Service
an engine during major overhaul, replace all oil seals Instruction No. 1301 for identification of fuel line.
SECTION 4.
IGNITION SYSTEM
4-1. GENERAL. All subject four, six and eight cyl- latest revision of Service Instruction No. 1042 and
inder engines are equipped with high tension ignition Service Bulletin 359.
systems which deliver high tension current directly
tothe spark plug outlets. Some eight cylinder engines REMOVAL AND DISASSEMBLY
are equipped with a low tension ignition system. This
system carries the low tension current, produced by 4-8. IGNITION HARNESS. Removetheterminalsfrom
the magneto, through a lead to a transformer mounted the top and bottom spark plugs. Detach all clips, clamps
on the magneto. The high tension current, produced and grommet plates securing the leads to the engine.
by the transformer, is carried back through one outlet Complete the removal of the harness by detaching the
in the harness assembly to the magneto. The highten- outlet plates from the magneto. Note that the Slick har-
sion current is then distributed, by the magneto dist- ness used on some engines is supplied as an assembly
ributor finger, to individual spark plug outlets. with the magneto and it will not be necessary to sep-
arate the two.
4-2. MAGNETOS. Dual ignition is furnished by three
types of magnetos onAvco Lycomingengines. (1) Con- NOTE
ventional magneto, (2) impulse coupling magneto, and
(3) retard breaker magneto. Either an impulse coup- Before detaching clamps, Clips, grom-
ling or a retard breaker magneto is always used on met plates etc. , mark the location of each.
the left side of the engine. A brief description of the Differences in various installations make
impulse coupling magneto and the retard breaker mag- it impossible for this manual to point out
neto follows. the correct attaching pOints.
4-3. IMPULSE COUPLING MAGNETO. The purpose 4-9. MAGNETOS. (Four Cylinder Engines). Loosen
ofthe impulse coupling is: (1) To spin magnet (between and remove the 5/16-18 nuts, washers (also clamps on
impulse trips) faster than engine cranking speed, thus Slick and -1200 series magnetos) which secure the mag-
generating a better spark for starting; (2) automatically neto to the engine. See figure 4-1. Remove magneto
retard spark when starting engine. When engine is run- and gasket (1) Note that anadapter (7) is used with the
ning, the impulse coupling acts as a drive coupling for impulse coupling magneto. Remove this adapter and
the magneto. gasket (6). No further disassembly of the magneto is
4-4. RETARD BREAKER MAGNETO. The retard required other than the removal of the magneto gear
breaker magneto incorporated two sets of breaker (5) from the drive shaft. Replace the washer (4) and
points and provides a fixed retard and long duration nut (3) to prevent damage to the drive shaft threads.
boosted spark for easier starting. A source of DC
power and a starting vibrator are required to com- 4-10. MAGNETOS. (Six Cylinder Engines). Loosen
plete the installation and it is recommended that the and remove the 5/16-18 nuts, washers andlockwashers
magneto manufacturer be contacted for information on (also clamps on -1200 series). See figure 4-1. Remove
the various vibrators and switching arrangements magnetos, gaskets (1), adapters (7) and gaskets (6).
available. The -200, -700 and -1200 series magnetos Reach inside the drive pad and remove drive cushions
incorporate an integral feed-thru capacitor and re- (11) magneto gear and cushion retainer (5) and ball
quire no external noise filter in the magneto ground bearing (12). Disassemble the nut (3) and bushing (10),
lead. (drive coupling (13) from conventional and retard
breaker magnetos) and Woodruff keys (9) from the
4-5. ENGINE FIRING ORDER. 4 cylinder engines (ex- drive shaft.
cept LIO series) 1-3-2-4. LIO series 1-4-2-3. 6 cyl-
inder engines, 1-4-5-2-3-6. LIO series 1-6-3-2-5-4. NOTE
8 cylinder engines, 1-5-8-3-2-6-7-4.
See Service Instruction 1252 for the con-
4-6. IGNITION HARNESSES. Ignition harnesses vary version of 8 cylinder engine with -700
with the engine models; however, for purposes of des- series magnetos to -1200 series mag-
cription, all harnesses are composed of the same basic netos engine.
components. BaSically, each lead is composed of a
magneto terminal assembly, the ignition cable and the 4-11. MAGNETOS. (Eight Cylinder Engines). Loosen
spark plug end assembly. The number of leads in the the 5/16-18 nuts and remove the nuts, lockwashers
harness assembly is, of course, determined by the and clamps. Remove magnetos, gaskets (1), adapters
number of cylinders on the engine. (7) and gaskets (6). Reach inside the drive pad and re-
move the drive cushions (11), retainers (15), centering
4-7. SPARK PLUGS. For information relative to ap- plates (16) and magneto gears (5). No disassembly of
proved spark plugs for the subject engines consult the the -700 series magneto is required.
I til ~ i •
12
11\ ~
5 12 6
I
13
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o
S8- 700 SERIES MAGNETO DRIVE ASSEMBLIES
TABLE 4-1
1 Bottom 1 Right 32
3 Bottom 2 Right 24
2 Top 3 Right 38
4 Top 4 Right 32
1 Top 1 Left 41
3 Top 2 Left 34
2 Bottom 3 Left 32
4 Bottom 4 Left 25
INSPECTION
r
bly is in obviously new condition and is known to have MARK THIS TOOTH WITH
been recently installed, it is recommended that the COLORED PENCIL AND
harness be replaced at overhaul. ASSEMBLE BETWEEN
MARKED TEETH ON
4-13. MAGNETOS. As previously mentioned, this IDLER GEAR
manual will not endeavor to describe overhaul pro-
cedures for trade accessories. Consult the manufac-
turer I s applicable overhaul manual for inspection pro-
cedures.
-,
r--- __
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/ 2 3 4
12
4-22. MAGNETOS. As previously mentioned, this
overhaul manual will not endeavor to describe overhaul
1. Spring 7. Spark Plug Nut procedures for trade accessories. Consult the manu-
2. Sleeve (Insulator) 8. Hex Ferrule facturer's applicable manual for overhaul procedures.
3. Electrode Screw 9. Drive Ferrule However, Avco Lycoming Service Bulletins Nos. 183A,
4. Drive Ferrule 10. Electrode Screw 235A, 277, 311, 312, Service Instructions Nos. 1019,
5. Housing 11. Sleeve (Insulator) 1055, 1074, 1163, 1165 and Service Letters Nos. L122
6. Cable 12. Spring and L134A, contain information relative to the mag-
netos covered in this manual. These publications should
Figure 4-5. Lead Assembly (Slick) be consulted to ascertain if they affect your installation.
4-4 Revised October 1974
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 4
Ignition System
NOTE
ling will not move beyond the point where it trips and
the spark occurs. Reverse the rotation apprOximately
0
25 until the timing pin hole appears in the center of
the vent plug hole.
NOTE
FIRING ORDER
1-5-8-3-2-6-7-4
.~
!
HOUSING INDENT
c. Remove the switch, coil and retard leads b. Tighten the two setscrews that secure the
from their terminals in the distributor block. block in the magneto.
d. Loosen the two setscrews mounted radially in
c. Secure the harness to the magneto with four
the rear flange of the magneto and carefully re-
move the distributor block from the magneto. setscrews. Be sure the coil and retard leads are
not pinched between the magneto and the cable
e. Reach into the magneto and grasp the rotor. outlet plate.
Notethat when the rotor is turnedcounterclock-
wise tothe point of breaker opening it will spring d. Replace switch, coil and retard leads.
forward in a clockwise direction if it is releas-
ed; therefore it must be held in the counterclock- 4-49. When this has been accomplished the magneto
wise position while the magneto is rotated back is properly timed to the engine. If a recheck is re-
and forth until the breaker points begin to open. quired, or at anytime magneto timing is checked, it
is necessary to hold out the backlash from the gears
4-48. Tighten the magneto mounting clamps and re- as described in paragraph 4-47 and the accompanying
place the breather plug, shield, lockwasher and screw note, while a second person turns crankshaft through
in the 'T" opening, or if the distributor block was re- 20 degrees to firing position of No. 1 cylinder.
moved:
a. Connect the capacitor, coil and retard leads 4-50. IGNITION HARNESS. After the magnetos have
to their terminals in the distributor block and been timed to the engine, assemble the leads to the
position the distributor block carefully in place spark plugs. Consult the applicable wiring diagram for
in the magneto. Be sure the coil and retard leads your installation. See figure 4-7, 4-8, 4-9, 4-10 or
are not pinched between the block and the housing. 4-11.
SECTION 5.
ACCESSORY HOUSING
5-1. It is assumed, at this time, that the magnetos and 5-10. Vacuum Pump Driven Gear (Where applicable)
all accessories have been removed from the accessory See figure 5-3. Remove the adapter (4) and gear (6)
housing. from the mounting pad on the upper right side of the
accessory housing.
5-2. Unless specifically called out tothe contrary, all
references to component parts will apply to all engines 5-11. Hydraulic Pump Driven Gear (Where applicable)
except those with a housing incorporating dual mag- Remove the adapter and gear from the mounting pad
netos in a single housing. These housings will be iden- on lower right side of the accessory housing.
tified as Dual Magneto Housings.
5-12. Propeller Governor Driven Gear (Where Appli-
DISASSEMBLY cable) See figure 5-3. Remove the propeller governor
oil line (12). Remove the adapter (10) from the mount-
5-3. Fuel Pump (Diaphragm type) - See figure 5-3. ing pad on lower right side of the accessory housing.
The fuel pump, (7) located at the lower left of the ac- Remove retaining ring (9), washer (5) from shaft gear
cessory housing, is removed by unscrewing the two and remove shaft gear (11) from adapter (10).
capscrews securing it to the housing.
5-13. Dual Drives - Vacuum Pump and Hydraulic
5- 4. Oil Pressure Screen Housing. (Where applicable) Pump - See figure 5-5. Remove brace (2), vacuum
See figure 5-1. This housing (3) located just above the and hydraulic pump adapter (13), and dual drive adapt-
center of the accessory housing, is removed by un- er (8). Remove accessory drive gear (9), dual acces-
screwing the four capscrews or three capscrews and sory drive gear (10), vacuum pump driven gear (12)
one nut (whichever is applicable) that secure it to the and idler gear (11).
accessory housing. On the 0-290-D series, the oil
cooler adapter is removed along with the oil pressure 5-14. Dual Drives - Vacuum Pump and Propeller Gov-
screen housing. ernor - See figure 5-5. Remove brace (2), vacuum
pump and propeller governor drive adapter (5), and
5-5. Thermostatic Valve and Oil Pressure Screen dual drive adapter (8). Remove accessory drive gear
Housing. See figure 5-1. This unit, (5) used on some (9), dual accessory drive gear (10), vacuum pump
installations, is located at the same place as the oil driven gear (12) and idler gear (11).
pressure screen housing described in paragraph 5-4
and is removed in the same manner.
5-15. Removal from Engine. The accessory housing
5-6. Oil Filter and Adapter. See figure 5-1. This unit, is removed from the engine by removing the attaching
usually installed as an option, replaces either the oil parts to the crankcase and oil sump. Since various
pressure screen housing or the thermostatic valve and gears are held in place through contact with the crank-
oil pressure screen housing. It can be removed as a case, put the housing on the bench with the inside up
unit from the accessory housing. Consult Service to avoid dropping loose gears.
Letter 157 for more detail information on all models.
5-16. See figure 5-4. If engine is equipped with "AN"
5-7. Oil Cooler Bypass Valve Assembly - See figure type fuelpump drive, remove the fuel pump idler gear
5-1. This assembly is used only in conjunction with (7) from the idler gear shaft (8). Remove the idler
the oil pressure screen housing and opening is plugged gear shaft from the housing.
when using either thermostatic valve or oil filter and
adapter. Remove plug (8), gasket (2), spring (7), and 5-17. Oil Pump. See figure 5-6. Remove the oil pump
plunger (12). body assembly from the accessory housing and detach
the oil pump impellers. Pull oil pump drive shaft from
5-8. Oil Filter (Dual Magneto Housing) See figure 5-2. the body. Do not remove the oil pump idler shaft un-
Remove filter assembly (11) by unscrewing the center less obvious damage is apparent. A later oil pump as-
bolt from the housing. Remove the thermostatic oil sembly (see figure 5-7) employs sintered iron impel-
cooler bypass valve (21) and gasket (20). Remove re- lers and the idler shaft and driven impeller are one
taining ring (10), sleeve (9), seat (8) and spring (7) of unit. In addition the oil pump drive shaft gear is keyed.
the oil filter by pass valve. These assemblies are not interchangeable.
5-9. Fuel Pump Driven Gear, AN Type (Where appli- 5-18. Oil Suction Tube (Where applicable) Removethe
cable) See figure 5-4. Removethe adapter (3) and gear cotter pins, nuts and washers from inside of housing
(5) from the mounting pad on the lower left side of the and bolts from the outside of the housing and remove
accessory housing. the oil suction tube.
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8. Cover 12. Propeller Governor Oil Line
Figure 5-3. Vacuum Pump and Propeller Governor Drive Assemblies and Propeller Governor Oil Line
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 5
Accessory Housing
5-19. Turbo Scavenge Pump (Where applicable) See on the accessory housing and assemble a washer and
figure 5-10 or 5-11. Disassemble as shown in the il- slotted nut on the studs. Tighten evenly and gradually,
lustration. turning the drive shaft while tightening to assure free
movement of the impellers. Tighten nuts to 150 inch
5-20. Oil Scavenge Pump (AIO-360, -320) See figure pounds torque and lockwire. The later oil pump as-
5-12. Disassemble as shown in the illustration. sembly employing sintered iron impellers is assem-
bled in the same manner with these exceptions. The
CLEANING driven impeller and idler shaft are manufactured as
a unit and the drive shaft is keyed. See figure 5-7.
5-21. Drilled Oil Passages. Remove all plugs from
oil passages. Particular care must be given to see CAUTION
that oil passages are thoroughly cleaned. Employ a
stiff bristle fibre brush and when the oil passages are Oil pump bodies are made for both clock-
cleaned, blowout the passages with a petroleum sol- wise and counterclockwise rotation en-
vent and air. Reinstall all threaded plugs. gines. Be sure you use the correct oil
pump body, these bodies are not inter-
5-22. Clean all accessory housing parts in accordance changeable.
with the general instructions as outlined in Section 3
of this manual 5-26. Oil Pump (Dual Magneto Housings) See figure
5-2. The oil pump assembly used in this series engines
INSPECTION is similar to and assembled in the same manner as
the first pump described in paragraph 5-25.
5-23. Replace all gaskets, oil seals, circlips and re-
taining rings during reassembly. 5-27. Oil Suction Tube. (Where applicable) Insert
two drilled bolts from the outside of the housing. As-
REPAIR AND REPLACEMENT semble a gasket and the oil suction tube over the bolt
ends and assemble plain washers, lockwashers and
5-24. Replace all gaskets, oil seals, circlips and re- slotted nuts and tighten to 75 inch pounds torque. Secure
taining rings during reassembly. with cotter pins.
10 II 9 8
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1. Gasket 7. Washer
2. Brace 8. Dual Drive Adapter
3. Cover 9. Accessory Drive Gear
4. Oil Seal 10. Dual Accessory Drive Gear
5. Vacuum Pump and Prop. Gov. Dual Drive Adapter 11. Idler Gear
6. Spacer 12. Vacuum Pump Driven Gear
13. Vacuum Pump and Hydraulic Pump Dual Drive Assembly
Figure 5-5. Vacuum Pump and Hydraulic Pump Dual Drive Assembly
(E ngines with AN fuel pump drive) and install the thrust are inserted from the crankcase side through holes in
washer and retaining ring that holds the idler gear on front of the right magneto. The two 1/4-20 x 1-3/4
the shaft. Be sure that a new oil seal has been inserted hex head bolts are inserted in the two holes adjacent
in the tachometer drive shaft bore. Rotate the oil to the left magneto. Assemble all bolts with plain wash-
pump drive shaft so that the lobes on the shaft align ers and lock washers.
withslots in the crankshaft gear. Note that in the Dual
Magneto Housing the oil pump drive shaft meshes with 5-30. Vacuum Pump Drive. See figure 5-3. If the en-
the crankshaft idler gear. gine is equipped with a vacuum pump drive, assemble
the unit as follows: Insert a new oil seal (3) into the
5-29. Apply a liberal coating of engine oil to the tach- recess in the pump side of the vacuum pump adapter
ometer drive shaft and all other contact surfaces, such assembly (4). Make sure that seal is inserted with the
as gear teeth and idler gear hub. Carefully fit the ac- grooved side toward the adapter. Place a new acces-
cessory housing in place on rear of crankcase, guiding sory driven gear washer (5) over the shaft of the vacuum
the housing first over the tachometer drive shaft and pump driven gear (6), lubricate the shaft, and insert
then on to the locating dowels: Secure the housing in the gear into the adapter being careful not to push oil
place with ten 1/4-20 x 15/16 hex head bolts and two seal out of its seat. Using a new gasket attach the adapt-
1/4-20 x 1-3/4 bolts. Two ofthe 1/4-20 x 15/16 bolts er tothe upper right side of the accessory housing with
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OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 5
Accessory Housing
5-33. "AN" Fuel Pump Drive. See figure 5-4. If the ing, using a new gasket, and install the bracket between
engine is equipped with an "AN" fuel pump drive, as- the vacuum pump pad and pressure screen housing
semble the unit as follows: Insert a new oil seal (1) mounting flange. Use spacer washers under ends of
into the recess in the pump side of the fuel pump adapt- brace if required for proper seating.
er assembly (3). Make sure that the seal is inserted
with the grooved side toward the adapter. Insert the CA ur ION
fuel pump driven gear (5) into the adapter being care-
ful not to damage the seal. Using a new gasket attach Brace must be seated properly so there is
the assembly to the lower left side of the accessory no stress at either end of bracket when nuts
housing with nuts, plain wahser and lockwashers. If are tightened.
the engine is equipped with fuel pump drive only place
a cover over the exposed end of the drive. If the en- 5-35. See figure 5-5. Dual Drive (Vacuum Pump and
gine is equipped with an AN fuel pump, install the Hydraulic Pump). If the engine is equipped with a vac-
pump on the adapter instead of the cover. uum pump and hydraulic pump dual drive, mount the
drive ass€mbly on the vacuum pump mounting pad at
5-34. See figure 5-5. Dual Drive (Vacuum Pump and the upper right side and fasten with a 1/4-20 nut, plain
Propeller Governor) If the engine is equipped with a washer and lock washer on the short stud in the acces-
vacuum pump and propeller governor dual drive, mount sory housing. Install the vacuum pump and hydraulic
the drive assembly on the vacuum pump mounting pad pump on the dual drive housing and fasten with required
at the upper right side and fasten with a 1/4-20 nut, nuts and washers; then install the bracket between the
three 1/4-20 socket head capscrews, and required vacuum pump pad and pressure screen housing flange.
plain washers and lock washers. Mount the vacuum Use spacer washers under end of brace if required for
pump and propeller governor on the dual drive hous- proper seating.
11
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Figure 5-11. Turbo Scavenge Pump and Governor Drive Assembly (0-360)
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I .. 0
.....
..... Figure 5-12. Oil Scavenge Pump Assembly (AIO-320, -360)
;. :s
CAUl
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 6
Cylinders, Pistons,
and Valve Train
SECTION 6.
CYLINDERS, PISTONS AND
VALVE TRAIN
6-1. The piston, being a reciprocating part, is nor- 6- 6. INTERCYLINDER BAFFLES. (Where applicable)
mally grouped with the crankshaft in a theoretical Using the intercylinder baffle tool (64885), turn the
breakdown of the engine into basic components. How- baffle retaining hooksO that it disengages the retainer.
ever, from a practical standpoint, it is felt that the Remove the intercylinder baffle and hook from between
piston should be considered with the cylinder insofar the cylinders.
as overhaul procedures are concerned. For example,
the basic configuration of the engine requires the re- 6-7. OILDRAINTUBES. Loosen hose clamps atlower
moval and reassembly of the pistons at the same time end of tube and slide tube out of hose. Loosen gland
the cylinders are removed or replaced. nut at cylinder head fitting and remove drain tube.
6-2. For the purposes of this manual, the valve train 6-8. Deleted
will be considered as all parts of the valve operating
mechanism beyond the camshaft, beginning with the
hydraulic tappet assembly.
6-9. Deleted
6-3. Although subject engines employ either parallel
valve cylinders or angle valve cylinders with either up
exhaust or down exhaust, basic overhaul procedures 6-10. CYLINDER ASSEMBLY (All models) Remove
are the same for all cylinders. The overhaul proce- rocker box covers and gaskets. Rotate the crankshaft
dures described in this section will be applicable to to place the piston of No. 1 cylinder at top center of
all cylinder assemblies except as noted. the compression stroke. (With the piston in this posi-
tion both valves will be closed and too piston exgended
6-4. Either plain steel, chrome plated, or nitride away from the crankcase to avoid damage when the
hardened steel cylinders may be employed on the en- cylinder is removed. )
gines discussed in this overhaul manual. The color 6-11. PARALLEL VALVE CYLINDERS (Except-
code for these cylinders is as follows: 0-235, 0-290-D, -D2) See figure 6-1. Remove the
valve rocker shaft (8) and remove valve rockers (5)
a. Plain steel All grey and valve stem cap from exhaust valve stem. Remove
the push rod by grasping the end and pulling through the
b. Chrome plated Orange paint on cylinder shroud tube (1). Remove the plain nut (4) lockplate (3)
fins below spark plug spring (2) and spacer. Pull the shroud tube (1) through
hole. the cylinder head and discard the shroud tube seals.
c. Nitride hardened Blue paint on cy linder fins 6-12. (0-235, 0-290-D, -D2). See figure 6-3. Re-
steel below spark plug hole. move valve adjusting nuts (19) and screws (18). Note
that the shroud tubes on these models cannot be re-
d. . 010 inch oversize Green when applied to moved until the cylinder is removed. Remove the valve
plain cylinders customer overhaul en- rocker shafts (14) and valve rockers (13 or 17). Re-
gines. move the push rods (12) from the shroud tubes.
e . . 020inchoversize Yellow when applied to 6-13. ANGLE VALVE CYLINDERS. See figure 6-5 or
plain cylinders customer overhaul en- 6-6. Remove rocker shaft covers (31) and gaskets.
gines. Push valve rockers shafts (20) outward to allow clear-
ance for removal of valve rockers (22) and thrust wash-
ers (23). Remove valve stem cap (32). Do not attempt
NOTE
to remove valve rocker shafts until the cylinder is re-
moved. Remove the push rods (13) by pulling through
A yellow color, on fins ABOVE spark plug
hole, indicates that long reach spark plugs the shroud tube (18). Using shroud tube wrench (ST-142)
are used. turn each shroud tube 90° either way, this releases
the detent on tube from spring. Remove the tubes by
first releaSing them from the seal seats in cylinder
REMOV AL FROM ENGINE head and then withdrawing tubes from seal retamers in
crankcase. Remove shroud tube seal sleeves (19) and
seals (14) from end of shroud tubes; also remove
6-5. It is assumed that the ignition harness, intake seals from crankcase. Discard all seals. Place washer
pipes and primer or fuelinjection lines have been pre- (15), springs (17) and sleeves (19) in the cleaning bas-
viously removed. keto
Revised May, 1972 6-1
Section 6 OVERHAUL MANUAL· LYCOMING DIRECT DRIVE AIRCRAFT ENGINES
Cylinders, Pistons,
and Valve Train
CAUTION
9 8
It is imperative that the various parts of
each tappet assembly be kept together dur-
1. Shroud Tube 6. Rocker Box ing all overhaul operations, in order that
2. Shroud Tube Spring 7. Valve Spring Seat all component parts may be reassembled
3. Shroud Tube Lockplate 8. Valve Rocker Shaft with theri original mating parts and each
4. Plain Nut 9. Valve Keys completed assembly inserted in its orig-
5. Valve Rocker inal location in the crankcase.
CAUTION
CAUTION
33 ~ !:(
n
32 <:)
\
'--------30
0
~
29 Z
Q
-
"-'"
31 ~ 28
27
~
'
1ft
n
-t
~
3. Inner valve spring seat
4. 1/2 inch cylinder base nut 15. Rocker shaft bushing 22
(0-290-D, -D2) 16. Exhaust valve guide
21
,..'"
"II
5. 3/8 inch cylinder base nut 17. Valve rocker
(0-290-D, -D2) (0-235-C,0-290-D) 20 / -t
1ft
6. Exhaust valve seat 18. Valve adjusting screw z
7. Intake valve seat (0-235-C,0-290-D) s:!
8. Exhaust valve 19. Nut (0-235-C, 0-290-D) Z
1ft
9. Intake valve 20. Screw &II
10. Shroud tube seal 21. Rocker box cover
11. Shroud tube 22. Intake valve guide n
12. Push rod
" _.
Q~
10
36. Valves ,..
::z:
37. Exhaust flange c
I""
II 38. Gasket
39. Valve stem cap
,..
~
Z
,..
c
I""
•
38
37 -------... ~
n
0
-
~
Z
Ci)
1. Valve retaining keys
2. Outer valve spring seats ~
:l1li
3. Outer valve springs
4.
5.
Auxiliary valve springs
Lower valve spring seats
35 ",""" ...n'"
~
6. Valve guides 33 :l1li
7. 3/8 inch nut <:
8. 1/2 inch nut 34----... '"~
9. Cylinder hold-down plate 23 :l1li
n
10. Valve seats
......,..
11. Grommet plate (V0-360, IVO-360)
24 :l1li
12. Exhaust valve oil line (VO-360, IVO-360) 25
13. Connector (VO-360, IVO-36'0)
14. Shroud tube '"
Z
15. Shroud tube seal S!
16. Push rod z
17. Heli-coil insert (spark plug) '"
VI
18. Shroud tube seal 26
19. Spacer 32 Gl=tW} ~ 11)
~£.
20. Springs 23. Valve rocker bushing !
1
24. Rocker box cover gasket
25. Rocker box cover
J. ..
:
10
26.
27.
28.
29.
Rocker shaft bushing
Oil seal ring
Intake valve
Exhaust valve
30.
31.
Exhaust valve seat
Valve rocker shaft cover m
~
32. Valve stem cap ;Ia
:z:
~
i; II ,..c
31-... .... ~
~
Z
c
,..~
I
~ 13
..... ~
8 n
o
~
Z
J 18 Q
-
tJ
27 ,
1j£ ;Ia
m
n
-I
tJ
;Ia
<:
m
!:
;Ia
n;Ia
26
1. Valve retaining keys 12. Intake valve seat
...
~
-I
2. Outer valve spring seats 13. Push rod m
3. Auxiliary valve springs 14. Shroud tube seals Z
Q
4. Outer valve springs 15. Shroud tube washer
5. Lower valve spring seats 16. Exhaust flange Z
m
2°~(!f
l1li
6. Heli-coil insert (spark plug) 17. Shroud tube spring
7. Valve guides 18. Shroud tube
8. 3/8 inch nuts 10. Shroud tube seal sleeve a~
=:
::I
9. 1/2 inch nuts 20. Valve rocker shaft a..'"
10. Cylinder hold-down plate 21. Valve rocker bushing a<f:-
~
:c.!" VI
11. Fin stabilizers 22. Valve rockers _. n
.. "II"
0>
I
a'ii-
_. ::I ::I
CJl Figure 6-5. Angle Valve Cylinder Assembly - Down Exhaust :I ~ 0\
21 22 23
m 19. Shroud tube seal sleeve an",
I " '< ..
m 20. Valve rocker shafts ~ ;- ;.
21. Valve rocker bushing !!.. ~ g
22. Valve rockers ....",
~ !!' 0\
23. Valve rocker thrust washer;; s:
24. Rocker box cover gasket ii' g
25. Rocker box cover ,..
26. Rocker shaft bushing
27. Cylinder base oil seal ring ~
1ft
28. Intake valve lIIII
::z:
,.---------\2
J \3
29.
30.
31.
Exhaust valve
Exhaust valve seat
Rocker shaft cover
....c •
,------\4 32. Exhaust valve cap ~
,-----\5 33.
34.
Rocker box drain tube
Drain tube hose
Z
c
•
-------32 \6 35. Drain tube hose nipple .... ••
3\
!(
26 • n
o
1\--_---1 ~
Z
Q
11~
28
29 1/ jJ ..
11-20
o
lIIII
1ft
...
n
1
~/
•;a
34-~
5. Lower valve spring seats 22
n
6. Spark plug insert 23 :IV
...•
7. Valve guides 33 ,,-, 24
"
"II
8. 3/8 inch cylinder base nut
9.
10.
1/2 inch cylinder base nut
Cylinder hold down plate
... 1ft
Z
11. Fin stabilizer ~
12. Intake valve seat Z
1ft
VI
13. Push rod
20~
14. Shroud tube oil seals
ea#J
15.
16.
Shroud tube washer
Exhaust flange :~--- cit' jJ
17. Shroud tube spring &~
18. Shroud tube 23
Figure 6-6. Angle Valve Cylinder Assembly (Up Exhaust)
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 6
Cylinders, Pistons,
and Valve Train
DISASSEMBLY
INSPECTION
6-S
OVERHAUL MANUAl LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 6
Cylinders, Pistons,
and Valve Train
6-28. CYLINDER BARREL (VISUAL INSPECTION)"
In addition to a thorough inspection of the cylinder bar-
rel to ascertain its general condition, make the fol-
lowing specific checks: ]--NICKS OR SCRATCHES
IN THIS AREA ARE CAUSE
a. Cooling Fins. It is recommended that notches FOR REJECTION.
or nicks be profiled with a hand grinder or file. A
cracked cylinder barrel is cause for rejection of the
cylinder.
6-9
Section 6 OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES
Cylinders, Pistons,
and Valve Train
6-40. USing an optical magnifier, examing the valve in
. , . . - - - FACE OF VALVE MUST RUN
the stem area and the tip for evidence of cracks, nicks,
TRUE WITH STEM WITHIN tool marks, or other indications of damage. Damage
.0015 of this nature seriously weakens the valve, making it
liable to failure. Any valve having a nick, with ragged
edges more than 1/16 inch in length should not be re-
used. A nick or tool mark of any sort in the keeper
groove of an exhaust valve is sufficient reason for not
reusing the valve. See figure 6-12.
GROOVE UNDER HEAD PiMPLES UNDER HEAD I-GROOVE 2-GROOVE UNDERCUT DOUBLE RIB
6-50. HYDRAULIC PLUNGER ASSEMBLY. Various a. Dip the plunger in light machine or engine oil.
hydraulic plunger assemblies are used in subject en- (Extra fast leakdown only. All other plunger assem-
gines. (Consult Service Instruction No. 1011). These blies must be checked dry. )
assemblies are differentiated by the leakdown rate. At
disassembly of the engine check the PiN on the hyd-
raulic plunger assembly. Hydraulic plunger assem- b. Hold the hydraulic cy linder between the thumb
blies must be used in sets and it is not permissible to and middle finger in a vertical position with one hand;
mix assemblies in the same engine. It is recommended thenplace the plunger inposition so that it just enters
the following procedure be followed at overhaul: the cylinder (figure 6-25).
Clci"
install new hydraulic plunger assemblies.
6-52. Line the hydraulic plunger assemblies side by WORN BODY NEW BODY
side on a flat surface and lay a straight edge across
the shoulder surface (figure 6-24). Any plunger as-
sembly that is more than 1/32 inch below the straight Figure 6-20. Appearance of Interior Shoulder
edge is "collapsed" and must be rejected. in New and Worn Tappet Bodies
COPPER
BRAZE
DR. ~TAP .t -20
~ DE.£P
-~-
IX XI;
'1
.L-_ _ _ _ _~_~_L_
3
5
4 I
*-20Xn F.HD.
tDIA.)(Z
COPPER
MCH;SCR.
C.R.S.
d. When the plunger does not bounce back but re- that any of the parts are magnetized, the plunger as-
mains collapsed, it is an indication that the ball check sembly must be replaced.
valve is not seating properly. When this condition ex-
ists, the hydraulic plunger assembly is defective and 6-58. VALVE SPRINGS. Check the condition of all
must be replaced. valve springs on a suitable spring tester, using the
NOTE loads and deflections as given in references 800 and
801, Table of Limits.
When an intake or exhaust valve hydraulic
plunger assembly has proven to be defec- MODIFICATIONS
tive, the valve itself must be replaced as
well as the hydraulic plunger assembly. 6-59. Several modifications have been made to var-
ious installations of the subject engines. It is sug-
6-56. To assemble the unit, unseat the ball by inserting gested that the following publications be consulted to
a thin clean bronze wire through the oil inlet hole. ascertain whether or not your particular installation
With the ball off its seat, insert the plunger and twist has been affected. Avco Lycoming Service Bulletin
clockwise so that the spring catches. No. 253 and 273. Avco Lycoming Service Instruction
No. 1035, 1073, 1123, 1135, 1136, 1262, 1280 and 1302.
6-57. DETECTION OF MAGNETIZED HYDRAULIC REPAIR AND REPLACEMENT
PLUNGER ASSEMBLIES. If the parts of ths plunger
assembly become magnetized the plunger may remain 6-60. General instructions for the repair of cylinder,
in a collapsed position. Check the parts for magne- piston and valve train parts will be found in Section m.
tization with a compass or small iron wire. In the event Specific Instructions follow.
Revised October 1974 6-13
Section 6 OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES
Cylinders, Pistons,
and Valve Train
NOTE
Figure 626. Valve Seat Dimensions for Reconditioning
-----PILOT
Valve Guide ID
REPLACEMENT DRIFT
6- 94. Angle Valve Cylinders. Install new rocker shaft 6-101. Burnish the bushing by using an arbor press to
bushings in the following manner: place the stop of the pass the valve rocker bushing burnisher (64541) com-
outer rocker shaft bushing installation drift (64815) pletely through the bushing. Remove the rocker from
between the inner rocker shaft bushing boss and the the fixture and check the finished ID with the valve
outer rocker shaft bushing boss. Assemble new bush- rocker bushing finish ID gage.
ing on drift, insert drift pilot through boss into stop
and tap bushing into place. Assemble the new bushing 6-102. Regrinding Cylinder Barrels. All unplated cyl-
on the pilot of the inner rocker shaft bushing instal- inder barrels which exceed allowable service limits
lation drift (64816) and position bushing and pilot. In- in diameter, taper or out-of-roundness, must be re-
sert drift through outer bushing into pilot and tap in- ground to .010 or .020 oversize. Nitrided cylinder
ner bushing into place. barrels employed on the 0-360-B, -D and 0-540-B
low compression engines may be ground to .010 over-
6-95. Parallel Valve Cylinders. Install new rocker size. Do not attempt to regrind a barrel on light weight
shaft bushings in the following manner: Place a new grinders such as block mounted automotive or similar
bushing on the driver of the inner rocker shaft bushing type machine.
installation drift (64825) and locate bushing and driver
in front of inner rocker shaft bushing hole in cylinder NOTE
head. Insert the pilot of the inner rocker shaft bush-
ing installation drift through the outer bushing hole and Only the nitrided barrels employed on the
tap inner bushing in place. When installing the outer series engines listed in the above para-
rocker shaft bushing, install the stop of the outer rocker graph may be reground oversize. All other
shaft bushing installation drift (64824) between the inner nitrided barrels must be either re- bar-
and outer rocker shaft bushing holes in the cylinder reled or reconditioned by chrome plating.
head. Place a new bushing on the outer rocker shaft
bushing installation drift and tap into place. 6-103. The oversize to which the cylinder is ground
must be determined by adding 0.004 of an inch (clean
6-96. Angle Valve Cylinders. After installing new up allowance) to the barrel diameter measured at the
rocker shaft bushing in cylinder head, ream the bush- point of greatest wear. This measured addition should
ing inside diameter. To do this, place the pilot of the not exceed 0.002 of an inch per wall. The barrel is
outer rocker shaft bushing ID semi-finish reamer then ground to the oversize above this figure. Unplated
(64819) through the outer bushing. Place the inner barrels with wear exceeding. 020 of an inch or appli-
rocker shaft bushing ID semi-finish reamer (64820) cable nitrided barrels with wear exceeding. 010 of an
through the outer bushing and ream the inner bushing. inch must be replaced. See reference 522, Table of
Repeat the same procedure, this time using the outer Limits.
and inner finish reamer (64821 and 64822). Check the
finish ID hole in the rocker shaft bushings with the 6-104. The following data are included as a guide in
rocker shaft bushing ID plug gage (64823). Clean the selecting an efficient wheel and set up for grinding
cylinder and reamed hole thoroughly. barrels to an oversize dimension.
6-97. Parallel Valve Cylinders. After installing new A. Unplated Steel Barrels
rocker shaft bushings in cylinder head, place the pilot
of the inner and outer rocker shaft bushing ID finish 1. Wheel
be fitted with corresponding oversize rings and pis- opposite the equalizer gap. Compress the assembly
tons and identified as diredted in Service Instruction several times with the fingers to make sure the ring
No. 1181. lies free and loose in the groove. Both the equalizer
6-107. Infield servicewhere one cylinder is worn be- and the regulating ring are symmetrical and may be in-
yond maximum limits, the worn cylinder and its op- stalled with either side upward.
posite cylinder should be reground to the same over- 6~ 116. Install compression rings in the remaining top
size dimensions and oversize pistons and rings be grooves. The compression rings are etched on one
used to maintain proper dynamic balance. side with the work "Top" and this side must be instal-
6-108. During complete engine overhaul when one or led with this side toward the top of the piston.
more cylinders require grinding, all cylinders should
be ground to the same oversize dimension. 6-117. (0-235-C). Invert the piston on the bench and
install the scraper ring in the groove below the piston
6-109. Reconditioning Nitrided Cylinder Barrels. Al- pin hole. Install the scraper ring with the scraping
though only the series engines listed in paragraph 6-102 edge toward the top of the piston.
may be ground oversize, other nitrided barrels can be WARNING
reconditioned by chrome plating or in some cases by
re- barreling. Consult the latest edition of Service Inst- Do not under any circumstances assemble
ruction No. 1047 for information relative to recondi- chrome plated piston rings in a chrome
tioning nitrided barrels. plated cylinder barrel. If in doubt as tothe
proper combination of rings to be used, re-
6-110. Reconditioning Chrome Plated Barrels. Al- fer to the latest edition of Service Instruc-
though it is not practical to remove wear steps by re- tion No. 1037 or contact the Service De-
grinding, such barrels can be restored by a stripping partment, Avco Lycoming Division.
6-135. Angle Valve Cylinder. Slide rocker shaft back valve clearance gage. Valve rocker clearance on all
and install rocker (22, figure 6-6) and thrust washer subject engines is .028 - .080. If clearance is out of
(23, figure 6-6). Before installing exhaust valve rock- limits adjust by using a shorter or longer push rod. In-
er place special cap (32, figure 6-6) over the exhaust serting a longer rod will decrease the clearance. Con-
valve stem. Slide rocker shaft back into position. Re- sult Service Instruction No. 1060 for identification of
peat with the other rocker arm and thrust washer. If push rods. At conclusion of valve rocker clearance
clearance between the valve rocker and cylinder head check, assemble rocker shaft covers (31 figure 6-5 or
cannot be brought within limits (See Table of Limits) 6-6) on angle valve cylinders temporarily to prevent
by the use of standard valve rocker thrust washers, displacement of valve rockers.
clean up the worn valve rocker support boss as de-
scribed in paragraph 6-87 and use any two of the selec- 6-137. (0-235-C, 0-290-D.) Set tappet clearance on
tive fit undersize washers to bring clearance' within these models in the following manner:
limits.
a. Set tappets on numbers 2 and 4 cylinders at zero
CAUfION clearance. This will load the camshaft on one side.
Exhaust and intake rocker assemblies are b. Rotate the crankshaft until No. 1 piston is at TDC
different due to angle of valves. Be sure of the compression stroke. Both valves will now be
rockers are correctly assembled. closed. Adjust each for a 0.007/0.009 clearance.
6-136. (All engines except 0-235, 0-290-D.) Check c. Following the procedure set forth in step "B" for
dry or unloaded valve tappet clearance by pushing in on numbers 3, 2 and 4 in that order.
push rod end of valve rocker and checking clearance
between end of valve rocker and valve stem tip, using d. Tappet clearance mustbe checked after engine
run-in. At that time clearance desired is O. 010 inch.
However, 0.006/0.012 is acceptable.
NOTE
NO. 10 On earlier models of the 10-540 series
some leaking at the rocker shaft cover stud
was experienced. This can be corrected by
the application to the studs of Gasoila, a
3.50
sealant manufactured by the Federal Pro-
3.38 3.81 cess Co. Be certain to wipe off excessive
3.69
sealant from the rocker shaft cover mount-
FIN NO.1 ing surface.
FIN NO.2
6-139. Installation of Cylinder Head Fin Stabilizers.
(Angle Valve Cylinders). Clean the stabilizers and af-
fected fin areas thoroughly to remove all traces of
Ftl NO.13 grease, dirt or other foreign matter.
FIN NO.14
6-140. Apply Dow CorningSilastic 140 adhesivetothe
fin stabilizers and press surfaces together in the loca-
tions described in figures 6-33 and 6-34.
NOTE
SECTION VII
CRANKCASE, CRANKSHAFT AND
RECIPROCATING PARTS
7-1. At this time it is assumed that all accessories, 7-9. From this point disassembly is the same for all
cylinders, accessory housing and sump have been re- crankcases. Reach down through the cylinder pads and
moved from the engine. push the left half of each main bearing insert down on
the crankshaft so they will not fall when the crankcase
DISASSEMBLY half is removed. Separate the crankcase by hand and
remove the bearing inserts, tappets, camshaft and
7-2. Starter Ring Gear Support - Remove the starter crankshaft assembly. Place each tappet body, as it is
ring gear support assembly (32, figure 7-5) from the removed, in its proper location in the cleaning basket.
crankshaft propeller flange by tapping lightly on the This is important as tappet bodies must be replaced
rear face ofthe assembly. The alternator or generator in the same location from which they were removed.
drive belt will be removed with this unit.
NOTE
7- 3. Prope ller Governor Oil Line. (Engines equipped
with propeller governor on accessory housing. ) If this
In the left crankcase half the intake tappet
line was not disassembled when removing the acces-
for its corresponding cylinder is located
sory housing, remove from the front of the crankcase
nearest the front of the crankcase, while
by unscrewing the threaded fitting.
in the right crankcase half the intake tap-
pet is nearest the rear of the crankcase.
7-4. See figure 7-5. Remove the crankshaft idler gears
(22) from the idler gear shafts (29). On engines em- 7-10. Propeller Governor Drive (Located on front left
ploying camshafts with separate gears, remove the side of crankcase). See figures 7-3 and 7-4. Remove
breather slinger (19), camshaft gear (14), and tach- the hex head plug (6) and gasket (5) from the propeller
ometer shaft spacer (18) by removing the 4 hex head governor housing. Remove the idler shaft (4) through
bolts (21) and lockplate (20) securing the assembly to the opening in the housing at the same time supporting
the camshaft. Remove the tachometer drive shaft (16) the idler gear (9) to prevent dropping and damaging.
by removing the pin (15). See figure 7-6. On engines Note that the idler shaft on four cylinder engines is pin-
using integral camshafts, remove the retaining ring ned to the housing. Pull the governor driven gear (8)
(14) and tachometer shaft spacer (13). Remove pin (11) from the housing.
and tachometer shaft (12).
7-11. Crankcase - Remove all threaded plugs to facili-
7- 5. Remove the nuts and bolts, from the parting sur-
tate cleaning. Remove and discard the rubber oil seals
face of the crankcase, which hold the crankcase halves enCircling the studs. (Doweled crankcases do not em-
together. Remove the crankcase from the overhaul
ploy oil seals at the dowels). Where applicable re-
stand and place on the work bench.
move the piston cooling oil jets (17, figure 7-1).
7-6. Remove oil filler tube. See figure 7-1. Remove
7-12. Remove the two crankshaft idler gear shafts from
oil pressure relief valve assembly (23 or 24). Remove
the rear of the crankcase halves. On the eight cylinder
oil seal retainer plates (19) (used on engines that do
engines remove also the two magneto drive gear shafts.
not have crankcase modified with machined groove to
accept oil seal with retaining lip on OD). 7-13. Camshaft Governor Drive Gear (6 and 8 cylinder
engines using camshaft with separate gears). See fig-
7-7. Hydro Control Valve. (0-235, 0-290 series.
ure 7- 5. Remove the governor drive gear (2) by re-
Where applicable.) See figure 7-15. Remove cotter
movingthe two external retaining rings (1) that secure
pin, slotted shear nut and hex head screw and remove
it to the camshaft.
lever. Remove the two 1/4 inch bolts securing the
cover tothe crankcase and remove the cover and valve
7-14. Crankshaft - With the crankshaft properly sup-
body.
ported at front and rear main bearings, remove the
7- 8. Crankcases that are doweled at the thru-studs (#2 nuts securing the rod caps to the connecting rod. Re-
saddle on 4 cylinder engines, #2 and 3 saddles on 6 move the rods by tapping on the rod bolts with a soft
cy linder engines and #2 - 3 and 4 saddles on 8 cylinder hammer. Discard the bearing inserts, bolts and nuts.
engines) must be separated by the use of pressure Reassemble each cap with its corresponding rod. Rods
plates (ST-122). Instructions for the use of the plates and caps are not interchangeable.
are given in figure 7-16. After the crankcase is sepa-
rated past the dowels remove the plates and lay the 7-15. To remove the crankshaft gear (26), flatten out
crankcase on the right side. Crankcases that are not the lockplate (24) and remove the hex head screw (23).
doweled may be separated by laying on the right side Tap the crankshaft gear gently, with a fibre drift, to
and gently tapping the thru- studs with a soft hammer. remove from the crankshaft. Do not remove the dowel
Wire the camshaft to the left crankcase half as shown from the rear end of the crankshaft unless it has been
in figure 7- 2. obviously damaged.
16~ I
24
__-------22---------.
17-f
n
21 20 19 18
1. Front Main Bearing Insert 9. Oil Relief Valve Plug 18. Crankshaft Oil Seal
2. Lifting Strap 10. Oil Relief Valve Screw 19. Retaining Plate
3. Oil Relief Valve Plug 11. Oil Relief Valve Plug 20. Washer
(Field Conversion) 12. Oil Relief Valve Insert 21. Screw
4. Ball 13. Oil Relief Valve Cap 22. Main Bearing Insert
5. Spring 14. 3/8-24 NF-3 Nut 23. Oil Relief Valve Assy.
6. Washer 15. Spring Pin (N on- adjustable)
7. Spacer 16. Oil Relief Valve Sleeve 24. Oil Relief Valve Assy.
8. Gasket 17. Piston Cooling Nozzle (Adjustable)
7-16. Remove the crankshaft oil seal (18, figure 7-1) CLEANING
from the crankshaft. Do not remove the propeller
flange bushings from the flange of the crankshaft unless 7-20. All crankcase, crankshaft and reCiprocating
they are damaged and/or loose. parts are cleaned in accordance with the general in-
structions outlined in Section 3. When cleaning the
7-17. Counterweights - See figure 7- 5. Counterweights crankshaft, clean the inSide of all crankpin and main
(8) are disassembled from the crankcase merely by bearing journals and all oil passages with suitable
removing the retaining rings (11), after which the brushes, after which flush thoroughly with clean sol-
washers (10), rollers (9) and counterweights (8) may vent and compressed air.
be detached from the crankshaft lug.
CAUTION
NOTE
Do not attempt under any circumstances to
All counterweights and their related parts clean the crankshaft without first removing
should be reassembled in the same location the crankshaft sludge tubes (where appli-
they occupied on the crankshaft before dis- cable). The solvent will loosen but not re-
assembly. For example, the retaining move accumulated sludge. This loose
washers used with the counterweights are sludge is certain either to form a stoppage
selectively fitted to the washer seats in the in the nearest oil passage, or to wash
counterweights during manufacture. It is through and cause a bearing failure.
advisable, therefore, to mark all counter-
weight parts during disassembly to insure 7-21. Piston Cooling Oil Jets. (Where applicable) Im-
proper identification. These markings
merse the piston cooling nozzle in petroleum solvent.
must be impermanent. No scoring, scratch- Hold the ball check valve off its seat in the nozzle by
ing, etching or other permanent marking
inserting a light copper wire or other relatively soft
of any kind is permissible on these parts. material through the threaded end of the nozzle and
wash thoroughly so that any dirt particles that may be
7-18. Sludge Tubes (4 cylinder engines - where appli-
under the ball seat will be waShed out.
cable). Remove the four crankshaft sludge tubes (30,
figure 7-5) with the sludge tube removal drift (P/N
64548) by placing drift end of the tool in the tube and
driving out the tube with the bar portion of the tool. 4 5 6
Do not clean the tubes but lay them aside to ascertain
the presence or absence of metal partic les in the sludge
deposits. Do not re-use sludge tubes. J..JJ
7-19. Sludge Tubes (6 and 8 cylinder engines - where
applicable). When removing either six or eight cyl-
inder engine sludge tubes use slide hammer puller
r
7
(P/N 64782) and an adapter. Adapter P/N 64547 for
six cylinder engines and adapter P /N 64784 for eight
cylinder engines. Remove the jaws from the slide ham-
mer puller and assemble the puller adapter on the
slide hammer puller. Remove collar from the adapter, 1. Dowel 6. Hex Head Plug
i-nsert the adapter through the sludge tube, and re- 2. Thrust Washer 7. Spring Pin
assemble the collar. Pull the tube out of the crankshaft 3. Idler Gear Bushings 8. Prop. Governor Driven
with a series of quick hard strokes of the slide ham- 4. Idler Gear Shaft Gear
mer. Do not clean tubes but lay them aside for exam- 5. Gasket 9. Prop. Governor Idler Gear
ination to ascertain the presence or absence of metal
particles in the sludge deposits. Do not re-use sludge Figure 7-3. Propeller Governor Drive
tubes. (4 cylinder engines with housing on crankcase)
I
bearings will be replaced with new bearings at overhaul or
Iupon removal from the engine. repaired or replaced. See Section 3 and paragraphs 7-44 thru
7-66.
7-24. Crankcase (Visual Inspection). Check carefully for
burrs, nicks and cracks around the bearing support webs. 7-28A. Crankshaft (Magnetic Particle Inspection). Inspect
Check bearing bores and inspect tang slots for any the crankshaft using a magnetic particle inspection
roughness that might cause improper seating of bearing procedure performed by a certified operator.
inserts. Check all drilled holes. a. Prior to magnetic particle inspection, completely
remove all traces of oil, grease, and dirt. This can be
7-25. Fretting on the contacting surfaces of the bearing accomplished best in a vapor degreaser using
saddle supports in the crankcase occurs on some engines. Trichlorethylene as a solvent or an equivalent
This condition is caused by slight motion between the environmentally friendly cleaning method. A 3 to 7
I contacting surfaces and results in abrasion of the metal power magnifying glass must also be used to aid in
surface. The affected areas have tiny pit holes and a frosted the inspection.
appearance, as contrasted to adjacent shiny unaffected
surfaces. See figure 7-7. This condition can be misleading b. Personnel performing the Magnetic Particle
because of its trivial appearance; nevertheless it can be the Inspection must be qualified and certified in
cause of severe engine damage. accordance with the latest revision of ASNT
Personnel Qualification SNT -TC-1 A or N AS-41 O.
7-26. Fretting, by itself in this area, does not appreciably
damage the structure of the metal, but the metal removed by c. The inspection technique must be capable of detecting
the fretting action does change the size of the bearing the smallest indication regardless of its orientation to
saddles sufficiently to cause loose thru-studs and undersize the magnetic flux. This technique must be able to
main bearing bores. If not detected during overhaul, establish two magnetic fields, perpendicular to one
excessively tight crankshaft bearing fits will result in another, in a plane parallel to the surface being
eventual engine failure. inspected.
CAUTION
"PID to be stamped
on this surface."
COATED SURFACE
Figure 7-4C.
temporarily (using new bearings) and check the crankpin 7-32. Camshaft (Dimensional Inspection). Support the
journal clearances in the same manner, see Table of Limits, camshaft in Vee blocks at its front and rear bearing journals
IReference 501. If clearances do not fall within prescribed I and check the run-out at the center bearing location. See
limits, the shaft must be brought undersize. See Repair and Reference 516, Table of Limits. Slight bending operations
Replacement section for instructions for regrinding. are permissible on the camshaft providing careful magnetic
inspection follows such procedures. Measure the diameter
7-31. Camshaft (Visual Inspection). Carefully inspect all I of the camshaft bearing journals and check them against the
surfaces of the camshaft for cracks, scoring, galling, bearings formed by the crankcase. Reference 514, Table of
corrosion, pitting or other damage; be particularly careful Limits.
when inspecting bearing surfaces. If a hydraulic tappet body
has been rejected for spalling, inspect the corresponding
cam lobe. Any indications of distress, surface irregularity or 7-33. Crankcase - Main Bearing Clearance. The following
feathering at the edge of the cam lobe is cause for rejection inspection of the engine listed below must be accomplished
of the camshaft. unless thru-studs are marked as shown in figure 7-11.
0-320-B Series Engines prior to 3815-39 7-35. Using cylinder base hold down plates and nuts, torque
0-340 Series Engines prior to 405-30 all thru-studs in the sequence shown in figures 7-21, 7-22 or
0-360-A, -C Series Engines prior to 3042-36 7-23.
0-540 Series Engines prior to 2790-40
0-290-D2
0-320
10-320
0.260 inch
0.260 inch
0.260 inch
/
A1O-320 0.260 inch
ATTEMPT TO INSERT.004' k : : ~\ '
0-360 0.370 inch FEELER GAGE HERE ~
ATTEMPT TO INSERT .004"
FEELER GAGE HERE
10-360
HO-360
0.370 inch
0.370 inch RIGHTCRAN<CASE
I
•.•. ~.'~' ---i--- //~.T~'
rx; ".
:xi' . '
HIO-360 0.370 inch Kqi) i ~.
§',
AIQ-360 0.370 inch 1>1 ~ ;x: ,
TIO-360 0.370 inch ,Xj'
:!tx;
fx: : ~~
'N
~~~~~~
0-540 (Except 0-540-G) 0.370 inch
0-540-G 0.430 inch
10-540 (Except IO-540-K, -M, -N and -R) 0.370 inch
IO-540-K, -M, -N,-R 0.430 inch .OOi·O~ERSIZE T: :TAP
CLEAN UP THREADS (TOOL NO 64907)
I g.
NO.4
CYLl~DER
88
L..-_ _ REPLACE THESE FOUR STUDS _ _-1
ON SIX CYLINDER SERIES
PILOT DIAMETER
TABLE 7-2 (MUST RUN TRUE WITH FRONT
AND REAR MAIN BEARINGS
Hole Size Reamer No. WITHIN .003)
.9369/.9377 None
.94201.9425 64874 (CHECK FLANGE RUN-OUT HERE AT
.9445/.9450 ST-210 .. r PERIPHERY OF CHAMFER
.94701.9475 64875
.9495/.9500 ST-211
.95201.9525 64876
~
fixture with the holes in the crankshaft lugs. Secure the ::{
/
to a suitable brace and proceed to hand ream the hole CADMIUM PLATE OVER THIS
in the crankshaft lug to proper size. / DISTANCE ONLY
4. Assemble the puller to the crankshaft in the same man- ENTIRE SURFACE AREA OF CRANKSHAFT
ner as described in "Step 1" except that the large puller IS NITRIDED EXCEPT PLATED AREA SHOWN
bushing is used instead of small puller bushing. Place the AND CRANKSHAFT GEAR MOUNTING SURFACE
correct size crankshaft bushing on the puller bolt, bet-
ween the crankshaft lug and the large puller bushing.
When the puller nut is tightened, the bushing will be forc-
ed into place in the crankshaft.
Figure 7-12. Limits for Straightening Bent Flange
CAUTION
new bushing in place in the rod. Be sure the split in the
The inside diameter of these bushings is finish- bushing is located so that it is toward the piston end of
ed at the factory and no further machining of the rod and 45 0 off the centerline.
bushing is necessary. Caution must be exercis-
ed when installing the bushings so that this 2. Use a suitable arbor press and the connecting rod
finished ID is not damaged. Because of possi- bushing burnisher (PIN 64580) to burnish bushing in
ble damage to the crankshaft, never, under any place. Pass the burnisher completely through the bushing.
circumstances, remove or install the roller Remove the rod from the holding block and finish bore
bushings by use of a drift. the bushing to diameter shown in Table of Limits,
5. After the bushing is installed, check its alignment with
I SSP1776, Ref. 600. Check the bushing ID with finish ID
gage (PIN 64767). Check alignment of the hole in the
the main bearings by placing the crankshaft in vee blocks bushing with connecting rod parallelism and squareness
on a surface plate. Install the wedge blocks, Tool No. gage (PIN 64530) as described in. paragraphs 7-39 and
ST-212, in the bushing and compare parallelism of the 7-40. If the assembly does not meet the requirements
wedge blocks with that of the main journals. Bushing must
be parallel with .002 per inch. Support the crankshaft in
the vee blocks at journals adjacent to the bushing location.
I shown in references 503 and 504, Table of Limits,
SSP1776, the entire assembly must be replaced.
the threads are undamaged. The threads can be cleaned steps. Do not attempt to reuse a crankshaft with an over-
by running a tap through them. Use a standard size pilot diameter.
.3125-24NF3 (P.D. .2854/2878) tap for 5/16 inch threads.
Use a standard .500-20NF3 (P.D. .4675/.4701) tap for 112 a. After removing the dowel, machine the pilot
inch threads. Check the depth of the thread by threading diameter in the end of the crankshaft to 2.129/2.130
a gear retaining bolt to the bottom of the hole and com- inch as shown in the illustration. See Figure 7-12A.
paring the exposed length of the bolt with the thickness Also, cut the .09 deep x .06R undercut as shown.
of the gear and lockplate.
b. Chrome or nickel plate the surface of the pilot
CAUTION diameter with a firmly bonded deposit that is free of
pin holes, blisters and any other imperfections that
Use extreme care when cleaning threads with could impair the function of the parts.
tap.
c. After plating, stress relieve the shaft by baking at
390 0 to 410 0 F. for 3 to 5 hours.
CAUTION
CAUTION 7-54. Starter Ring Gear. The latest edition of Service In-
struction No. 1141 contains all the information necessary to
accomplish the replacement of the starter ring gear.
Some old crankshaft gears are carborized all
over. If carborized, they will not nick when a file 7-55. Crankcase - Modification of Center Main Bearing Sup-
is used on scallop. If carborized all over, gear ports to Incorporate Body Fit Thru-Studs. This modifica-
should not be reworked. tion to be performed on the following listed engines only.
I~ /DOWEL HOLE
;:;~~.
~~
r;z-z60~ 0
~'-I
.$~ . /
~ 9;:'X"
:y/')~
'V. 0
~
Figure 712F. Rear End View of Crankshaft Showing Associated Parts
CAUTION
No field repair of crankshaft gear attaching threads is permitted. Crankshafts requiring this type of repair must
be returned to the factory through an authorized Lycoming Distributor.
CAUTION
Insure minimum dimension is measured between thrust face surface and pilot.
Figure 712G. Minimum Dimension of Crankshaft
710D Revised July 2011
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 7
Crankcase, Crankshaft.
and Reciprocating Parts
6. Assemble reamer to universal and proceed to
finish ream the holes, once again paying attention
to the preceding "caution" note.
Figure 7-13. Reconditioning Crankshaft Oil Seal 1. Apply a liberal coating of heavy grease to the
Surface threads of a standard 1/2-20 bottoming hand tap.
This will aid in subsequent cleaning of the relief
0-320-B Series Engines prior to 3815- 39 valve bore, since loose metal particles resulting
0- 340 Series Engines prior to 405-30 from the action of the tap will tend to adhere to the·
0-360-A, -C Series Engines prior to 3042- 36 tap when it is withdrawn from the bore. Insert the
0- 540 Series Engines prior to 2790-40 tap into the relief valve bore, making sure that the
tap is centered in the ball seat of the sleeve. Screw
1. With the crankcase assembled as directed in the tap into the sleeve a maximum of four full turns.
paragraphs 7-34 and 7-35, loosen and remove the
thru- studs from the locations shown in figure 7-11. CAUTION
2. Place the crankcase with the odd numbered cyl- Do not rotate tap in excess of four full turns
inder side down on eight inch parallel blocks. because the tap may damage the crankcase
if it is inserted too far beyond the sleeve.
3. Set the stop collar (PiN 64905) 5. 75 inches above
COUNTERWEIGHT COUNTERWEIGHT EAR
the cutting edge of special piloted reamer (PiN
64902). ROLLER BUSHING ON CRANKSHAFT
5. Remove the stop collar from the O. 547 inch dia- COUNTERWEIGHT BUSHING PULLER
meter reamer and assemble the collar 5. 50 inches
from the cutting edge of the O. 563 inch diameter Figure 7-14. Removal of Crankshaft Counterweight
finish reamer (PiN 64903). Bushing
2. Draw the tap and sleeve straight out of the bore with
a sharp quick pull. LEVER
4. Place a new relief valve sleeve into the crankcase bore HYDRAULIC VALVE COVER
with the seat end of the sleeve toward the crankcase.
Make sure that the sleeve is centered in the bore, insert
sleeve driver (ST-215) in the sleeve and drive sleeve into
place with light hammer blows on the driver.
5. If the sleeve does not make a 0.001 press fit with the
crankcase, but is loose, remove the standard size sleeve
and install an 0.003 inch oversize sleeve exactly as describ- Figure 7-15. Hydraulic Valve Assembly
ed in Step "4" above.
7-62. Expansion Plug. On engines equipped for fixed pitch
CAUTION propeller use the expansion plug installation drift (PIN 64681)
to install a new expansion plug in place in the front of the
In the event the hole in the crankcase is too small crankshaft (see figure 7-17) with the convex side toward the
for installation of the 0.003 inch oversize sleeve, front. Be sure the plug fits firmly against the shoulder pro-
place the sleeve in a lathe and lap it sufficiently vided for it on the inside diameter of the crankshaft.
to fit the hole in the crankcase. Never ream the
oil relief valve sleeve hole in the crankcase. 7-63. Plug. On engines equipped for controllable pitch pro-
peller, a plug is installed at the rear of the bore in the front
7-57. Oil Pressure Relief Valve (adjustable). The latest edi- of the crankshaft. If this plug has been removed during
tion of Service Instruction No. 1172 contains the informa- overhaul, install a new plug by sliding it sideways past the
tion relative to replacing the non-adjustable oil pressure relief crankshaft propeller oil tube (see figure 7-17). When the plug
valve assembly with the adjustable oil pressure relief valve is properly positioned in the rear of the bore (flange forward)
assembly if required. insert the oil plug drift (PIN 64770 for 1-3/4 inch plug, PIN
ST-46 for 1-3/8 inch plug) and seat the plug with several sharp
7-58. Crankcase - Fretting. Consult the latest edition of Ser- hammer blows on the drift.
vice Instruction No. 1112 for information relative to inspec-
tion and repair of crankcases damaged by fretting. NOTE
7-59. Crankcase - Fretting. The latest edition of Service In- Some crankshaft employ a 1-1/4 inch plug. This
struction No. 1123 contains all the requirements necessary size plug cannot be replaced in the field. The
to modify the crankcase to prevent fretting. crankshaft must be returned to Textron Lycom-
ing for repair.
7-60. Crankshaft Idler Gear Shaft Recess. Damaged or worn
idler gear shaft recesses in the crankcase can be repaired 7-64. Propeller Flange Bushings. If the propeller flange
as described in Service Instruction No. 1197. bushings have been removed from the crankshaft, new
bushings must be installed. Use the crankshaft flange bushing
REASSEMBLY replacement tool (ST-115) to install new bushings. Consult
the applicable Parts Catalog for proper location of the
7-61. Crankshaft Sludge Tube Assembly (Where applicable). bushings.
Support the crankshaft in a nearly vertical position and in-
stall new sludge tubes. Place a new sludge tube on the ap- 7-65. Crankshaft Gear. Assemble the gear to the crankshaft
plicable drift, PIN 64547 for six and eight cylinder engines using both a new lockplate and bolt. Refer to Figure
and PIN 64548 for four cylinder engines, and drive sludge 7-12F. The correct bolt, lockplate and dowel for each
tube to its correct depth. See figure 7-17 for four cylinder gear are shown in Table 7-4. Tighten the bolt to 125
engines and figure 7-18 for six and eight cylinder engines. inch lbs. torque, then with a hammer and brass drift,
tap lightly around the pilot flange of the gear and listen
NOTE for sharp solid sounds from the hammer blows that
would indicate that the gear is seated against the
Sludge tubes are not employed in later model crankshaft. As a check on seating against the crankshaft,
crankshafts. However, this is not to imply that attempt to insert a pointed .001 inch thick feeler gage
sludge tubes can be removed and not replaced or shim stock between the gear and crankshaft at each
in those crankshafts originally using sludge of the three scallops. The .001 feeler gage, or any
tubes. smaller feeler gage, must Nar fit between the two sur-
faces at any location. (.001 feeler gage is used as an indicator, 7-66. Counterweight Assembly. When assembling
however there must be no clearance between crankshaft and counterweights which have previously been installed on the
gear.) Retighten the gear attaching bolt to the proper tor- engine, use the identifying marks, made on the various parts
que. Tighten the 5/16 inch bolt to 204 inch-pound torque or during disassembly, to enable matching each washer with the
the 1/2 inch bolt to 660 inch-pound torque. Measure the proper seat on the counterweight from which it was removed.
clearance between the O.D. of the gear flange and the pilot Install washer (10) and retaining ring (11) on one side of the
I.D. of the crankshaft. There should not be more than .0005 counterweight (8), place the counterweight on its proper ear
inch clearance at any point. Bend the lockplate against the on the crankshaft, insert the roller (9) and secure the assembly
bolt head. by installing the washer and retaining ring on the second
TO TO
SEPARATE DOWELED CRANKCASES ASSEMBLE DOWELED CRANKCASES
Step 1. Right Side of Crankcase Showing Step 1. Right Side of Crankcase Showing
Installation of Bolts on Half-Inch Cylinder Studs Bolts Installed on Thru-Studs
Step 2. Right Side of Crankcase Showing Step 2. Right Side of Crankcase Showing
Installation of Plate Plate Assembled Over Bolts
Step 3. Left Side of Crankcase Showing Step 3. Right Side of Crankcase Showing Pressure
Installation of Plate Plate Utilized to Pull Halves of Crankcase Together
Figure 7-16. Separation and Assembly of Doweled Crankcases Using Pressure Plates
side of the counterweight. Install the circlip with the sharp crankpins. The order of assembly must be such that the
edge of the circlip towards the outside as shown in Figure 7 numbers stamped on the caps and rods will be down (toward
19. Insert one end of the counterweight retaining ring gap the sump).
gage (P/N 64892) between the ends of the retaining ring,
making sure the gage is resting on the bottom of the groove. 769. There are two types of connecting rod bolt and nut
The gage must pass between the ends of the retaining ring assemblies employed. One is tightened to a specified torque
and, when rocked back and forth, must clear the inside edge and the other to a stretch length. When tightening to a
of the top of the retaining ring. If the gage does not pass stretch length alternately tighten the nut and check the
freely between the ends and under the top of the ring, the length using stretch bolt gage (P/N 64945 or ST488). If the
ring is not seated properly. Make sure all rings are properly stretch limit is exceeded. The connecting rod bolt must be
seated. Consult the latest revision of Service Instruction No. replaced.
1012 for proper location of each counterweight on the
crankshaft. 770. Camshaft (With Separate Gears). See Figure 75. On
six and eight cylinder engines assemble the Woodruff key
767. Connecting Rods. Assemble two new connecting rod (3), install the governor drive gear (2) and secure with
bolts in each connecting rod cap and install new bearing retaining rings (1).
inserts in the connecting rod and connecting rod cap,
making sure the tang of each bearing insert enters locating 771. (a) Camshaft (with separate gears) Except O235 and
slot in cap and connecting rod. Assemble each connecting O290 – Secure the tachometer shaft (16) to the end
rod assembly and tighten nuts moderately tight. Measure the of the camshaft with a pin (15). Assemble the
ID of each bearing and check for clearance against camshaft gear (14) over the stepped dowel (12) on the
measurements taken previously on the diameter of crankpin camshaft and insert the spacer (18) into the center
journals. recess of the camshaft gear. Assemble the breather
slinger (19) and secure assembly to the camshaft gear
NOTE with lockplate (20) and hex. head screw (21).
Connecting rods are marked at manufacture with (b) (O235, O290) – The tachometer shaft is installed
the part number followed by a letter (A through E) in the accessory housing. Assemble the tachometer
designating weight groups. Replacement sets of drive pin (15) in the camshaft. Assemble the camshaft
rods must be of the same weight classification. gear (14) over the stepped dowel (12) and secure to
Individual rods may be replaced by a service rod the camshaft with lockplate (20) and hex. head screw.
bearing the letter “S”.
772. (a) Camshaft (with integral gears) Except O235 and
768. Place the crankshaft on a suitable support on the bench O290 – Assemble tachometer shaft centering spacer
so that all crankpins are free for installation of connecting and install pin and tachometer shaft, secure with
rods. Disassemble connecting rods after checking ID, retaining ring.
thoroughly coat both inserts and the crankpin journals with
preservative oil and assemble rods on their respective (b) (O235, O290) – Install pin and tachometer shaft
in camshaft gear and secure with retaining ring.
7-73. Crankcase. Place both crankcase halves on a suitable 7-74. Propeller Governor Drive. See Figures 7-3 and 7-4.
stand that allows the rods to pass freely through the The propeller governor drive IS located on the front left-
crankcase with the interior of each half of the crankcase hand side of the crankcase.
facing upward. Place new bearing inserts in the center and
rear main bearings of both crankcase halves. NOTE
Temporarily position the front main bearing in place in the Engines that are built with the set screw
left crankcase half. Ensure that the bearing is properly incorporated are assembled with a PIN LW-14021
seated on the two dowels. I idler gear shaft. Engines that are built with the PiN
MS-9048-lll spring pin incorporated a PIN 77876
NOTE idler gear shaft. Replace PIN 77876 idler gear shaft
with a PIN LW -14021 idler gear shaft.
The front main bearing, unlike the center and rear
bearings, splits on the horizontal centerline of the a. Lubricate the propeller governor drive shaft gear with a
engine. mixture of 15% STP and 85% aviation-grade oil.
Use a pencil to mark a vertical reference on each bearing b. Place a new accessory driven gear washer over the end
and the crankcase, at any convenient point along the line of of the shaft.
intersection, to locate the bearing radial and axial planes.
c. Secure the shaft in place using a 13116 inch diameter
NOTE external retaining ring.
These marks are necessary to ensure proper seating d. Insert the dowels in the propeller governor idler gear
of the bearing halves on the two locating dowels assembly.
when the crankshaft is placed into position in the
crankcase. e. Place the governor driven gear in the drive housing at
the front left of the crankcase.
NOTE
f. Place a washer on the threads of the hex head plug.
0-235-C, 0-290-D, 0-290-D2 series and 0-320-
E2D do not employ the front main bearing g. Screw the hex head plug into the end of the idler gear
described. They employ the same main bearings in shaft.
all locations. Also if the 0-235-C, 0-290-D and 0-
290-D2 use a hydro control valve they employ a h. Insert the set screw into the idler gear shaft. Ensure
different front main bearing. Consult the that the set screw enters the hole in the idler shaft
appropriate Parts Catalog. before tightening the screw.
Figure 7-18. Dimensions to Drive Sludge Tubes (Six and Eight Cylinder Engines)
I. Remove the set screw and apply a light coat of Loctite 7-7S. See Figure 7-S. Assemble an idler gear shaft (29) to
290 to the set screw. With a clean lint-free cloth wipe the rear of each crankcase half in the following manner.
away any excess Loctite 290.
a. Insert the pilot of the shaft into the hole in the
j. Install and tighten set screw. crankcase.
To ensure that there is adequate material in the set d. Secure with the applicable fastenings (27). Consult the
screw hole to peen on top of the screw, it may be appropriate Parts Catalog.
necessary to select a screw that is shorter than the
one previously removed. Also, a smaller diameter 7-76. Place the left crankcase half on a suitable support on
center punch may be required to reach the top of the bench with the cylinder pads down.
the shorter set screw. (Lycoming personnel use one
CAUTION
ground to an approximate Soo/60° included angle.
Refer to Table 1 to determine the set screw THERE MUST BE APPROXIMATELY 6
dimension and part number.) See Figure 7- I SA. INCHES OF CLEARANCE BETWEEN THE
CRANKCASE AND THE BENCH.
TABLE I
7 -77. Lay the right crankcase half on the bench with the
I DESRIPTION PART NO.
cylinder pads down.
I Set Screw - 10-32 x .19 inch long ANS6SBI032H3
I Set Screw - 10-32 x .2S inch long ANS6SBI032H4
7-7S. A counterbored recess is provided for an oil seal ring
I Set Screw - 10-32 x .31 inch long ANS6SB 1032HS
at each bolt and stud location. Install a new oil seal ring at
l. Place the idler gear shaft through the opening in the the base of each stud.
housing and through the idler gear assembly inside
NOTE
the crankcase.
Oil seal rings are not used at center saddles that are
m. Install the bushings over the end of the idler gear
doweled nor at center saddles on 0-320 and 0-360
shaft.
wide cylinder flange models using thru-studs that
n. Determine the thickness of the thrust washer required are not attached by screw threads.
to achieve a clearance of 0.02 I inch using a feeler
gauge between the crankcase and spacer. 7-79. Lubricate the face of each tappet body with Lubri-
Bond (A) or equivalent, and reinstall in the same location in
the crankcase.
NOTE I
flp has a 50 i6Co
InCluded angle
New tappet bodies must be installed whenever a
new camshaft is installed.
NOTE 2
NOTE
WASHER The choice of cleaning agents should be limited to
approved consumables complying with local, state
. /~;/ ~ASSEMBLE CIRCLIP and federal regulations. The toxicity of cleansing
f---.,----,-'"""...... ....//1 WITH SHARP EDGE OF agent will, however, depend on the type of
i CIRCLIP TOWARDS contamination encountered on the part to be
OUTSIDE cleaned. Use the least toxic of available cleaning
materials which will satisfactorily accomplish the
work.
CAUTION
ON SOME LYCOMING PARTS, PROTECTIVE
COATINGS ARE APPLIED TO THE PARENT
Figure 7-19. Assembly of Washer and Circlip METAL. TAKE PARTICULAR CARE WHEN
In Counterweight SELECTING THE CLEANING METHOD TO
ENSURE THAT THESE PROTECTIVE
7-81. Using engine oil pre-lubricate the main bearing COATINGS ARE NOT REMOVED FROM THE
journals of the crankshaft and the rear and center main PARENT METAL. DO NOT USE ALKALIES
bearings in the left crankcase half. Remove the front main ON ALUMINUM, MAGNESIUM,
bearing halves from the left crankcase half and coat each ALUMINIZED AND PAINTED AREAS.
bearing half liberally and assemble the bearing on the USING METHYL-ETHYL-KETONE OR
crankshaft. Rotate the bearing on the journal so that the EQUIV ALENT, CLEAN ALL TRACES OF
three oil transfer holes will be uppermost when the SEALANT AND SILK THREAD (IF PRESENT)
crankshaft is placed in the left crankcase half. Pick up the FROM THE CRANKCASE PARTING
assembled crankshaft by the odd numbered connecting rods SURFACES.
and lower the crankshaft into the left crankcase half
permitting the even numbered rods to protrude through their See Figure 7-19A for proper application of POB and silk
respective cylinder mounting pads. Using the reference thread or Figure 7-19B for application of RTV-102 or
marks made previously adjust the front main bearing so that Loctite-515 sealants.
the halves are seated squarely on the locating dowels.
Sealing of crankcase parting surfaces with POB sealant
and "00" silk thread is as follows:
7-82. See Figure 7-24. If either the crankcase or the
crankshaft has been replaced, then the crankshaft end POB sealant, a non-hardening compound, is to be applied
clearance must be checked. With the crankshaft seated in onlv to one half of the crankcase. On the outside mating
I the left crankcase half, move the crankshaft as far aft as surfaces, as shown in Figure 7-19A, apply a thin film of
possible and check the clearance of the crankcase thrust POB sealant. No build-up is permissible. Visibly, where
point at Point A. The clearance must be between 0.009 and sealant is applied, it should produce only a wet
0.026 inches (see Table of Limits, Reference 506). Move appearance on the machined surface. If the crankcase
I the crankshaft as far forward as possible and check the halves are not mated together within one hour of the
crankshaft oil slinger clearance at Point B. The clearance application of the sealant then the mating surfaces will
must be between 0.002 and 0.007 inches (see Table of need to be re-cleaned and the sealant reapplied. Note that
Limits, Reference 507). If additional clearance is needed, this sealant is used primarily to hold the silk thread in
regrind the front face of the crankshaft slinger (Point B) place. Be certain to wipe clean all inner edges of any
Recheck the clearance as indicated above. excess sealant. Also ascertain that no sealant has come in
contact with the bolt holes or any surface other than the
7-83. Using engine oil, pre-lubricate the main bearings of shaded area shown in Figure 7-19A.
the right crankcase half.
After sealant is properly applied, run lengths of "00" silk
7-84. CAUTION thread on the inside of the bolt holes without touching
together and press firmly into solvent to keep thread in
ONLY LYCOMING APPROVED SEALANTS place.
ARE TO BE USED IN THIS APPLICATION. Sealing of crankcase parting surfaces with RTV-\02 or
USE OF ANY OTHER NON-APPROVED LOCTITE-515 sealant is as follows:
SEALANT COUND RESULT IN A LOSS OF NOTE
CLAMPING FORCE AND/OR TROQUE,
WHICH WILL RENDER THE ENGINE Silk thread is not required when RTV -102 or
UNAIRWORTHY. LOCTITE-515 is used.
Figure 7-19A. Sealing Area for POB Sealant and "00" Silk Thread
,Jkrtr - - ~-r. :W
rn
~ 11{r\o~'''\ ~'\\
-
·1 .// ro)\ ,ko \ / (0;\ I
I' .~ \ I "",'~ V:i' ./ i)A,O~
, " oLdOJ!i \ \ OJ,
'I'
Ii.!
'II'
1.1
!
"~::, INSURE THAT THEAREAABOVE
CAMSHAFT IS FREE OF SEALANT
~ ~/
.~~-=@,
•
, ..
1
'!
iL,-~~~--
••
I
RTV-l02 or LOCTITE-515 is to be applied onlv to one point where the dowels are encountered. At this
half of the crankcase. On the outside mating surfaces. as point assemble the pressure plate as described in
shown in Figure 7-19B, apply a thin film of sealant. No Figure 7-16 and complete the assembly.
build-up is permissible for this application. RTV -102
sealant will be a white semi-solid as it is applied. 7-86. Install all crankcase fastenings. Consult the applicable
LOCTITE-515 sealant will be a dark purple semi-solid as Parts Catalog for correct attaching parts.
it is applied. If the crankcase halves are not mated
together within one hour of the application of either 7-87. In order to insure uniform locating on the main
sealant, then the mating surfaces will need to be re- bearings, it is necessary to tighten the studs and bolts in the
cleaned and the sealant reapplied. Be certain to wipe following sequence.
clean all inner edges of any excess sealant. Also, clean all
~ 907 in. MINIMUM DISTANCE FROM
inner edge of excess sealant. Also ascertain that no BOTTOM OF GROOVE TO OPPOSITE
sealant has come in contact with bolt holes or any surface EDGE OF CIRCLIP
other than the shaded areas shown in Figure 7-19B. 222 in. MINIMUM GAP
Crankcases that are doweled at the thru-studs can Figure 7-20. Location of Gap When Installing
only be brought together as described above to the Retaining Rings
NOTE
0-235 series engines employ 3/8 inch split located at the 1:00 o'clock position on right hand
thru-bolts and are only tightened to 300 (standard) rotation and 11 o'clock position on left hand
inch pounds. (reverse) rotation engines viewed faCing propeller end
of engine.
7-91. Torque 3/8 inch nuts at front main bearing (4,
figure 7-21; 5, figure 7-22 or 6, figure 7-23) to 300 NOTE
inch pounds.
Crankshaft oil seal may have either a flat
7-92. Using sequence specified (5 thru 9, figure 7-21; surface OD and held in place by retaining
6thru 12, figure 7-22 or 7thru 15, figure 7-23)Ughten plates (19, figure 7-1) or a raised Up on
1/4 inch nuts at crankcase parting face to 75 inch the OD to enter a machined groove in the
pounds. crankcase. These seals are not inter-
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 7-96. Coat the OD of the seal and the split of the seal
inch pounds. with No. 20 Pliobond or Silastic 140 sealant. Assemble
the seal uniformly in the crankcase with the lip match-
7-94. USing any sequence tighten the remaining 1/4 ing at the split. Be sure no pliobond gets on the I. D. of
inch nuts at crankcase parting face to 75 inch pounds. the seal or on the crankshaft. See Service Instruction
No. 1303 for method of installing solid ring oil seal.
7-95. Assemble the crankshaft oil seal 18, figure 7-1
in the following manner. Assemble the seal with the NOTE
TIGHTEN ON RIGHT SIDE Crankshaft oil seal may have either a flat
surface OD and held in place by retaining
TIGHTEN ON LEFT SIDE plates (19, figure 7-1) or a raised lip on
the OD to enter a machined groove in the
2@ TIGHTEN
ON LEFT SIDE crankcase. These seals are not inter-
changeable.
bled over the flange bushing also identified with "0" marked in three different places with timing marks in
etched on crankshaft flange next to bushing. The starter the form of small etched circles. The smaller dia-
ring gear must be located correctly to assure proper meter gear is marked at one place with the etched cir-
alignment of the timing marks on the ring gear. cles on two adjacent teeth and at another place a single
tooth is marked. The larger diameter gear is marked
7-99. Crankshaft Idler Gears (4 cylinder engines). at one place with the etched circles on two adjacent
Place the crankshaft idler gear on the idler gear shaft teeth, and the crankshaft gear has small etched circles
located to the left between the camshaft gear and the on single gear teeth at two different locations. The
crankshaft gear. The crankshaft idler gear is marked single marked tooth on the idler gear must mesl1 with
in two places with a small etched circle. One of these the two marked teeth of the camshaft gear while the
marki? is located at the space between gear teeth and marked teeth on the crankshaft gear must mesh with
the second is located on a gear tooth. The camshaft the marked teeth of the idler gear. (See figure 2-8).
gear is marked with two etched circles on adjacent
teeth, while the crankshaft is marked with an etched 7-102. Install the right crankshaft idler gear in place
circle on one of the gear teeth. The marked tooth on on the idler shaft making sure that the second marked
the idler gear must mesh with the space between the tooth on the crankshaft gear meshes with the space
marked teeth on the camshaft gear, while the marked between the two marked teeth on the smaller gear sur-
space on the idler gear must mesh with the marked face of the idler gear. (See figure 2-8).
tooth of the crankshaft gear. See figure ~-7.
7-103. Note that the magneto gears shown in figure
7-100. The crankshaft idler gear must be assembled in 2-8 are marked with a circle on one tooth. This tooth
its proper relationship with both the camshaft gear and must mesh between the two circles etched on adjacent
the crankshaft gear because no other combination of teeth of the larger diameter gear of the crankshaft
these three gears will permit correct valve timing. idler gears.
Assemble the second crankshaft idler gear on the idler
gear shaft on the right side. The pOSition of the timing 7-104. Crankshaft Idler Gears (8 cylinder engines).
mark on this gear is immaterial. Check the backlash Place the left crankshaft idler gear on the idler shaft
between gears. located to the left and between the camshaft gear and
crankshaft gear. It will be noted that this dual gear is
7-101. Crankshaft Idler Gears (6 cylinder engines). marked in three different places with timing marks in
Place the left crankshaft idler gear on the idler shaft the form of small etched circles. The larger diameter
located to the left and between the camshaft and crank- gear is marked at one place with the etched circles on
shaft gears. It will be noted that this dual gear is two adjacent teeth and at another place a single tooth
SECTION 8.
8-1. General. To accomodate the number of engine Remove the studs and clamps that secure the intake
models, covered inthis manual, a number of oilsump pipe extensions and remove the extensions.
configurations are employed. Basically all oil sumps
are similar and overhaul procedures will apply to all 8-10. Oil Sumps - Remove the fastenings from the
models unless specifically called out to the contrary. periphery of the sump and remove the sump.
DISASSEMBLY
8-13. Fuel Injectors (Bendix). Remove and clean the
8-4. Intake Pipes. Loosen and remove the capscrews fuel inlet screen on strainer. Clean the strainer in un-
that attach the intake pipe flange to the cylinder intake leaded gasoline or Varsol cleaning fluid.
port. Depending on installation, either loosen hose
clamps and slide intake pipe off connection or pull in- 8-14. Fuel Injector (Simmonds). Clean all exposed
take pipe from the sump or induction housing. Discard surfaces of the fuel pump and throttle body assemblies
the "0" rings. Mark the intake pipes as they are re- with a dry lint free cloth.
moved from the engine so they may be reassembled
in the same location from which they were removed. 8-15. InjectorNozzles - (Simmonds). To clean nozzle
Engines employing tunes induction will have intake orifices use a stream of dry compressed air. Do not
pipes matched in length and diameter. use a probe of any kind to clean nozzle orifices.
8-5. Carburetor or Fuel Injector. Remove the carb- 8-16. Injector Nozzles - (Bendix). Remove the nozzle
uretor or fuel injector from either the air inlet hous- and submerge it in cleaning solvent (Stoddard Solvent,
ing or from the mounting pad on the sump. Remove Methyl Ethyl Ketone or equivalent). Remove nozzle
the air inlet housing on installations employing same. from solvent, and dry with clean, dry compressed air.
Carburetor or fuel injector mounting pads may be in- Under normal conditions, the shield and screen are
corporated on either the bottom, front or rear of the NOT removed from the nozzle assembly. However, if
oil sump. either the shield or screen are removed from the noz-
zle, both must be thoroughly cleaned prior to reas-
8-6. Oil Suction Screen. See figure 8-1 thru 8-4. The sembly and the shield must have a tight fit on body
oil suction screen housing may be found at any number when installed.
of locations on the sump. Unscrew the hex head plug
and remove gasket and oil suction screen. NOTE
8-7. Induction Housing (10-540, TIO-540). See figure At no time is it permissible to use a sharp
8-3. Remove the air inlet housing from the sump and tool such as a wire to clean out an air bleed
induction housing. Remove the induction housing from nozzle.
the bottom of the sump. Remove the studs (14) and
clamps (15) that secure the intake pipe extensions and INSPECTION
remove the extensions (16).
8-17. Inspect the sump according to the general in-
8-8. Induction Housing (IO-720-A, -C). See figure 8-4. structions contained in Section 3.
Remove the induction housing (8) from the bottom of
the sump. 8-18. Oil Suction Screen. Before cleaning the screen,
inspect for evidence of metal particles, which could
8-9. Induction Housing (IO-720-B). Remove the air serve as an aid to locate deterioration in some section
inlet housing from the induction housing. Remove the of the engine. Inspect screen for distortion or open-
induction housing cover and the induction housing. ings of the mesh.
3---c:::J
2
4
I
•
II
12
II
10
,..-----9
7
8-19. Carburetors. Inspection of carburetors must 8-22. Pump Assembly - Inspect mounting surfaces and
determine parts serviceablility and repair and re- fastenings for security. Check for leakage, cracks or
placement requirements. Check applicable manufac- other damage to pump housing. Check pump fittings
turer's publications for limits to be used when conduc- and lines connected to pump for cracks or other dam-
ting inspection. age. Check mixture controllever for damage and wear.
Inspect linkage connected to mixture control lever for
8-20. Bendix Fuel Injectors. The fuel metering section damage and/or wear.
should be inspected along with its corresponding fuel
lines and fittings for damage or fuel leakage. Check 8-23. Throttle Body - Check all of the following parts
all fuel lines for deformation, restrictions and fuel for damage and/or wear. (a) Throttle lever and link-
leakage. Check throttle and mixture control rods for age. (b) Throttle body. (c) Accelerator pump linkage,
deformation. levers and lines (d) Fuel manifold assembly, (e) All
other fittings and lines.
8-21. Simmonds #530 Fuel Injectors - The following 8-24. Nozzle Assembly. Check nozzle lines for wear,
inspection procedures are applicable to Simmonds # damage or leakage. Inspect installed nozzles for se-
530 fuel injectors. curity of mounting. Make sure fuel lines are connect-
8-2 Revised May, 1972
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 8
Oil Sump ond
Fuel Induction
edsecurely to the nozzles. Check for clogged nozzles. REPAIR AND REPLACEMENT
Remove nozzles, if clogged, and conduct a priming
operation to make certain fuel flows from the nozzle. 8-25. Intake Pipe Connection Removal. In the event
that any of the intake pipe connections are loose or
damaged, remove the defective connection by collaps-
NOTE
ing it with a chisel or punch.
Nozzles for this system are a matched set 8-26. Intake Pipe Connection - Installation. Place a
and are stamped "A", "B" or "C". Fuel new connection on the end of the swaging tool (64781)
flows for these nozzles are: and tighten the screw until the rollers have expanded
sufficiently to hold the connection on the tool. Insert
a. "A" - 280t0284cc per minute at 9. 8 the connection into the hole in the sump, making sure
psi supply pressure. that the connection is fully inserted in the hole and
seated on the machined shoulder provided. Begin to
rotate the tool, stopping every couple of turns to ex-
b. "B" - 276 t0280ccper minute at 9. 8 pand the rollers by tightening the screw one or two
psi supply pressure. full turns. When the groove in tte connection is fully
swaged in the groove in the sump, (this will be evi-
c. "C" - 272 to 276 cc per minute at 9.8 denced by the increased resistance of the screw) col-
psi supply pressure. lapse the rollers and withdraw the swaging tool.
0--- 2
I
6~
7-----,0
8 I)
• 3
2 0-6 6---<:>
0-1 ~7
4 5
.~
10-_$1"
16
the manufacturer's publications. Consult Avco Ly- gasket assemble the oil sump to the crankcase and
coming, Service Bulletins nos. 305B, 320, 321, 322A, accessory housing. Consult the applicable parts cata-
331, 335 and 342 and be certain the fuel injector and log for correct fastenings. Tighten all fastenings to
nozzle lines have been modified to conform with these proper torque.
bulletins.
12-----'
II----ill
5---0
4 (0 3
9
0-9
6
--"----8
Q~>----------7
Q
1. Gaskets 7. Helicoil
2. Intake Pipe Flange 8. Induction Housing
3. Intake Pipes 9. Oil Seal
4. 1 Inc h Plug 10. 1/2 Inch Plug
5. Gasket 11. 3/4 Inch Plug
6. Oil Suction Screen 12. Oil Sump
8-32. Induction Housing (la-nO-A, -C). See figure housing to the sump and the induction housing cover to
8-4. Assemble the induction housing (8) to the bottom the induction housing. Assemble the air inlet housing
of the sump. to the induction housing.
8-33. InductionHousing (la-nO-B). Assemble the in- 8-34. Carburetor or Fuel Injector - Using a new gasket,
take pipe extensions in the induction housing and se- install the carburetor or fuelinjector on its mounting
cure with clamps and studs. Assemble the induction pad. Note that the serial numbers of the pump assem-
SECTION 9.
TEST PROCEDURE
9-3. The following instruments should be used, plus 2. A cooling shroud equivalent to a test cell cooling
any additional instruments that may be deemed neces- shroud is installed.
sary by the operator. 0° to 600°F. temperature gage,
counter tachometer, fuel flow meter, fuel pressure 3. The airframe gages may not be used. All nec-
gage, manifold pressure gage, oil temperature gage, essary calibrated gages shall be installed indep-
oil pressure gage and an oil flow measuring device. endent of the airframe.
RSA-5ADI MA-4-5
THROTTLE OPEN
FUEL INLET
.250-18 NPT
FULL RICH
PSH-5BD
......
ENGINE RUN-IN TEST LIMITS ." cr
"-----"
c; OJ
0-235-C1,-C1B,-C2A
-C2B -E 2-5 80/87 0.9 .50 75-85 25 165-230 190-210 500 2800
~
m
'O-235=F-~c;-::-.f~~'~~'-"
O~235=C2C~-~~~~-- -~-ilO/87
-~'-rOOli30 O. 9
0.9
-~~~50~~~~
.50
75-8525
75---85-25
165-236
165-230
190-21O~'~~~500~'
~i90=2To-500-~~2~
2800---
,."
X
.. .
HO-360-R , ,13=15 91/96 , 1. 4 ,78, 75-85 25 165-230 ,190=210 500 2700
tffi
IO-540:~L:l_
IO:540-D, -N, :R_~~
)Q-54Q:K,:r"L:lVIL:13
c¥IO-5~4'o-A , ." ...~,...
18-28
~_~~}~_:?§
_~_ JLl!~§~_
9)/~2~~~~
18-28 ... ___ }QQD30 _ ~~~_
_1!l::-_2L_ ~ __ ~_1_QQ/HQ1,-8
1. B _J-,O~ __ ~ _75-85~ ~!)... 16~=-2_3Q_l~Q:~!0
L~4~_,_7iL. ~~-=8lL r--~_16~~:?3JL. 190-2J.L5()Q_~_21Q'o_,_
.1,(J~~_
1. 0
7~:8!) ~_~~~-~~Q ___ 19Q:21~0
_75-8~25 165:2~_0~t!!Q~:?1()
___ ~_~~2J5~
475~~~~ _ _?700_~_
4_7!j 2E5_ _
-t
m
Z
S!
::tI
(!l I!QLr"TIO-54Q-A 37:3_9 1'oO/130~ . . 1 , 8 1. O~~ 2_512_5-230 190-~1()__~,_HL __ ~~?575 __ ~_ Z
<
...... TIQ~TIQ=-54Q:g, -E 37-39 ._lOOi1:3(L~_~ __ L~~ l.0 ~~JJ5_:7~L~J5 165:2_30 1!!(J=~HQ~~~_~_ 500_~ __ ~~?!jJ~ _ _ m
(f) CII
(!l TJ(), LTIO-Ji-i0-J, -N, -F 37-39.. . 10QD30 ~_LJl l,_O__~:Jl~ 25 165-23Q_~19il-21O _~_175__ ~_~~~~_~ _ _
0.. TIO, LnQ~!jJl()-=JL_ ___ __~ __ ~~~7:~!!~~_~_ ~_~_~~LQQLL39m~~ __ ~ .J-,()~_~ _ 75-85 _JJLcl§~=?~Q~~J~_Q:~J()_~ ___ ?_QQ~ 2575
o
(:) IJ():'7 2 O-~A-,-=!3, :: ~,:D ... . ~2j:~1'l 100/ 130_ .~~~~,_Q~_ _105_ ~ 75 - 85 2 5 }J)~ - 2 30 .. _L99-=2JQ~ __ ~17?_ . _ ~6Ji_Q_~
M-
g. * - Desired during oil consumption run.
(!l
>-;
...... ** - Do not exceed 3150 RPM - for test stand at 24-25 inch Hg. manifold pressure. For oil consumption run, operate at 3100 RPM at 24 inch Hg. manifold
'"
-.::J pressure.
"'"
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 9
Test Procedure
9-4. Test stand oil supply pressure to engines which 9-13. PRESSURE CARBURETORS. New or recondi-
can be run simulated wet sump shall be held to 1. 5 - tioned pressure carburetors must undergo a minimum
2.0 psi throughout the run. Test stand oil supply pres- of eight hours soaking before being placed in service.
sure to engines run simulated dry sump shall be held This can be accomplished before or after installation
to 0.5 - 3.0 psi at rated conditions. Personnel should on the engine and is accomplished in the following man-
consult Service Bulletin No. 113 when desiring to use ner. With the throttle lever wide open and the mix-
dry sump test stand installation for wet sump engines. ture control lever in "full rich" position, inject fuel
into the fuel inlet connection until fuel flows from the
9- 5. Engines equipped with an integral full flow oil fuel outlet. Close the throttle and move the mixture
filter, should be run- in with a slave filter and the reg- control to "idle cut- off".
ular filter installed at the end of the run.
9-14. Pre-Oiling 6 and 8 Cylinder Engines. After as-
9-6. Turbocharged Engines. A slave filter should be sembly of engine is complete, engines to be primed
installed between the oil supply hose and the turbo- with the same lubricating oil as used in the engine by
charger oil inlet. This slave filter should have a fil- forcing 35 psi oil thru one main gallery until oil flows
tering capability of 100 microns or less and have a from the opposite gallery with the front end of the gal-
pressure relief valve set to 15 - 18 psi differential. leryopen.
This will assure that no metal particles are carried
9-15. Attach the instrument connections and connect
to the turbocharger lubrication system.
oil and fuel lines. Connect throttle and mixture con-
9-7. Any engine accessory drive, such as the prope Her trol levers to the stand controls. Be sure the cables
governor drive, which transmits oil pressure through are free and not binding and that the travel is suffi-
oil passages in the engine and which is not pressurized ciently long enough to completely open and close the
by normal operation on the test stand shall be checked throttle and to move the mixture control lever from
for leakage at normal oil pressure by means of a special full rich to idle cut- off. Install the applicable cooling
drive cover with oil transfer holes as required. The shroud, test club and adapter. See Section 11. Be cer-
oil passages involved shall be inspected for external tain the test club will turn up rated RPM ± 50. See
leaks at the completion of the run. Table 9-1.
9- 8. It is de sir able to have some method of maintaining 9-16. It is desirable to keep a log sheet and record
the instrument readings during each speed of the run-
the oil temperatures within the specified limits dur-
ing the run-in. See Table 9-1. Engine should be idled in schedule. See Table 9- 2.
0
until oil temperature is approximately 140 F. before 9-17. Before starting be certain that the magneto switch
starting the run-in schedule. See Table 9-2. is in the "off" position. Turn the engine over a few
revolutions to ascertain that no interference exists
9-9. Operate during the run-in with (MIL-L-6082, within the arc of the test club or within the engine it-
Grade 1100) lubricating oil or if engine is to be stored self. If it does not turn freely, do not try to force it
with a mixture of 35%MIL-C-6529, type 1 and 65% MIL- or attempt to start until the cause has been determined
L-6082. and the fault corrected.
9-10. Fuel shall conform to specifications. See Table
9-18. RUN-IN. Start the engine in accordance with the
9-1.
following procedure.
9-11. Engines equipped with a fuel pump shall be tested a(l). Float type carburetor or Simmonds Injector -
with a test stand fuel system terminating in a float Place mixture control in "full rich" position.
Chamber vented to the atmosphere. The fuel level in
this chamber shall be below the entrance to the fuel a(2). Pressure Carburetor or Bendix FuelInjector-
pump by at least one foot. The fuel pressure to the Place mixture control in idle cut- off position.
chamber shall be maintained at 2 to 5 psi. b. Turn fuel valve to "on" position.
9-12. Engines not equipped with a fuel pump shall be c. Set throttle at 1/10 open position.
tested with either a remote or installed representative d(l). Turn magneto switch to "left" and engage
fuel pump. starter.
TABLE 9-2
RECOMMENDED RUN-IN SCHEDULE
RPM LOAD TIME (MINUTES) REMARKS
a. Move the mixture control lever toward the required direction until proper idle speed is
idle cut- off position with a smooth, steady pull obtained.
and note tachometer. An increase of more than
10 RPM indicates an excessively rich mixture 9-29. PRESERVATION AND STORAGE. In the event
while an immediate decrease (if not preceded by the engine is to be stored at the completion of the run-
a momentary increase) indicates the mixture is in the engine should be preserved in the following
too lean. If mixture is too rich, turn idle air manner.
bleed adjustment screw counter-clockwise, if
9- 30. Upon completion of the run-in, drain the oil.
the mixture is too lean turn the idle air bleed
Refill the engine with a 1 to 1 mixture of MIL- L-6529,
adjustment screw clockwise. Make adjustments
until a check results in a pick-up of five (never Type 1, and Bayol "D" or equivalent.
more than 10 RPM). Each time an adjustment is
made the engine should be run up to 2000 RPM 9-31. Remove top spark plugs, and with the crankcase
full of oil, slowly turn the propeller through two (2)
to clear the engine before the check is made. If
idle speedis affected by this change turn throttle revolutions. Let engine stand for ten (10) minutes after
lever stop adjustment in the direction required which the propeller should be turned back and forth
to obtain proper idle speed. through 90° for twelve (12) cycles. Drain the preser-
vative oil.
3. Mixture Control Lever Linkage. If proper idle 9- 32. Spray the exhaust port and valve of each cylinder
cannot be obtained by the first two steps proceed with the piston approximately 1/4 turn before top center
as follows. of the exhaust stroke using MIL-C-6529 oil, Type 1.
9- 37. Engines shall have spark plugs installed in the TABLE 9-3
bottom cylinder location and dehydrator plugs, PiN
40238 installed in the upper cylinder location. The ig- RECOMMENDED REPRESERVATION SCHEDULE
nition harness shall be attached to the spark plugs in
the bottom locations and have ignition cable protectors RPM LOAD TIME (MINUTES)
(AN-4060) on the top locations.
1200 Prop. Load 5
9- 38. Exhaust ports and other openings should be closed 1800 Prop. Load 5
with suitable covers. The turbine outlet on turbo- 2400 Prop. Load 5
charged engines should be covered. Normal Rated See Table 9-1 15
9-40. Although the above procedure should prevent 9- 43. Pressure Carburetors and Fuel Injectors -
corrosion under favorable conditions it is recom- Carburetors and fuel injectors shall be emptied of all
mended that the engine be periodically inspected for residual fuel and flushed with oil, MIL-O-6081, Grade
evidence of corrosion. If corrosion should be present, 1010. Injectors will have approximately one (1) ounce
the affected part should be cleaned and the engine re- poured into inlet under gravity head. The injector will
preserved. Also, engines preserved by the above pro- be rocked to cover all interior surfaces. Injectors with
cedures are not adequately protected for extended fluor 0- silicone diaphragms and seals (no cure date) do
periods of storage. If at the end of 60 days it is found not require flushing. Carburetors shall have the oil
that the engine must remain in storage it must be supplied to the inlet port at a pressure of from 5 to 8
represerved. psi. Mixture controls shall be at full rich during the
flushing operation. Under no circumstances shall the
9-41. REPRESERVATION RUN - The represervation regulator air chambers, air passages, or automatic
run should be accomplished under the same conditions mixture control be flushed with oil; these must be kept
as the run-in after overhaul except that only the fol- dry at all times. Drain excess oil and install plugs or
lowing time schedule must be followed. caps. Lock the throttle in the closed position.
NOTICE
The basic Table of Limits, SSP-1776 has been completely revised and reissued herewith as SSP-1776-5. It is made up of the
following four parts, each part contains five sections.
This publication supersedes and replaces the previous publication SSP-1776-4. To make sure that SSP-1776-5 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.
DEFINITIONS
Ref. (1st column) The numbers in the first column headed “Ref.” are shown as a reference 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 the limit is
applicable.
Chart (2nd column) The letter in this column is used as a symbol to designate engine models to which the
specific limits are applicable. A list of the letter and the engines to which it refers is
shown on the following page.
Nomenclature (3rd column) This is a brief description of the parts or fits specified in the adjacent columns and
indicated in the diagram at end of each section.
Dimensions (4th and 5th columns) The dimensions shown in column 4 are the minimum and maximum dimensions for
the part as manufactured. The dimensions shown in column 5 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.
Clearance (6th and 7th columns) Like the dimensions shown in the 4th and 5th 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 such instances, the specified
maximum clearance must not be exceeded.
In some instances, where a parts revision has caused a dimensional or tolerance change, the superseded dimensional data has been
deleted from the list; provided compliance with the change is mandatory.
This manual contains torque values specifications for various type of hardware used on Lycoming Engines.
The importance of correct torque application cannot be overemphasized. Under-torque can cause premature wear of nuts and bolts,
as well as the parts they secure. Over-torque can cause wear or premature failure of a bolt or nut from overstress on threaded areas
REQUIRED PRACTICES
NOTE: Make sure that the torque applied is for the size of the bolt shank not the wrench size.
NOTE: Do not exceed the maximum torque plus the friction drag. If the hole and nut castellation do not align, change washer or
nut and try again. Exceeding the maximum recommended torque is not recommended.
• Calibrate the torque wrench at least once a year, or immediately after it has been abused or dropped, to ensure
continued accuracy.
• Be sure the bolt and nut threads are clean and dry, unless otherwise specified by the manufacturer.
• Apply a smooth even pull when applying torque pressure. If chattering or a jerking motion occurs during the final
torque, back off the nut and retorque.
• When installing a castle nut, start alignment with the cotter pin hole at the minimum recommended torque plus
friction drag torque.
If special adapters are used which will change the effective length of the torque wrench, the final torque indication or wrench setting
must be adjusted accordingly. Identify the correct torque wrench indication or setting with the adapter installed. Refer to AC 43.13-
1B for details.
i Introduction
Drag Torque
VARIABLE AFFECTING TORQUE. Several variables must be taken into consideration when determining the amount of torque
to apply to a given fastener. Standard torque charts are developed for dry, un-plated conditions. Surface variables to be taken into
account for each specific application include thread roughness, lubrication, hardening, scale, paint, and plating.
Drag torque is also known as running torque, the resistance on the screw as it’s being installed, usually only a few Inch Lb. Drag
torque is the natural friction between a fastener and its nut, nut plate, etc.
NOTE: When specific torque values are included in a technical manual for a specific item, those values shall be used. This means
that friction drag torque was already included for known conditions.
• Run the nut down to near contact with the washer or bearing surface and check the friction drag torque required to turn the
nut.
• Add the friction drag torque to the desired torque. This is referred to as “final torque,” which should register on the indicator
or setting for a snap-over type torque wrench.
• Final torque = friction drag torque + desired torque.
Letters of the alphabet and numbers are used as symbols throughout the Table of Limits to represent specific interpretations and to
designate engine models. Letters in parenthesis refer to dimensional characteristics; letters without parentheses indicate engine
models. They are listed below with the separate definitions.
(A) These fits are either shrink fits controlled by machining, fits that may readily be
adjusted, or fits where wear does not normally occur. In each case, the fit must be held
to manufacturing tolerance.
(B) Side clearance of wedge type rings must be measured with face of ring flush with
piston.
(D) These dimensions shown are measured at the bottom of the piston skirt at right angles
to the piston pin.
(E) Permissible wear on crankshaft (rod and main bearing journals) to be minus .0015 on
diameter.
(L) Loose fit; wherein a definite clearance is mentioned between the mating surfaces.
(T) Tight fit; shrink or interference fit.
(WD) Wide Deck Crankcase.
The illustrations shown are 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 revision of Service Instruction No. 1037.
Introduction ii
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
NOTE: In “Chart” column, a number appearing after a letter indicates an exception to the basic model.
For example, A1 (O-235-F. –G, -J, -K, -L, -M, -N –P) is an exception to the basic model A (O-235-C, -E, -H)
When referencing any section in this Table of Limits for a dimension or clearance, if the there is no specific A1 row for a
particular reference number, the A limits also apply to the A1 engine models.
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
500 A All Main Bearings and Crankshaft .0025L
.0055L .0060L
B-D-G-J-S-T-Y-BD-BE-AF Main Bearings and Crankshaft
(Thin Wall Bearing - .09 Wall .0015L
Approx.) .0045L .0060L
B-G-J-S-T-Y-AF Main Bearings and Crankshaft
(Thick Wall Bearing - .16 Wall .0011L
Approx.) .0041L .0050L
A Diameter of Main Bearing Journal 2.3735
on Crankshaft 2.375 (E)
B-D-G-J-S-T-Y-BD-BE Diameter of Main Bearing Journal
on Crankshaft 2.3745
(2-3/8 in. Main) 2.376 (E)
S1-S11-S12-T1-T3-AF Diameter of Main Bearing Journal
on Crankshaft 2.6245
(2-5/8 in. Main) 2.626 (E)
S8-S10-S13 Diameter of Front Main Bearing
Journal on Crankshaft 2.3750
(2-3/8 in. Main) 2.3760 (E)
S1-S11-S12-T1-T3-AF Diameter of Front Main Bearing
Journal on Crankshaft 2.6245
(2-5/8 in. Main) 2.6255 (E)
500 A-B-B1-D-G*-BD-BE Crankcase Bearing Bore Diameter
(All) (Thin Wall Bearing) (2-3/8 2.566 2.5685
in. Main) 2.567
G**-J-S-T-Y Crankcase Bearing Bore Diameter
(All Except Front) (Thick Wall 2.6865 2.6890
Bearing) (2-3/8 in. Main) 2.6875
T1-T3-AF Crankcase Bearing Bore Diameter
(Front Only) (Thin Wall Bearing) 2.816 2.8185
(2-5/8 in. Main) 2.817
T1-T3-AF Crankcase Bearing Bore Diameter
(All Except Front) (Thick Wall 2.9365 2.9390
Bearing) (2-5/8 in. Main) 2.9375
S1-S12-T-AF Crankcase Bearing Bore Diameter
(All) (Thin Wall Bearing) (2-5/8 2.816 2.8185
in. Main) 2.817
G**-J-S-T-Y Crankcase Bearing Bore Diameter
(Front Only) (Thin Wall Bearing) 2.566 2.5685
*O-320-A, -E Narrow Deck, (2-3/8 in. Main) 2.567
**O-320-A, -E Wide Deck
501 ALL Connecting Rod Bearing and .0008L
Crankshaft .0038L .0050L
A-B-D-G-J-S-T-Y-BD Diameter of Connecting Rod 2.1235
Journal on Crankshaft (2-1/8 in.) 2.125 (E)
S-T-AF Diameter of Connecting Rod 2.2485
Journal on Crankshaft (2-1/4 in.) 2.250 (E)
A-B-D-G-J-S-T-Y-BD-BE Connecting Rod Bearing Bore
Diameter (2-1/8 in.) (Measured At 2.2870
Axis 30O on Each Side) 2.2875
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
501 S-T-AF Connecting Rod Bearing Bore
Diameter (2-1/4 in.) (Measured At 2.4205
Axis 30O on Each Side) 2.4210
502 ALL Connecting Rod - Side Clearance .004L
.010L .016L
503 ALL Connecting Rod - Alignment .010 in 10 Inches
504 ALL Connecting Rod – Twist .012 in 10 Inches
505 Crankshaft Run-Out at Center
Main Bearing
4 CYLINDER Mounted on No. 1 and 4 Journals
Max. Run-Out No. 2 Journal .002 .002
Mounted on No. 1 and 4
Journals Max. Run-Out No. 3
Journal .005 .0075
Mounted on No. 2 and 4 Journals
Max. Run-Out No. 3 Journal
.003 .0045
6 CYLINDER Mounted on No. 2 and 5 Journals
Max. Run-Out No. 1 Journal
.002 .002
Mounted on No. 2 and 5 Journals
Max. Run-Out No. 3 Journal
.005 .0075
Mounted on No. 2 and 4 Journals
Max. Run-Out No. 3 Journal
.003 .0045
Mounted on No. 3 and 5 Journals
Max. Run-Out No. 4 Journal
.003 .0045
8 CYLINDER Mounted on No. 2 and 6 Journals
Max. Run-Out No. 1 Journal
.002 .002
Mounted on No. 2 and 4 Journals
Max. Run-out No. 3 Journal
.003 .0045
Mounted on No. 3 and 5
Journals Max. Run-Out No. 4
Journal .003 .0045
Mounted on No. 4 and 6 Journals
Max. Run-Out No. 5 Journal
.003 .0045
Mounted on No. 2 and 6 Journals
Max. Run-Out No. 3, 4 and 5 .005 .0075
Journals
506 ALL Crankshaft and Crankcase Front .009L
End Clearance .016L .026L
507 ALL Clearance – Front Face of
Crankshaft Oil Slinger to Front
Face of Recess in Crankcase .002
(Crankshaft Against Thrust Face) .007L (A)
SSP-1776-5-PT1 1-2 Revised February 2016
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
508 ALL Crankshaft – Prop. Flange
Run-Out .002 .005
509 ALL Starter Ring Gear and Support .014T
.022T (A)
510 A-B-D-G-J-S-T-Y-AF-BD-BE Crankshaft Timing Gear and .0005T
Crankshaft .0010L (A)
A-B-D-G-J-S-T-Y-AF Tappet Body and Crankcase .0010L
.0033L .004L
511 BD-BE Tappet Body and Crankcase .0010L
.0030L .004L
A-B O.D. of Tappet .6232
(Solid Tappets) .6240 .6229
B1-D-G-J-S-T-Y-AF O.D. of Tappet .7169
(Flat Tappets) .7177 .7166
B1-D-G-J-S-T-Y-AF O.D. of Tappet .8420
(Roller Tappets) .8428 .8417
BD-BE O.D. of Tappet .8740
.8745 .8737
A-B I.D. Tappet Bore in Crankcase .6250
(Solid Tappets) .6263 .6266
B1-D-G-J-S-T-Y I.D. Tappet Bore in Crankcase .7187
(Flat Tappets) .7200 .7203
B1-D-G-J-S-T-Y-AF I.D. Tappet Bore in Crankcase .8437
(Roller Tappets) .8445 .8448
BD-BE I.D. Tappet Bore in Crankcase .8755
(Small Bore Tappet) .8773 .8776
BD-BE I.D. Tappet Bore in Crankcase .9545
(Large Bore Tappet) .9555
512 All Models Using Roller Tappet Plunger Assembly and .0010L
.0067L
Tappets Body – (Roller Tappets) .0047L
All Models Using Straight Body Tappet Plunger Assembly and .0010L
.0067L
Tappets Body – (Straight Body Tappets) .0047L
All Models Using Hyperbolic Tappet Plunger Assembly and .0010L
.0087L
Tappets Body – (Hyperbolic Tappets) .0067L
513 ALL Tappet Socket and Body .002L
(Hyperbolic Flat and Roller .007L .009L
Tappets)
514 ALL Camshaft and Crankcase .002L
.004L .006L
515 ALL Camshaft – End Clearance .002L
.009L .015L
516 ALL Camshaft Run-Out at Center .000
Bearing Journal .001 .006
517 All Models Using Counterweight Bushing and .0013T
Counterweights Crankshaft .0026T (A)
518 All Models Using Counterweight Roller – End .007L
Counterweights Clearance .025L .038L
519 All Models Using Counterweight and Crankshaft – .003L
Counterweights Side Clearance* .013L .017L
*Measure below roller next to flat.
Revised April 2018 1-3 SSP-1776-5-PT1
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
520 All Models Using Counterweight Bore and Washer .0002L
Counterweights O.D. .0030L (A)
521 All Models Using I.D. of Counterweight Bushing .7485
Counterweights .7505 .7512
522 All O.D. of Counterweight Roller (See
(AS APPLICABLE) latest revision of Service
Instruction No. 1012)
523 D Thrust Bearing and Propeller Shaft .0000 .002L
.0012L
524 D Thrust Bearing and Thrust Bearing .003T
Cap Clamp Fit (Shim to this Fit) .005T (A)
525 D Thrust Bearing Tilt .027 Tilt
526 D Crankshaft Run-Out – Rear Cone
Location .003
527 D Crankshaft Run-Out – Front Cone
Location .007
528 D Thrust Bearing and Thrust Bearing .0016L
Cage .0034L .0045L
Dimensions Clearances
Mfr. Min. Mfr. Min.
& Max. Service & Max. Service
Ref. Chart Nomenclature Max. Max.
600 ALL Connecting Rod and Connecting Bushing P/N LW-13923 to be burnished in place
Rod Bushing Bushing P/N 01K28983 is not burnished in place
ALL Finished I.D. of Connecting Rod 1.1254
Bushing 1.1262
601 A-B-D-G-J-BD Length Between Connecting 6.4985
Rod Bearing Centers 6.5015
S-T-Y-AF-BE Length Between Connecting 6.7485
Rod Bearing Centers 6.7515
602 ALL Connecting Rod Bushing and .0008L
Piston Pin .0021L .0025L
603 ALL Piston Pin and Piston .0003L
.0014L .0018L
ALL Diameter of Piston Pin Hole in 1.1249
Piston 1.1254
ALL Diameter of Piston Pin 1.1241
1.1246
604 A-G-J-S-T-AF-BD-BE Piston and Piston Pin Plug .0002L
.0010L .002L
A-G-J-S-T-AF-BD-BE *Diameter of Piston Pin Plug 1.1242
1.1247
605 B-D-G-J-S-T-Y-AF Piston Pin and Piston Pin Plug .0005L
(Optional) .0025L .005L
G-J-S-T-Y-AF *Diameter of Piston Pin Plug .5655
.5665
B-D Diameter of Piston Pin Plug .8405
(Thin Wall Pin) .8415
*See latest edition of Service Instruction No. SI-1267.
606 A-B Piston Ring and Piston – Side
Clearance (Top Ring Comp.) .000
(Plain) Full Wedge .004L .006L (B)
B-D Piston Ring and Piston – Side
Clearance (Top Ring Comp.) .0025L
(Chrome) Full Wedge .0065L .008L (B)
G-J-S-T-Y-AF-BD-BE Piston Ring and Piston – Side
Clearance (Top Ring Comp.) .0025L
Half Wedge .0055L .008L (B)
606 B Piston Ring and Piston – Side
Clearance (2nd Ring Comp.) .0025L
(Chrome) Full Wedge .0065L .008L (B)
A-B-D-G-J-S-T-Y-AF-BD-BE Piston Ring and Piston – Side
Clearance (2nd Ring Comp.) Full .000
or Half Wedge .004L .006L (B)
J Piston Ring and Piston – Side
Clearance (3rd Ring Comp.) Half .000
Wedge .004L .006L (B)
606 ALL Piston Ring and Piston – Side .002L
Clearance (Oil Regulating) .004L .006L (B)
A Piston Ring and Piston – Side .003L
Clearance (Bottom) .0055L .007L(B)
Piston Specifications
Min. Piston Dia. Cylinder Barrel Max. Clearance
608 Piston Number Top Bottom Maximum Diameter Piston Skirt & Cyl.
608
14B23917 4.3470 4.3555 4.3795 .021L
609
610 14B23918* 4.3290 4.3605 4.3805 .018L
14B23919 4.3470 4.3555 4.3795 .021L
14C28324 4.8395 4.8590 4.8805 .018L
14D21953-S 5.0790 5.1090 5.1305 .018L
14D23907 5.0790 5.1090 5.1305 .018L
14D23908* 5.0790 5.1090 5.1305 .018
14D23909* 5.0790 5.1090 5.1305 .018
14D23910* 5.0790 5.1090 5.1305 .018
14D23912* 5.0790 5.1090 5.1305 .018
14D23913 5.0790 5.1090 5.1305 .018L
14D23914* 5.0790 5.1090 5.1305 .018L
14D23915 5.0790 5.1090 5.1305 .018L
14D23916 5.0790 5.1090 5.1305 .018L
14D28056 5.0790 5.1090 5.1305 .018L
14E23911* 5.2720 5.3020 5.3235 .018L
70396† 4.8290 4.8620 4.8805 .018L
75984-S 4.8395 4.8590 4.8805 .018L
LW-10208-S 5.0790 5.1090 5.1305 .018L
NOTES:
Refer to the latest revision of Service Instruction No. SI-1037 for a listing of engine models and piston part numbers
applicable for each engine model.
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 both
diameters; this sum, divided by 2, represents the average diameter of the cylinder.
* - High Compression.
† - Piston no longer available from Lycoming Engines.
Maximum taper and out-of-round for cylinder in service is .0045 inch.
To find the average out-of-round, measure 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. Difference between diameters must not exceed .0045 inch.
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
611 A Exhaust Valve Seat and Cylinder .0065T
Head .010T (A)
B-D-G-J-S-T-Y-BD-BE Exhaust Valve Seat and Cylinder .0045T
Head .008T (A)
S1-S2-S3-S5-S6-S7-S9-S10- Exhaust Valve Seat and Cylinder .0075T
S11-S12-S13-S14-T2-T3-AF Head .011T (A)
A O.D. Exhaust Seat 2.0025
2.004
B-D-G-J-S-T-Y-BD-BE O.D. Exhaust Seat 1.7395
1.741
S1-S2-S3-S5-S6-S7-S9-S10- O.D. Exhaust Seat 1.9355
S11-S12-S13-S14-T2-T3-AF 1.937
A I.D. Exhaust Seat Hole in Cylinder 1.994
Head 1.996
B-D-G-J-S-T-Y-BD-BE I.D. Exhaust Seat Hole in Cylinder 1.733
Head 1.735
611 S1-S2-S3-S5-S6-S7-S9-S10- Exhaust Seat Hole in Cylinder 1.926
S11-S12-S13-S14-T2-T3-AF Head 1.928
612 A Intake Valve Seat and Cylinder .0070T
Head .0105T (A)
B-D-G-J-S-T-Y-AF-BD-BE Intake Valve Seat and Cylinder .0066T
Head .010T (A)
A O.D. Intake Seat 2.0965
2.0975
A1-B-D O.D. Intake Seat 1.9265
1.928
B1-C-J-S-T-Y-BD-BE O.D. Intake Seat 2.0815
2.083
S1-S2-S3-S5-S6-S7-S9-S10- O.D. Intake Seat 2.2885
S11-S12-S13-S14-T2-T3-AF 2.290
A I.D. Intake Seat Hole in Cylinder 2.087
Head 2.089
A1-B-D I.D. Intake Seat Hole in Cylinder 1.918
Head 1.920
B1-G-J-S-T-Y-BD-BE I.D. Intake Seat Hole in Cylinder 2.073
Head 2.076
S1-S2-S3-S5-S6-S7-S9-S10- I.D. Intake Seat Hole in Cylinder 2.280
S11-S12-S13-S14-T2-T3-AF Head 2.282
613 ALL Exhaust Valve Guide in Cylinder .001T
Head .0025T (A)
613 A-B-D-J O.D. Exhaust Valve Guide .5933
.5938
Y O.D. Exhaust Valve Guide .6267
.6272
G-J-S-T-AF-BD-BE O.D. Exhaust Valve Guide .6633
.6638
S1 O.D. Exhaust Valve Guide .6953
.6958
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
613 A-B-D-G-J I.D. Exhaust Valve Guide .5913
Hole in Cylinder Head .5923
Y I.D. Exhaust Valve Guide .6247
Hole in Cylinder Head .6257
G-J-S-T-AF-BD I.D. Exhaust Valve Guide .6613
Hole in Cylinder Head .6623
S1 I.D. Exhaust Valve Guide .6933
Hole in Cylinder Head .6943
614 ALL Intake Valve Guide and .0010T
Cylinder Head .0025T
ALL O.D. Intake Valve Guide .5933
.5938
ALL I.D. Intake Valve Guide .5913
Hole in Cylinder Head .5923
615 A-B-D Exhaust Valve Stem and Valve .0020L
Guide .0038L (A)
A1-G-J-S-T-BD-BE Exhaust Valve Stem and Valve .0040L
Guide (Parallel Valve Heads) .0060L (A)
Y Exhaust Valve Stem and Valve .0035L
Guide .0053L (A)
S1-S2-S3-S5-S6-S11-S12-T2- Exhaust Valve Stem and Valve .0037L
T3-AF Guide (Angle Valve Heads) .0050L (A)
S7-S9-S10-S13-S14 Exhaust Valve Stem and Valve
Guide (Angle Valve Heads - .0035L
Helicopter) .0055L (A)
A-B-D O.D. Exhaust Valve Stem .4012
.4020
A1 O.D. Exhaust Valve Stem .4320
.4333
G-J-Y O.D. Exhaust Valve Stem .4332
.4340
G-J-S-T-BD-BE O.D. Exhaust Valve Stem .4932
(Parallel Valve Heads) .4945 .4915
S1-S2-S3-S5-S6-S7-S9-S10- O.D. Exhaust Valve Stem .4955
S11-S12-S13-S14-T2-T3-AF (Angle Valve Heads) .4965 .4937
Service allowable limits
of .4937 or .4915 is
applicable only to inconel
or nimonic valves
A-B-D Finished I.D. Exhaust Valve .4040
Guide .4050
A1-G-J Finished I.D. Exhaust Valve .4370
Guide .4380
Y Finished I.D. Exhaust Valve .4375
Guide .4385
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
621 ALL Valve Rocker Bushing and Bushing Must Be
Valve Rocker Burnished In Place
622 ALL Valve Rocker Shaft Bushing .0022T
and Cylinder Head .0038T (A)
ALL Valve Rocker Shaft Bushing .7380
Hole in Cylinder Head .7388
623 A-B-D-G-J-S-T-Y Valve Rocker and Cylinder
Head - Side Clearance .005L
(Parallel Valve Heads) .013L .016L
S1-S2-S3-S5-S6-S7-S9-S10- Valve Rocker and Cylinder .002L
S11-S12-S13-S14-T2-T3-AF Head – Side Clearance .020L
(Angle Valve Heads) .024L
624 A-B-J Push Rod and Ball End .0005T
.0025T (A)
625 A Intake and Exhaust Valve .705
Guide Height .725
ALL Intake Valve Guide Height .705
(Parallel Valve Heads) .725
ALL EXCEPT O-235 Exhaust Valve Guide height .765
(Parallel Valve Heads) .785
ALL Intake and Exhaust Valve Guide .914
height (Angle Valve Heads) .954
SSP-1776-5-PT1 1-12
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION II – CYLINDERS
1-13 SSP-1776-5-PT1
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
OIL PUMP
700 ALL Oil Pump Drive Shaft and Oil .0010L
Pump Body or Cover .0025L .004L
701 A-B-D-G-J-S-T-AF Oil Pump Drive Shaft and .0015L
Accessory Housing .0030L .006L
Y Oil Pump Drive Shaft and .0015L
Accessory Case .0030L .006L
BD-BE Oil Pump Drive Shaft and .0010L
Crankcase .0025L .004L
702 S-T-AF (DUAL MAGNETO) Oil Pump Drive Shaft – End .015L
Clearance .050L .065L
BD-BE Oil Pump Drive Shaft – End .017L
Clearance .037L .047L
703 A-B-D-G-J-S-T-Y-AF Oil Pump Impellers – Diameter .002L
Clearance .006L .008L
BD-BE Oil Pump Impellers – Diameter .0035L
Clearance .0075L .009L
704 ALL (EXCEPT BD-BE) Oil Pump Impellers – Side .002L
Clearance .0045L .005L
BD-BE Oil Pump Impellers – Side .003L
Clearance .005L .006L
AS APPLICABLE Width of Oil Pump Impellers .622
.624 .621
AS APPLICABLE Width of Oil Pump Impellers .747
.749 .746
AS APPLICABLE Width of Oil Pump Impellers .995
.997 .994
BD-BE Width of Oil Pump Impellers .622
.623 .620
705 S-T-AF Oil Pump Impeller and Idler Shaft .0010L
(DUAL MAGNETO) .0025L .004L
A-B-D-G-J-S-T-Y-AF Oil Pump Impeller and Idler Shaft .001T
(Alum. and Sinterbond) .003T (A)
BD-BE Oil Pump Impeller and Idler Shaft .002T
.004T (A)
706 A-B-D-G-J-S-T-Y-AF Oil Pump Idler Shaft and Oil .0005L
Pump Body .0020L .003L
BD-BE Oil Pump Idler Shaft and Oil .0010L
Pump Body .0025L .003L
S-T-AF (DUAL MAGNETO) Oil Pump Idler Shaft and Oil .0000
Pump Body .0015T (A)
707 A-B-D-G-J-S-T-Y-AF Oil Pump Idler Shaft and .0010L
Accessory Housing .0025L .0035L
BD-BE Oil Pump Idler Shaft and .0010L
Crankcase .0025L .0035L
708 G2-S2 Scavenge Pump Drive Shaft and .0010L
Adapter .0025L .004L
709 G2-S2 Scavenge Pump – End Clearance .000
.045L .060L
SSP-1776-5-PT1 1-14
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
SCAVENGE PUMP
710 G2-S2 Scavenge Pump Impellers – .007L
Diameter Clearance .011L .014L
711 G2-S2 Scavenge Pump Impellers – Side .003L
Clearance .005L .006L
G2-S2 Width of Impellers 1.496
1.498 1.495
712 G2-S2 Scavenge Pump Impellers and .0010L
Idler Shaft .0025L .004L
713 G2-S2 Scavenge Pump Body and Idler .0000
Shaft .0015T (A)
714 S-T4-AF (WIDE DECK) Turbocharger Scavenge Pump .0010L
Drive and Adapter .0025L .004L
715 S-T4-AF (WIDE DECK) Turbocharger Scavenge Pump .0010L
Shaft and Adapter .0020L .0035L
716 S-T4-AF (WIDE DECK) Gerotor Pump – Rotor – Side .0015L
Clearance .003L .004L
717 S-T4-AF (WIDE DECK) Gerotor Pump Housing and .0005L
Adapter .0020L (A)
718 S-T4-AF (WIDE DECK) Turbocharger Scavenge Pump – .0055L
End Clearance .0365L .0415L
T4 (DUAL MAGNETO) Turbocharger Scavenge Pump – .0105L
End Clearance .0395L .0445L
FUEL PUMP
719 A-B-D-G-J-S-T AC Fuel Pump Plunger and .0015L
Accessory Housing .003L .005L
720 J-S-T-AF Crankshaft Idler Gear and .001L
Crankshaft Idler Gear Shaft .003L .005L
721 S-T-AF Crankshaft Idler Gear Shaft and .0020L
(DUAL MAGNETO) Accessory Housing .0035L .0065L
S-T-AF Crankshaft Idler Gear Shaft and .0020L
(DUAL MAGNETO) Crankcase .0035L .0065L
722 S-T-AF AN Fuel Pump Idler Gear and .001L
Shaft .003L .005L
723 S-T-AF AN Fuel Pump Idler Shaft and .0020L
(DUAL MAGNETO) Accessory Housing and Crankcase .0035L .0065L
S-T-AF AN Fuel Pump Idler Shaft and .0020L
(DUAL MAGNETO) Crankcase .0035L .0065L
724 A-B Crankshaft Idler Gear – End .003L
Clearance .043L .058L
G-J-S-Y Crankshaft Idler Gear – End .005L
Clearance .040L .055L
T-AF Crankshaft Idler Gear – End .007L
Clearance .037L .052L
S (DUAL MAGNETO) Crankshaft Idler Gear – End .020L
Clearance .030L .040L
T-AF (DUAL MAGNETO) Crankshaft Idler Gear – End .015L
Clearance .038L .046L
1-15 SSP-1776-5-PT1
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
FUEL PUMP (CONT.)
725 S AN Fuel Pump Idler Gear – End .010L
Clearance .045L .055L
T-AF AN Fuel Pump Idler Gear – End .002L
Clearance .018L .024L
S-T-AF AN Fuel Pump Idler Gear – End .015L
(DUAL MAGNETO) Clearance .038L .045L
726 S-T-Y-AF AN Fuel Pump Drive Shaft Gear .0010L
and Adapter .0025L .004L
727 S AN Fuel Pump Drive Shaft Gear – .035L
End Clearance .069L .079L
T-AF AN Fuel Pump Drive Shaft Gear – .044L
End Clearance .081L .091L
T-AF AN Fuel Pump Drive Shaft Gear – .035L
(DUAL MAGNETO) End Clearance .073L .083L
Y AN Fuel Pump Drive Shaft Gear – .000L
End Clearance .067L .075L
GOVERNOR & HYDRAULIC PUMP
728 T-AF Front Governor Drive Idler Shaft .0010L
(NARROW DECK) (Both Ends) and Crankcase .0025L .004L
729 G1-G2-S2-S4-S6-T-AF Front Governor Idler Gear and .0010L
(WIDE DECK) Shaft .0025L .004L
730 BD-BE Front Governor Drive Gear and .0010L
Crankcase .0025L .004L
BD-BE Front Governor Drive Gear and .0005L
Camshaft .0025L .004L
731 G1-G2-S-T-AF Front Governor Gear and .0010L
Crankcase .0025L .004L
BD Front Governor Gear and .0010L
Crankcase .0030L .004L
732 G1-G2-S-T-AF Front Governor Gear – End .008L
Clearance .016L .021L
BD-BE Front Governor Gear – End .0045L
Clearance .0165L .021L
733 G-J-S Rear Governor Gear and Adapter .0010L
.0025L .005L
G-S Rear Governor Gear and .0010L
(DUAL MAGNETO) Accessory Housing .0025L .005L
734 G-J-S Rear Governor Gear – End .002L
Clearance .024L .034L
G-S Rear Governor Gear – End .002L
(DUAL MAGNETO) Clearance .037L .044L
735 T-AF Hydraulic Pump Gear and Adapter .0010L
.0025L .004L
T-AF (DUAL MAGNETO) Hydraulic Pump Gear and .0010L
Accessory Housing .0025L .004L
736 T-AF Hydraulic Pump Gear – End .010L
Clearance .066L .076L
T-AF (DUAL MAGNETO) Hydraulic Pump Gear – End .007L
Clearance .032L .039L
SSP-1776-5-PT1 1-16
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
VACUUM & TACHOMETER
737 A-B-G-J-S-T-Y-AF Vacuum Pump Gear and Adapter .0010L
.0030L .0045L
737 S-T-AF Vacuum Pump Gear and .0010L
(DUAL MAGNETO) Accessory Housing .0025L .004L
737 D Vacuum Pump Gear and .0010L
Accessory Housing .0025L .006L
738 A-B-G-J-S-T-AF Vacuum Pump Gear – End .010L
Clearance .057L .075L
D Vacuum Pump Gear – End .003L
Clearance .020L .030L
Y Vacuum Pump Gear – End .000
Clearance .067L .075L
S Vacuum Pump Gear – End .012L
(DUAL MAGNETO) Clearance .044L .055L
T-AF Vacuum Pump Gear – End .017L
(DUAL MAGNETO) Clearance .039L .050L
739 A-B-Y Tachometer Drive Shaft and .0015L
Adapter .0035L .006L
BD-BE Tachometer Drive Shaft and .0010L
Adapter .0050L .0065L
739 D-G-J-S-T-AF Tachometer Drive Shaft and .0015L
Accessory Housing .0035L .006L
740 G-J-S Vacuum Pump Gear and Adapter .0010L
(DUAL DRIVE) .0025L .004L
741 G-J-S Vacuum Pump Gear – End .000
(DUAL DRIVE) Clearance .017L .027L
742 G-J-S Idler Gear and Shaft .0010L
(DUAL DRIVE) .0030L .005L
743 G-J-S Idler Gear – End Clearance .021L
(DUAL DRIVE) .041L .060L
744 G-J-S Propeller Governor Gear and .0013L
(DUAL DRIVE) Adapter .0028L .005L
G-J-S Hydraulic Pump Gear and Adapter .0013L
(DUAL DRIVE) .0028L .005L
745 G-J-S Propeller Governor or Hydraulic .000
(DUAL DRIVE) Pump – End Clearance .054L .074L
MAGNETO, GENERATOR, STARTER
746 T Magneto Bearing and Gear .0005T
.0001L .0005L
746 D Magneto Bearing and Gear .0008T
.0001L .0005L
747 T Magneto Bearing and Crankcase .0002T
.0007L (A)
747 D Magneto Drive Bearing and .0006T
Adapter .0008T (A)
748 S7 Magneto Bearing and Gear .0001T
.0010T (A)
1-17 SSP-1776-5-PT1
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION III – GEAR TRAIN –
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
MAGNETO, GENERATOR, STARTER (CONT.)
749 S7 Magneto Bearing and Adapter .000
.0012L .0015L
750 S-T-AF Magneto Drive Gear and .0010L
(DUAL MAGNETO) Crankcase .0025L .003L
751 S-T-AF Magneto Drive Gear – End .005L
(DUAL MAGNETO) Clearance .073L .083L
752 AF Magneto Drive Gear and Shaft .001L
.003L .005L
753 BD-BE Magneto Drive Gear and .001L
Crankcase Bushing .003L .005L
754 Y Magneto Shaft Gear and Magneto .001L
Case .003L .005L
755 Y Magneto Shaft Gear and Support .001L
Assembly .003L .005L
756 Y Magneto Shaft Gear and
Accessory Drive Shaft Gear – End .0075L
Play .0125L .015L
757 Y Accessory Drive Shaft Gear and .001L
Support Assembly .003L .005L
758 S Magneto Gear and Bushing .0005L
(S4LN-21 and S4LN-1227) .0020L .0035L
T Magneto Gear and Bushing .0015L
(S6LN-21 & S6LN-1227) .0035L .0055L
T-AF Magneto Gear and Bushing .0015L
(DUAL MAGNETO) .0035L .0055L
7095 BD-BE Bushing – Magneto Drive .0025T
and Crankcase .0045T (A)
759 D Generator Gear Bushing and .0020T
Generator Gear .0035T (A)
760 D Generator Gear Bushing and .001L
Generator Drive Coupling Adapter .0028L .005L
761 D Bendix Drive Gear Bushing and .0005T
Crankcase .0025T (A)
762 D Bendix Drive Gear and Bendix .0010L
Drive Gear Bushing .0025L .005L
763 D Bendix Drive Shaft and Bendix .003L
Drive Housing .005L .010L
764 D Bendix Drive Shaft – End .000
Clearance .0059L .080L
SSP-1776-5-PT1 1-18
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION III – GEAR TRAIN
Oil Pumps
1-19 SSP-1776-5-PT1
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION III – GEAR TRAIN
Scavenge Pumps
SSP-1776-5-PT1 1-20
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION III – GEAR TRAIN
Fuel Pumps
1-21 SSP-1776-5-PT1
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION III – GEAR TRAIN
Front Governor
SSP-1776-5-PT1 1-22
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION III – GEAR TRAIN
1-23 SSP-1776-5-PT1
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION III – GEAR TRAIN
1-25 SSP-1776-5-PT1
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION III – GEAR TRAIN
1-27 SSP-1776-5-PT1
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION IV – BACKLASH
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
800 A-B-G-J-S-T-Y-AF Camshaft and Vacuum Pump – .004
Backlash .015 .020
801 BD-BE Camshaft and Vacuum and Oil .006
Pump Drive – Backlash .014 .020
802 Y Camshaft and Fuel Pump – .004
Backlash .015 .020
803 A-B-G-J-S-T-Y-AF Camshaft and Crankshaft Idler – .004
Backlash .015 .020
804 A-B-G-J-S-T-Y-AF Crankshaft and Crankshaft Idler – .004
Backlash .015 .020
805 A-B-G-J-S-T-AF Magneto Drive and Crankshaft .004
Idler – Backlash .015 .020
806 BD-BE Magneto Drive and Crankshaft .006
Gear – Backlash .014 .020
807 BD-BE Crankshaft Gear and Vacuum and .006
Oil Pump Drive – Backlash .014 .020
808 A-B-D-G-J-S-T-Y-AF Oil Pump Impellers – Backlash .008
.015 .020
BD-BE Oil Pump Impellers – Backlash .008
.012 .020
809 S-T-AF Oil Pump Drive and Crankshaft .004
(DUAL MAGNETO) Idler – Backlash .015 .020
810 Y Magneto and Magneto Shaft Gear .004
– Backlash .015 .020
811 Y Accessory Drive Shaft Gear and
Magneto Driven Shaft Gear – .003
Backlash .005 .012
812 Y Crankshaft Gear and Accessory
Drive Shaft Gear – Spline .002
Backlash .005 .015
813 G-J-S Camshaft and Propeller Governor .004
(DUAL DRIVE) or Hydraulic Pump – Backlash .015 .020
814 G-J-S Governor or Hydraulic Pump
(DUAL DRIVE) Drive and Drive Gear – Spline .0013
Backlash .0073 .010
815 G-J-S Governor or Hydraulic Pump and .004
(DUAL DRIVE) Idler – Backlash .015 .020
816 G-J-S Vacuum Pump and Idler – .004
(DUAL DRIVE) Backlash .015 .020
817 S-T-AF AN Fuel Pump Idler and .004
Crankshaft Idler – Backlash .015 .020
818 S-T-AF AN Fuel Pump Idler and Fuel .004
Pump Drive – Backlash .015 .020
819 S-T-AF Crankshaft Gear and AN Fuel .004
(DUAL MAGNETO) Pump Idler – Backlash .015 .020
820 T-AF Hydraulic Pump and Crankshaft .004
Idler – Backlash .015 .020
SSP-1776-5-PT1 1-28
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION IV – BACKLASH
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
821 G-J-S Propeller Governor Drive and
Crankshaft Idler – Backlash .004
(Rear Governor) .015 .020
822 G1-G2-S2-S4-S6-T-AF Propeller Governor Idler and
Camshaft – Backlash .004
(Front Governor) .015 .020
823 G1-G2-S2-S4-S6-S11-T-AF Propeller Governor Drive and
Idler – Backlash (Bevel Gears) .004
(Front Governor) .008 .015
824 BD-BE Propeller Governor Drive and
Camshaft – Backlash .003
(Bevel Gears) (Front Governor) .011 .015
825 D Crankshaft Timing Gear and .004
Camshaft Gear – Backlash .015 .020
826 D Camshaft Gear and Generator .004
Gear – Backlash .015 .020
827 D Crankshaft Gear and Generator .004
Gear – Backlash .015 .020
828 D Magneto Coupling Spline – .001
Backlash .005 .0075
829 D Vacuum Pump Gear and Vacuum
Pump Drive Gear – Backlash .004
.015 .020
830 D Starter Drive and Bendix Drive .004
Gear – Backlash .015 .020
831 D Bendix Drive Shaft Spline and
Bendix Drive Gear Spline – .001
Backlash .006 .015
832 S Injector Pump Idler Gear and
Injector Pump Drive Shaft Gear – .004
Backlash .015 .020
1-29 SSP-1776-5-PT1
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION IV – BACKLASH
1-31 SSP-1776-5-PT1
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION IV – BACKLASH
SSP-1776-5-PT1 1-32
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION IV – BACKLASH
1-33 SSP-1776-5-PT1
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION V – SPECIAL TORQUE REQUIREMENTS
New
Chart Thread Size Nomenclature Torque Limits
Ref.
918 ALL (AS 1-1/4-12 Oil Pressure Relief Valve 300 in.-lbs.
APPLICABLE)
919 ALL 1/4 Hex Head and Hose Clamps (Worm Type) 20 in.-lbs.
Below
5/16 Hex. Head Hose Clamps (Worm Type) (Metal to 45 in.-lbs.
and Above metal: example: heat shield to exhaust
pipe)
5/16 Hex. Head Hose Clamps (Worm Type) 30 – 35 in.-lbs.
and Above
920 ALL Cylinder Head Drain Back Hose Clamps 10 in.-lbs.
S-T Exhaust V-Band Coupling Torque Data
921 T-Bolt Split 1/4 In. Drilled Hex Nut With
Coupling Size Lycoming Part Vendor Part
Type Locknut Safety Wire Torque In.-Lbs.
Tube OD Number Number
Torque In.-Lbs.
1.75 in. LW-12093-4 MVT69183-175 65 75
2.00 in. LW-12093-5 MVT69183-200 85 75
2.25 in. LW-12093-6 MVT69183-225 85 75
2.25 in. LW-12125-3 MVT69197-225 85
3.69 in. LW-13464 U4204-55-369M 70
3.69 in. LW-15768 NH1004420-10 70
922 ALL Turbocharger V-Band Torque Data
Turbocharger Model No. V-Clamp Part No. V-Clamp Diameter Torque In.-Lbs.
TO-473* 400500-600 6.00 in. 40 – 80
TEO659* 400500-685 6.85 in. 40 – 50
THO8A60* 400500-775 7.75 in. 40 – 60
THO8A69* 400500-775 7.75 in. 40 – 60
301E10-2** TC-6-15 6.50 in. 15 – 20
* - AiResearch turbocharger.
** - Rajay turbocharger.
See latest revision of Service Instruction No. 1238 for assembly procedure.
Chart Thread Size Nomenclature Torque Limits
ALL DUAL
927 1/2-20 Crankshaft Gear Bolt 660 in.-lbs.
MAG. MODELS
BD 1/4 Crankshaft Gear Bolts 96 – 120 in.-lbs.
Cylinder Hold Down Studs
3/8-16 100 in.-lbs.
(Crankcase Driving Torque)
Cylinder Hold Down Studs
928 ALL 7/16-14 200 in.-lbs.
(Crankcase Driving Torque)
Cylinder Hold Down Studs
1/2-13 250 in.-lbs.
(Crankcase Driving Torque)
A-B-D-BD-BE-J-
3/8 Cylinder Hold Down Nuts 300 in.-lbs.
G-Y-S-T-AF
929 A1 7/16 Cylinder Hold Down Nuts 420 in.-lbs.
B-D-BD-BE-J-G-
1/2 Cylinder Hold Down Nuts 600 in.-lbs.
Y-S-T-AF
Cylinder Hold Down and Crankcase Parting Flange Nuts’ Tightening Procedures – See latest revision of
Service Instruction No. 1029
SECTION V – SPRINGS
Length COMP. LOAD
Lycoming Wire at Comp.
Ref. Chart Nomenclature Part No. Dia. Length Mfr. Min. Mfr. Service
Min. Max.
950 A-B-D-G-J-S-T- Outer Valve
LW-11800 .177 1.30 in. 112 lb. 122 lb. 109 lb. min.
Y-BD-BE Springs (Parallel)
S1-S2-S3-S5-S6- Outer Valve
S7-S9-S10-S11- Springs (Angle)
LW-11796 .182 1.43 in. 116 lb. 124 lb. 113 lb. min.
S12-S13-S14-T2-
T3
951 A-B-D-G-J-S-T- Auxiliary Valve
LW-11795 .135 1.17 in. 61 lb. 67 lb. 58 lb. min.
Y-BD-BE Spring (Parallel)
S1-S2-S3-S5-S6- Auxiliary Valve
S7-S9-S10-S11- Spring (Angle)
LW-11797 .142 1.33 in. 75 lb. 83 lb. 72 lb. min.
S12-S13-S14-T2-
T3-AF
952 ALL (AS Oil Pressure Relief
APPLICABLE) Valve Spring
Identification
Lycoming Dye Free Length
Part Numbers
61084 None 2.18 .054 1.30 in. 8.5 lb. 9.5 lb. 8.3 lb. min.
LW-18085 Purple/White 1.93 .067 1.44 in. 14.50 lb. 15.23 lb. 13.8 lb. min.
68668 Purple 2.04 .054 1.30 in. 7.1 lb. 7.8 lb. 6.9 lb. min.
77467 Yellow 1.90 .054 1.30 in. 6.4 lb. 7.1 lb. 6.2 lb. min.
LW-11713 White 2.12 .059 1.44 in. 10.79 lb. 11.92 lb. 10.5 lb. min.
953 A-B-G-J-S-T-Y- Oil Cooler Bypass
AF Spring .0465 1.94 in. 6.50 lb. 7.25 lb. 6.41 lb. min.
954 BD-BE Oil Filter Bypass
Spring .047 1.00 in. 3.05 lb. 3.55 lb. 3.0 lb. min.
955 D Magneto Coupling
Spring .091 .603 in. 20 lb. 22 lb. 19 lb. min.
SSP-1776-5-PT1 1-38
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION V – SPECIAL TORQUE REQUIREMENTS
1-39 SSP-1776-5-PT1
SERVICE TABLE OF LIMITS
PART I – DIRECT DRIVE ENGINES
SECTION V – SPECIAL TORQUE REQUIREMENTS
SSP-1776-5-PT1 1-40
SERVICE TABLE OF LIMITS
STANDARD TORQUE
UNLESS OTHERWISE LISTED
Torque limits for propeller attaching bolts to be supplied by propeller aircraft manufacturer.
NOTE: Refer to Table VIII for torque value conversions (In. Lb. or Ft. Lb. to Nm).
TABLE I TABLE II
BOLTS, SCREW AND NUTS PIPE PLUGS
Torque Torque Torque
Thread Thread Thread
In. Lb. Ft. Lb. In. Lb. Ft. Lb. In.-Lbs.
8 20 to 22 ----- 7/16 600 to 660 50 to 55 1/16-27 NPT 40 to 44
10 49 to 54 ----- 1/2 900 to 984 75 to 82 1/8-27 NPT 40 to 44
1/4 96 to 106 ----- 9/16 1320 to 1452 110 to 121 1/4-18 NPT 85 to 94
5/16 204 to 228 17 to 19 5/8 1800 to 1980 150 to 165 3/8-18 NPT 110 to 121
3/8 360 to 396 30 to 33 3/4 3240 to 3564 270 to 297 1/2-14 NPT 160 to 176
3/4-14 NPT 230 to 252
THIN NUTS (1/2 DIA. OF BOLT) – 1/2 LISTED TORQUE
1-11-1/2 NPT 315 to 347
TABLE III TABLE IV
FLEXIBLE TUBE CONNECTIONS
CRUSH TYPE GASKETS
(SEALASTIC OR EQUIVALENT FITTINGS)
Thread Pitch on Part to be
ANGLE OF TURN Tube Torque In.-Lbs.
Tightened Thread
Size
Threads Per Inch Aluminum Copper Aluminum Alloy Steel
8 135° 67° (-3) 3/16 3/8 - 24 30 to 50 70 to 80
10 135° 67° (-4) 1/4 7/16 - 20 40 to 65 90 to 100
12 180° 90° (-5) 5/16 1/2 - 20 60 to 80 135 to 150
14 180° 90° (-6) 3/8 9/16-18 75 to 125 270 to 300
16 270° 135° (-8) 1/2 3/4-16 150 to 250 450 to 500
18 270° 135° (-10) 5/8 7/8 - 14 200 to 350 650 to 700
20 270° 135°
24 360° 180° TABLE V
28 360° 180° STUDS MIN. DRIVING TORQUE
NOTE: Install all crush type gaskets except the self Threads Torque In.-Lbs.
centering type, with the unbroken surface against the flange 1/4-20 15
of the plug or part being tightened against the seal. Turn the 5/16-18 25
part until the sealing surfaces are in contact and then tighten 3/8-16 50
to the angle of turn listed for the appropriate thread size.
NOTE: Lubricate Threads Unless Otherwise Specified.
TABLE VI
JAM NUT OR STRAIGHT THREAD O-RING BOSS
Tube Size Thread Torque Ft. Lbs.
-03 3/8 – 24 8–9
-04 7/16 – 20 13 – 15
-05 1/2 – 20 14 – 15
-06 9/16 – 18 23 – 24
-08 3/4 – 16 40 – 43
-10 7/8 – 14 43 – 48
-12 1-1/16 – 12 68 – 75
-14 1-3/16 – 12 83 – 90
-16 1-5/16 – 12 112 – 123
-20 1-5/8 – 12 146 – 161
-24 1-7/8 – 12 154 – 170
-32 2-1/2 – 12 218 – 240
1-41 SSP-1776-5-PT1
SERVICE TABLE OF LIMITS
STANDARD TORQUE (CONT.)
UNLESS OTHERWISE LISTED
TABLE VII
METAL TUBE FITTINGS
Wrench torque for tightening AN-818 Nut (pound inches) Minimum bend radii
measured to tubing
Aluminum-alloy tubing Steel tubing Aluminum-alloy tubing centerline. Dimension in
Dash Nos. Tubing (Flare MS33583) for use inches
Ref. OD inches on oxygen lines only
Minimum Maximum Minimum Maximum Alum.
Minimum Maximum Steel
Alloy
-2 1/8 20 30 75 85 -- -- 3/8 --
-3 3/16 25 35 95 105 -- -- 7/16 21/32
-4 1/4 50 65 135 150 -- -- 9/16 7/8
-5 5/16 70 90 170 200 100 125 3/4 1-1/8
-6 3/8 110 130 270 300 200 250 15/16 1-5/16
-8 1/2 230 260 450 500 300 400 1-1/4 1-3/4
-10 5/8 330 360 650 700 -- -- 1-1/2 2-3/16
-12 3/4 460 500 900 1000 -- -- 1-3/4 2-5/8
-16 1 500 700 1200 1400 -- -- 3 3-1/2
-20 1-1/4 800 900 1520 1680 -- -- 3-3/4 4-3/8
-24 1-1/2 800 900 1900 2100 -- -- 5 5-1/4
-28 1-3/4 -- -- -- -- -- -- -- --
-32 2 1800 2000 2660 2940 -- -- 8 7
TABLE VIII
TORQUE CONVERSIONS
In. Lb. Ft. Lb. Nm In. Lb. Ft. Lb. Nm In. Lb. Ft. Lb. Nm
5 0.42 0.56 100 8.33 11.30 1000 83.33 113.00
10 0.83 1.13 200 16.67 22.60 2000 166.70 226.00
20 1.67 2.26 300 25.00 53.90 3000 250.00 339.00
30 2.50 3.39 400 33.33 45.19 4000 333.30 451.90
40 3.33 4.52 500 41.67 56.49 5000 416.70 564.90
50 4.17 5.65 600 50.00 67.79 6000 500.00 677.90
SSP-1776-5-PT1 1-42
SERVICE TABLE OF LIMITS
CHART MODELS
AQ TIO-541
AZ TIGO-541
(A) These fits are either shrink fits controlled by machining, fits that may readily be
adjusted, or fits where wear does not normally occur. In each case, the fit must be held
to manufacturing tolerance.
(B) Side clearance on piston rings must be measured with face of ring flush with piston.
(D) The dimensions shown are measured at the bottom of the piston skirt at right angles to
the piston pin.
(E) Permissible wear of the crankshaft (rod and main bearing journals) to be minus 0.0015
on the diameter.
(L) Loose fit; wherein a definite clearance is mentioned between the mating surfaces.
• Deleted NOTES that reference S.I. 1243 in Piston • Revised burnishing instructions for connecting rod
Application Table bushing in reference number 600
• Added pages and figures for all 900 Series reference • Revised the Mfr. Min. & Max. Clearance for Piston Ring
numbers in Section V Gap (Compression) Nitrided Cylinders (Choke Barrels)
and Piston Ring Gap (Oil) in reference number 607
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
506 AQ (CONT.) Mounted on No. 3 and 5
Journals Max. Run-Out No. 4
Journal .003 .0045
AQ-AZ Crankshaft and Crankcase – .005L
Front End Clearance .016L .026L
507 AQ Clearance – Front Face of
Crankshaft Oil Slinger to Front
Face of Recess in Crankcase
(Crankshaft Against Thrust .002
Face) .007 (A)
508 AQ-AZ Crankshaft Propeller Flange
Run-Out .005
509 AQ Starter Ring Gear and Support .014T
.022T (A)
510 AQ-AZ Crankshaft Timing Gear and .002L
Crankshaft .0005L (A)
511 AQ-AZ Tappet Body and Crankcase .0010L
.0030L .004L
AQ-AZ O.D. of Tappet .9990
.9995 .9987
AQ-AZ I.D. Tappet Bore in Crankcase 1.0005
1.0018 1.0021
514 AQ-AZ Camshaft and Crankcase .002L
.004L .006L
515 AQ-AZ Camshaft – End Clearance .002L
.004L .015L
516 AQ-AZ Camshaft Run-Out at Center .000
Bearing Journal .001 .006
517 AQ-AZ Counterweight Bushing and .0013T
Crankshaft .0026T (A)
518 AQ-AZ Counterweight Roller – End .003L
Clearance .025L .038L
519 AQ-AZ Counterweight and Crankshaft –
Side Clearance (Measure Below .003L
Roller Next to Flat) .013L .017L
520 AQ-AZ Counterweight Bore and Washer .0002L
O.D. .0030L (A)
521 AQ-AZ I.D. Counterweight Bushing .7485
.7505 .7512
AZ I.D. Counterweight Bushing (2nd 1.030
order) 1.032 1.0327
522 AQ-AZ O.D. of Counterweight Roller
(See latest revision of Service
Instruction No. 1012)
523 AZ Thrust Bearing and Propeller .0001L
Shaft .0012L .002L
524 AZ Propeller Shaft and Rear Bearing .0015L
.0030L .0040L
SSP-1776-5-PT2 2-2
SERVICE TABLE OF LIMITS
PART II – INTEGRAL ACCESSORY DRIVE ENGINES
SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
524 AZ Propeller Shaft Bearing Bore 2.1865
Diameter 2.1875 2.1885
525 AZ Thrust Bearing and Crankcase .0006L
.0010T (A)
526 AZ Thrust Bearing and Thrust
Bearing Cap Clamp Fit (Shim to .003T
this Fit) .005T (A)
527 AZ Thrust Bearing Tilt at 4 Foot .027 Tilt
528 AZ Thrust Bearing End Play .006
.008 .010
529 AZ Crankshaft and Crankshaft Front .0002T
Bearing .0015T (A)
Dimensions Clearances
Mfr. Min. Mfr.
& Max. Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max.
600 AQ-AZ Connecting Rod and Connecting Bushing P/N LW-13923 to be burnished in place
Rod Bushing Bushing P/N 01K28983 is not burnished in place
AQ-AZ Finished I.D. of Connecting Rod 1.1254
Bushing 1.1262
601 AQ-AZ Length Between Connecting Rod 6.7485
Bearing Centers 6.7515
602 AQ-AZ Connecting Rod Bushing and .0008L
Piston Pin .0021L .0025L
603 AQ-AZ Piston Pin and Piston .0003L
.0014L .0018L
AQ-AZ Diameter of Piston Pin Hole in 1.1249
Piston 1.1254
AQ-AZ Diameter of Piston Pin 1.1241
1.1246
604 AQ-AZ Piston and Piston Pin Plug .0002L
.0010L .002L
AQ-AZ *Diameter of Piston Pin Plug 1.1242
1.1247
605 AQ-AZ Piston Pin and Piston Pin Plug – .0005L
Nitrided and Chrome Cylinders .0025L .005L
AQ-AZ *Diameter of Piston Pin Plug .5655
.5665
* See latest revision of Service Instruction No. 1267.
606 AQ-AZ Piston Ring and Piston – Side .0025L
Clearance (Top Ring Comp.) .0055L .008L (B)
AQ-AZ Piston Ring and Piston – Side .000L
Clearance (2nd Ring Comp.) .004L .006L (B)
AQ-AZ Piston Ring and Piston - Side .002L
Clearance (Oil Regulating) .004L .006L (B)
607 AQ-AZ Piston Ring Gap (Compression)
Chrome Cylinders (Straight .020
Barrels) .030 .047
AQ-AZ Piston Ring Gap (Compression)
Nitrided and Chrome Cylinders .045
(Choke Barrels) .065 .067
AQ-AZ Piston Ring Gap (Oil Regulating) .015
(All Barrels) .040 .047
For Choke Barrels – Ring gap is measured within 4 inches from bottom. Ring gap at top of travel must not be less than
.0075.
For All Other Barrels – Ring gap is measured at top limit of ring travel.
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
Engine and Piston Application Min. Piston Diameter Cylinder Barrel Max.
Engine Chart Type of Maximum Clearance
Code Letter Piston Number Top Bottom Type of Piston Surface Diameter Piston Skirt
& Cyl.
608 AQ-AZ 76966, LW-10545 5.0790 5.1090 Forged-Cam N-C 5.1305 .018L
608
609
610
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
both diameters; this sum, divided by 2, represents the average diameter of the cylinder.
*=High Compression.
Maximum taper and out-of-round permitted for cylinder in service is .0045 inch.
To find the average out-of-round, measure 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. Difference between diameters must not exceed .0045 inch.
Piston diameter at top is measured at top ring land (between top and second compression ring grooves) at right angle to
piston pin hole; diameter at bottom of piston is measured at the bottom of the piston skirt at right angles to the piston
pin.
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
611 AQ-AZ Exhaust Valve Seat and Cylinder .0075T
Head .011T (A)
AQ-AZ O.D. Exhaust Seat 1.9355
1.937
AQ-AZ I.D. Exhaust Seat Hole in 1.926
Cylinder Head 1.928
612 AQ-AZ Intake Valve Seat Hole in .0065T
Cylinder Head .010T (A)
AQ-AZ O.D. Intake Seat 2.2885
2.290
AQ-AZ I.D. Intake Seat Hole in Cylinder 2.280
Head 2.282
613 AQ-AZ Exhaust Valve Guide and .0011T
Cylinder Head .0030T (A)
AQ-AZ O.D. Exhaust Valve Guide .6954
.6963
AQ-AZ I.D. Exhaust Valve Guide Hole .6933
in Cylinder Head .6943
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
614 AQ-AZ Intake Valve Guide and Cylinder .0010T
Head .0025T
AQ-AZ O.D. Intake Valve Guide .5933
.5938
AQ-AZ I.D. Intake Valve Guide Hole in .5913
Cylinder Head .5923
615 AQ-AZ Exhaust Valve Stem and Valve .0037L
Guide .0050L (A)
AQ-AZ O.D. Exhaust Valve Stem .4955
.4965 .4937
AQ-AZ Finished I.D. Exhaust Valve .4995
Guide .5005
1/2 inch diameter exhaust valves may have exhaust valve guides that are .003 in. over the maximum inside diameter
limit, anytime up to 300 hours of service. After 300 hours of service, inside diameter of exhaust valve guide may increase
.001 in. during each 100 hours of operation up to the recommended overhaul time for the engine, or not to exceed .015
inch over the basic I.D. See latest revision of Service Instruction No. 1009 for recommended overhaul time.
616 AQ-AZ Intake Valve Stem and Valve .0010L
Guide .0028L .006L
AQ-AZ O.D. Intake Valve Stem .4022
.4030 .4010
AQ-AZ Finished I.D. Intake Valve .4040
Guide .4050
617 AQ-AZ Intake and Exhaust Valve and
Valve Cap – Clearance (Rotator
Type with Small Diameter .000
Head) .004L .005L
618 AQ-AZ Dry Tappet Clearance .040
.105
619 AQ-AZ Valve Rocker Shaft and Valve .0001L
Rocker Bushing .0013L .0025L
AQ-AZ Finished I.D. of Valve Rocker
Shaft (Bushing) in Cylinder .6246
Head .6261 .6270
620 AQ-AZ Valve Rocker Shaft and Valve .0007L
Rocker Bushing .0017L .004L
AQ-AZ Finished I.D. of Rocker Arm .6252
Bushing .6263 .6270
AQ-AZ O.D. Valve Rocker Shaft .6241
.6245 .6231
621 AQ-AZ Valve Rocker Bushing and
Valve Rocker Bushing Must Be Burnished in Place
622 AQ-AZ Valve Rocker Shaft Bushing and .0022T
Cylinder Head .0038T (A)
AQ-AZ Valve Rocker Shaft Bushing .7380
Hole in Cylinder Head .7388
623 AQ-AZ Valve Rocker and Cylinder .002L
Head – Side Clearance .020L .024L
2-9 SSP-1776-5-PT2
SERVICE TABLE OF LIMITS
PART II – INTEGRAL ACCESSORY DRIVE ENGINES
SECTION II – CYLINDERS
2-11 SSP-1776-5-PT2
SERVICE TABLE OF LIMITS
PART II – INTEGRAL ACCESSORY DRIVE ENGINES
SECTION III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
ACCESSORY DRIVE, COMPRESSOR, BREATHER, PROPELLER SHAFT, ALTERNATOR, & STARTER
763 AQ-AZ Accessory Drive Gear
Intermediate and Crankcase (2 .0010L
Places) .0030L .005L
764 AQ-AZ Accessory Drive Gear – End .016L
Clearance .018L .020L
765 AQ-AZ Accessory Drive Gear and .0010L
Crankcase .0030L .005L
766 AQ-AZ Compressor Drive Shaft and .0010L
Compressor Drive Adapter .0030L .005L
767 AQ-AZ Compressor Drive Shaft – End .0005
Clearance .0295 .040
768 AQ-AZ Breather Slinger Gear and Shaft .0021L
.0035L .005L
769 AQ-AZ Breather Slinger Gear – End .008
Clearance .017 .025
770 AZ Propeller Shaft Drive Gear and .0025L
Bearings .0050L .0060L
771 AZ Propeller Shaft Drive Gear – .005
End Play .015 .022
772 AZ Propeller Shaft and Rear Bearing .0015L
.0030L .0040L
773 AZ Alternator Driven Gear and .0025L
Adapter Bushing .0045L .0065L
774 AZ Starter Drive and Alternator .004
Drive Gear – End Play .008 .011
775 AZ Starter Driven Gear and Adapter .0015L
Bushing .0030L .005L
776 AZ Starter Drive Shaft (Slip .0015L
Coupling) and Crankcase .0040L .007L
777 AZ Starter Idler Gear and Idler Gear .0005L
Bearing .0020L .005L
SSP-1776-5-PT2 2-12
SERVICE TABLE OF LIMITS
PART II – INTEGRAL ACCESSORY DRIVE ENGINES
SECTION III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
808 AQ-AZ Oil Pump Impellers – Backlash .008
.013 .020
822 AQ Propeller Governor Idler and .005
Camshaft – Backlash .015 .020
823 AQ-AZ Propeller Governor Drive and .004
Idler – Backlash .008 .015
825 AQ-AZ Crankshaft Timing Gear and .005
Camshaft – Backlash .015 .020
826 AQ-AZ Accessory Drive and Accessory .004L
Drive Intermediate .006L .010L
827 AQ-AZ Accessory Drive Gear
Intermediate and Idler – Spline .002
Backlash .005 .007
828 AQ-AZ Accessory Idler and Vacuum
and Hydraulic Pump Gear – .004
Backlash .011 .016
829 AZ Propeller Shaft – Reduction
Gear Total Backlash at 4 Foot .38
Radius .75 .90
830 AZ Starter (Bendix – Slip Coupling)
and Starter Drive Gear – .016
Backlash .031 .045
831 AQ-AZ Accessory Idler and Magneto .005
Drive Shaftgear – Backlash .015 .020
832 AZ Starter Drive Gear and Starter
and Alternator Drive Shaft Gear .004
– Backlash .008 .015
833 AZ Alternator Drive Gear and
Starter and Alternator Drive .003
Shaftgear – Backlash .008 .012
834 AQ-AZ Fuel Pump Idler Gear and
Vacuum and Hydraulic Pump .002
Drive Gear – Backlash .015 .020
835 AQ-AZ Fuel Pump Idler Gear and Fuel .0006
Pump Drive – Backlash .0160 .021
836 AQ-AZ Magneto Drive Shaft Gear and
Magneto Coupling – Spline .0010
Backlash .0045 .0075
837 AQ-AZ Accessory Drive Gear and
Compressor Drive Shaft – Spline .0040
Backlash .0076 .014
838 AQ-AZ Crankshaft Gear and Accessory
Drive Shaftgear – Spline .0040
Backlash .0076 .014
839 AQ Breather Slinger Gear and .005
Accessory Idler – Backlash .015 .020
840 AZ Front Crankshaft Spline Bushing
and Alternator and Starter Shaft .001
Gear – Spline Backlash .005 .006
SSP-1776-5-PT2 2-18
SERVICE TABLE OF LIMITS
PART II – INTEGRAL ACCESSORY DRIVE ENGINES
SECTION IV – BACKLASH
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
841 AZ Propeller Shaft Drive Gear and
Alternator and Starter Shaft Gear .001
– Spline Backlash .004 .006
842 AZ Propeller Shaft Drive Gear and .008
Driven Gear – Backlash .014 .016
843 AZ Starter Slip Coupling Gear and .0002
Starter Idler – Backlash .0045 .0075
844 AZ Bendix Starter Motor Shaft Gear .0002
and Idler – Backlash .0045 .0075
845 AZ Propeller Shaft Spline and
Propeller Shaft Driven Gear – .008
Spline Backlash .011 .015
(When Measured at O.D. of .020
Propeller Gear) .028 .036
Accessory Drives
2-19 SSP-1776-5-PT2
SERVICE TABLE OF LIMITS
PART II – INTEGRAL ACCESSORY DRIVE ENGINES
SECTION IV – BACKLASH
Accessory Drives
SSP-1776-5-PT2 2-20
SERVICE TABLE OF LIMITS
PART II – INTEGRAL ACCESSORY DRIVE ENGINES
SECTION V – SPECIAL TORQUE REQUIREMENTS
2-21 SSP-1776-5-PT2
SERVICE TABLE OF LIMITS
PART II – INTEGRAL ACCESSORY DRIVE ENGINES
SECTION V – SPRINGS
COMP. LOAD
Length
Lyc. at Comp. Mfr. Mfr. Service
Ref. Part No.
Wire Length Min. Max. Max.
Chart Nomenclature Dia.
950 AQ-AZ Outer Valve Spring LW-11798 .192 1.610 in. 136 lb. 144 lb. 133 lb.
76351 .177 1.610 in. 136 lb. 144 lb. min.
951 AQ-AZ Auxiliary Valve Spring LW-11799 .148 1.48 in. 86 lb. 94 lb. 83 lb.
76352 .142 1.48 in. 86 lb. 94 lb. min.
952 AQ-AZ Oil Pressure Relief
Valve Spring
Lycoming Identification
Part Free
Numbers Dye Length
7.1 lb.
68668 Purple 2.04 .054 1.30 in. 7.1 lb. 7.8 lb. min.
10.5 lb.
LW-11713 White 2.12 .059 1.44 in. 10.79 lb. 11.92 lb. min.
8.3 lb.
LW-11138 None 2.64 .051 1.44 in. 8.55 lb. 9.45 lb. min.
955 AQ-AZ Fuel Drain Check Valve Spring 5.35 lb.
.047 .75 in. 5.50 lb. 6.50 lb. min.
956 AQ-AZ Oil Filter Relief Valve Spring 3.00 lb.
.054 1.93 in. 3.05 lb. 3.55 lb. min.
957 AZ Shroud Tube Spring 13 lb.
.105 2.09 in. 14 lb. 16 lb. min.
958 AQ-AZ Pressurizing Valve Spring .63 lb.
.032 .455-.485 .65 lb. .75 lb. min.
959 AZ Spring Between Crankshaft and 46 lb.
Starter and Alternator Drive Gear .13 1.40 in. 48 lb. 52 lb. min.
960 AZ Alternator Drive Coupling Spring 9 lb.
.047 .83 in. 10 lb. 11 lb. min.
SSP-1776-5-PT2 2-22
SERVICE TABLE OF LIMITS
PART II – INTEGRAL ACCESSORY DRIVE ENGINES
SECTION V – SPECIAL TORQUE REQUIREMENTS
TABLE VI
JAM NUT OR STRAIGHT THREAD O-RING BOSS
Tube Size Thread Torque Ft. Lbs.
-03 3/8 – 24 8–9
-04 7/16 – 20 13 – 15
-05 1/2 – 20 14 – 15
-06 9/16 – 18 23 – 24
-08 3/4 – 16 40 – 43
-10 7/8 – 14 43 – 48
-12 1-1/16 – 12 68 – 75
-14 1-3/16 – 12 83 – 90
-16 1-5/16 – 12 112 – 123
-20 1-5/8 – 12 146 – 161
-24 1-7/8 – 12 154 – 170
-32 2-1/2 – 12 218 – 240
SSP-1776-5-PT2 2-30
SERVICE TABLE OF LIMITS
STANDARD TORQUE (CONT.)
UNLESS OTHERWISE LISTED
TABLE VII
METAL TUBE FITTINGS
Wrench torque for tightening AN-818 Nut (pound inches) Minimum bend radii
measured to tubing
Aluminum-alloy tubing Steel tubing Aluminum-alloy tubing centerline. Dimension in
Dash Nos. Tubing (Flare MS33583) for use inches
Ref. OD inches on oxygen lines only
Minimum Maximum Minimum Maximum Alum.
Minimum Maximum Steel
Alloy
-2 1/8 20 30 75 85 -- -- 3/8 --
-3 3/16 25 35 95 105 -- -- 7/16 21/32
-4 1/4 50 65 135 150 -- -- 9/16 7/8
-5 5/16 70 90 170 200 100 125 3/4 1-1/8
-6 3/8 110 130 270 300 200 250 15/16 1-5/16
-8 1/2 230 260 450 500 300 400 1-1/4 1-3/4
-10 5/8 330 360 650 700 -- -- 1-1/2 2-3/16
-12 3/4 460 500 900 1000 -- -- 1-3/4 2-5/8
-16 1 500 700 1200 1400 -- -- 3 3-1/2
-20 1-1/4 800 900 1520 1680 -- -- 3-3/4 4-3/8
-24 1-1/2 800 900 1900 2100 -- -- 5 5-1/4
-28 1-3/4 -- -- -- -- -- -- -- --
-32 2 1800 2000 2660 2940 -- -- 8 7
TABLE VIII
TORQUE CONVERSIONS
In. Lb. Ft. Lb. Nm In. Lb. Ft. Lb. Nm In. Lb. Ft. Lb. Nm
5 0.42 0.56 100 8.33 11.30 1000 83.33 113.00
10 0.83 1.13 200 16.67 22.60 2000 166.70 226.00
20 1.67 2.26 300 25.00 53.90 3000 250.00 339.00
30 2.50 3.39 400 33.33 45.19 4000 333.30 451.90
40 3.33 4.52 500 41.67 56.49 5000 416.70 564.90
50 4.17 5.65 600 50.00 67.79 6000 500.00 677.90
2-31 SSP-1776-5-PT2
SERVICE TABLE OF LIMITS
NOTE
In “Chart” column, a number appearing after a letter shows exception to basic model.
(A) These fits are either shrunk fits controlled by machining, fits that may readily be
adjusted, or fits where wear does not normally occur. In each case, the fit must be held
to manufacturing tolerance.
(B) Side clearance on piston rings must be measured with face of ring flush with piston.
(C) Replacements to correct these items must be made to give uniform backlash within
0.001 between the stationary gear and pinions, and within 0.001 between the pinions
and the ring gear.
(D) These dimensions shown are measured at bottom of piston skirt at right angles to
piston pin.
(E) Permissible wear of the crankshaft (rod and main bearing journals) to be minus 0.0015
on the diameter.
(L) Loose fit; wherein a definite clearance is mentioned between the mating surfaces.
• Deleted NOTES that reference S.I. 1243 in Piston • Revised burnishing instructions for connecting rod
Application Table bushing in reference number 600
• Added Ref. number 930 to Section V table and figure for • Revised the Mfr. Min. & Max. Clearance for Piston Ring
torque value for brass union nut on stainless steel injector Gap (Compression) Nitrided Cylinders (Choke Barrels)
fuel lines and primer lines (Both Ends) and Piston Ring Gap (Oil) in reference number 607
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
500 E-H1-H2-H4 All Main Bearings and .0015L
Crankshaft .0045L .0060L
H3-H5-P-AB-AC Main Bearings and Crankshaft .0011L
(Except Front) .0041L .0050L
H3-H5-P-AB-AC Front Main Bearings and .0011L
Crankshaft .0041L .0050L
E-H-P Diameter of Main Bearing 2.3745
Journal on Crankshaft 2.376 (E)
E-H1-H2-H4 Crankcase Bearing Bore 2.566
Diameters (All) 2.567 2.5685
H3-H5-P-AB-AC Crankcase Bearing Bore 2.6865
Diameters (All) 2.6875 2.6890
501 ALL Connecting Rod Bearings and .0008L
Crankshaft .0038L .0050L
ALL Diameter of Connecting Rod 2.1235
Journal on Crankshaft (2-1/8 in.) 2.125 (E)
ALL Connecting Rod Bearing Bore
Diameter (Measured at axis 30° 2.2870
on each side) 2.2875
502 ALL Connecting Rod Side Clearance .004L
.010L .016L
503 ALL Connecting Rod Alignment .010 in 10 Inches
504 ALL Connecting Rod Twist .012 in 10 Inches
505 ALL Crankshaft Run-Out at Center
Main Bearings
Mounted on No. 1 and 4
Journals Max. Run-Out No. 2
and 3 Journals .005 .0075
Mounted on No. 1 and 3
Journals Max. Run-Out No. 2
Journal .003 .0045
Mounted on No. 2 and 4
Journals Max. Run-Out No. 3
Journal .003 .0045
506 ALL Crankshaft and Crankcase Front .006L
End Clearance .015L .025L
510 E-H1-H2-H3 Crankshaft Timing Gear and .0015L
Crankshaft .0005T (A)
H4-H5-P-AB-AC Crankshaft Timing Gear and .0000
Crankshaft .0015T (A)
511 ALL Tappet Body and Crankcase .0010L
.0033L .004L
ALL O.D. of Tappet .7169
.7177 .7166
ALL I.D. Tappet Bore in Crankcase .7187
.7200 .7203
3-1 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
512 ALL Tappet Plunger Assembly and .0010L
Body (Hyperbolic) .0067L .0087L
513 ALL Tappet Socket and Body .002L
(Hyperbolic) .007L .009L
514 ALL Camshaft and Crankcase .002L
.004L .006L
515 ALL Camshaft – End Clearance .002L
.009L .015L
516 ALL Camshaft Run-Out at Center .000
Bearing Journal .001 .006
517 ALL Counterweight Bushing and .0013T
Crankshaft .0026T (A)
518 ALL Counterweight Roller – End .007L
Clearance .025L .038L
519 ALL Counterweight and Crankshaft – .003L
Side Clearance* .013L .017L
* - Measure below roller next to flat.
520 ALL Counterweight Bore and Washer .0002L
O.D. .0030L (A)
521 ALL I.D. of Counterweight Bushing .7485
.7505 .7512
522 ALL O.D. of Counterweight Roller
(P/N 69433) (See latest revision .5045
of Service Instruction No. 1012) .5050
AC O.D. of Counterweight Roller
(P/N 73287) (See latest revision .5189
of Service Instruction No. 1012) .5194
ALL O.D. of Counterweight Roller
(P/N 70416) (See latest revision .6945
of Service Instruction No. 1012) .6950
523 ALL Thrust Bearing and Propeller .0000
Shaft .0012L .002L
526 ALL Thrust Bearing and Thrust
Bearing Cap Clamp Fit (Shim to .003T
this fit) .005T (A)
527 ALL Thrust Bearing Tilt .027 Tilt
528 ALL Thrust Bearing – End Play .006
.008 .010
530 ALL Propeller Shaft Run-Out (Rear
Cone Location) .003
531 ALL Propeller Shaft Run-Out (Front
Cone Location) (Propeller Shaft
Installed) .007
532 E-H1-H2-H3 Starter Jaw and Crankshaft .0005L
.0040L (A)
533 ALL Thrust Bearing and Reduction .0006L
Gear Housing .0024L .0035L
SSP-1776-5-PT3 3-2
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
534 ALL Crankshaft and Crankcase Front .0010T
Bushing .0025T (A)
535 ALL Pinion – End Clearance .011
.016 .030
536 ALL Pinion Shaft and Cage (See
latest revision of Service .0001T
Instruction No. 1236) .0005T
ALL Pinion Shaft and Cage (See
latest revision of Service Select for Hand Push
Instruction No. 1114) Fit (C) .002
537 ALL Propeller Shaft and Crankshaft .0020L
Bushing .0035L .005L
ALL I.D. Propeller Shaft Bushing in 1.251
Crankshaft 1.2525 1.253
This Diameter must be concentric with Front
Main Bearing within .003 in. TIR.
538 ALL Stationary Gear and Plate – End .000
Clearance .004 .007
539 ALL Ring Gear and Drive Plate – End .000
Clearance .004 .007
540 P-AB-AC Reduction Gear Governor and
Magneto Housing and Reduction .004T
Gear Housing Sleeve .006T (A)
541 H4-H5-P-AB-AC Rear Crankshaft Spline Bushing .0002T
and Crankshaft .0015T (A)
3-3 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION I – CRANKCASE, CRANKSHAFT AND CAMSHAFT
Dimensions Clearances
Mfr. Min. Mfr.
& Max. Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max.
600 ALL Connecting Rod and Bushing P/N LW-13923 to be burnished in place
Connecting Rod Bushing Bushing P/N 01K28983 is not burnished in place
Finished I.D. of Connecting 1.1254
Rod Bushing 1.1262
601 E-H-P Length Between Connecting 6.4985
Rod Bearing Centers 6.5015
AB-AC Length Between Connecting 6.4785
Rod Bearing Centers 6.7515
602 ALL Connecting Rod Bushing and .0008L
Piston Pin .0021L .0025L
603 ALL Piston Pin and Piston .0003L
.0014L .0018L
ALL Diameter of Piston Pin Hole in 1.1249
Piston 1.1254
ALL Diameter of Piston Pin 1.1241
1.1246
604 H-P-AB-AC Piston and Piston Pin Plug .0002L
.0010L .002L
H-P-AB-AC *Diameter of Piston Pin Plug 1.1242
1.1247
605 ALL Piston Pin and Piston Pin Plug .0005L
(Optional) .0025L .005L
H-P-AB-AC *Diameter of Piston Pin Plug .5655
.5665
E Diameter of Piston Pin Plug .8405
(Thin Wall Pin) .8415
*See latest revision of Service Instruction No. 1267.
606 ALL Piston Ring and Piston – Side
Clearance (Top Ring Comp.) .0025L
Half Wedge .0055L .008L (B)
ALL Piston Ring and Piston – Side
Clearance (2nd Ring Comp.) .000
Full or Half Wedge .004L .006L (B)
ALL (AS APPLICABLE) Piston Ring and Piston – Side
Clearance (3rd Ring Comp.) .000
Half Wedge .004L .006L (B)
ALL Piston Ring and Piston – Side .002L
Clearance (Oil Regulating) .004L .006L (B)
ALL (AS APPLICABLE) Piston Ring and Piston – Side .003L
Clearance (Oil Scraper) .0055L .007L (B)
607 ALL Piston Ring Gap (Comp.) Plain
and Chrome Cylinders (Straight .020
Barrels) .030 .047
ALL Piston Ring Gap (Comp.)
Nitrided and Chrome Cylinders .045
(Choke Barrels) .065 .067
ALL Piston Ring Gap (Oil .015
Regulating) (All Barrels) .040 .047
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
607 ALL (AS APPLICABLE) Piston Ring Gap (Oil Scraper) .015
(All Barrels) .030 .047
For Choke Barrels – Ring gap is measured within 4 inches from bottom. Ring gap at top of travel must not be less than
.0075.
For All Other Barrels – Ring gap is measured at top limit of ring travel.
Engine and Piston Application Min. Piston Diameter Cylinder Barrel Max.
Engine Chart Type of Maximum Clearance
Code Letter Piston Number Top Bottom Type of Piston Surface Diameter Piston Skirt
& Cyl.
608 E 67266, 71553 4.8395 4.8540 Forged-Round P 4.8805 .018L
608 E 73620, 73628 4.8395 4.8540 Forged-Round N 4.8805 .018L
609 E 67266, 71553, 73620,
610 73628, 73932 4.8395 4.8540 Forged-Round C 4.8805 .0225L
E 75984 4.8395 4.8590 Forged-Cam C-N 4.8805 .018L
H-P 69236 5.0905 5.1040 Forged-Cam P-C 5.1305 .0225L
H-P 71545, 71608* 5.0905 5.1025 Forged-Round C 5.1305 .024L
H-P-AB-AC 71940, 72249*,
72578, 73947*,
73976 5.0905 5.1040 Forged-Round C 5.1305 .0225L
H-AC 71940, 72249*,
73947*, 73976 5.0905 5.1040 Forged-Round N 5.1305 .023L
H-P-AB 74242, 75617* 5.0790 5.1090 Forged-Cam C 5.1305 .018L
H-P-AB-AC 74242, 76258* 5.0790 5.1090 Forged-Cam N 5.1305 .018L
AC 75617*, 76258* 5.0790 5.1090 Forged-Cam C-N 5.1305 .018L
H-P-AB-AC 73264*, 75961,
76966, 78203*,
78762, LW-10207*,
LW-10208,
LW-10545 5.0790 5.1090 Forged-Cam C-N 5.1305 .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
both diameters; this sum, divided by 2, represents the average diameter of the cylinder.
*=High Compression.
Maximum taper and out-of-round permitted for cylinder in service is .0045 inch.
To find the average out-of-round, measure 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. Difference between diameters must not exceed .0045 inch.
Piston diameter at top is measured at top ring land (between top and second compression ring grooves) at right angle to
piston pin hole; diameter at bottom of piston is measured at the bottom of the piston skirt at right angles to the piston
pin.
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
611 ALL Exhaust Valve Seat and Cylinder .0075T
Head .011T (A)
ALL O.D. Exhaust Seat 1.9355
1.937
ALL I.D. Exhaust Seat Hole in 1.926
Cylinder Head 1.928
612 ALL Intake Valve Seat and Cylinder .0065T
Head .010T (A)
E-H-P O.D. Intake Seat 2.1675
2.169
AB-AC O.D. Intake Seat 2.2885
2.290
E-H-P I.D. Intake Seat Hole in Cylinder 2.159
Head 2.161
AB-AC I.D. Intake Seat Hole in Cylinder 2.280
Head 2.282
613 ALL Exhaust Valve Guide and .001T
Cylinder Head .0025T (A)
ALL O.D. Exhaust Valve Guide .6633
.6638
ALL I.D. Exhaust Valve Guide Hole .6613
in Cylinder Head .6623
614 ALL Intake Valve Guide and Cylinder .001T
Head .0025T (A)
ALL O.D. Intake Valve Guide .5933
.5938
ALL I.D. Intake Valve Guide Hole in .5913
Cylinder Head .5923
615 ALL Exhaust Valve Stem and Valve .0037L
Guide .0050L
ALL O.D. Exhaust Valve Stem .4957
.4965 .4937
Service allowable limits of .4937 is
applicable only to inconel or
nimonic valves.
ALL Finished I.D. Exhaust Valve .4995
Guide .5005
½ inch diameter exhaust valves may have exhaust valve guides that are .003 inch over the maximum inside diameter
limit, anytime up to 300 hours of service. After 300 hours of service, inside diameter of exhaust valve guide may increase
.001 inch during each 100 hours of operation up to the recommended overhaul time for the engine, or not to exceed .015
inch over the basic I.D. See latest revision of Service Instruction No. 1009 for recommended overhaul time.
616 ALL Intake Valve Stem and Valve .0010L
Guide .0028L .006L
ALL O.D. Intake Valve Stem .4022
.4030 .4010
ALL Finished I.D. Intake Valve .4040
Guide .4050
SSP-1776-5-PT3 3-10
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION II – CYLINDERS
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
617 ALL Valve and Valve Cap Clearance .000
.004L .005L
618 ALL Dry Tappet Clearance .028
.080
619 ALL Valve Rocker Shaft and Valve .0001L
Rocker Bushing .0013L .0025L
ALL Finished I.D. of Valve Rocker
Shaft (Bushing) in Cylinder .6246
Head .6261 .6270
620 ALL Valve Rocker Shaft and Valve .0007L
Rocker Bushing .0017L .004L
ALL O.D. Valve Rocker Shaft .6241
.6245 .6231
ALL Finished I.D. of Rocker Arm .6252
Bushing .6263 .6270
621 ALL Valve Rocker Bushing and
Valve Rocker Bushing Must Be Burnished In Place
622 ALL Valve Rocker Shaft Bushing and .0022T
Cylinder Head .0038T (A)
ALL Valve Rocker Shaft Bushing and .7380
Hole in Cylinder Head .7388
623 ALL Valve Rocker and Cylinder .002L
Head – Side Clearance .020L .024L
625 ALL Intake and Exhaust Valve Guide .914
Height .954
MEASURE VALVE GUIDE HEIGHT
FROM THE VALVE SPRING SEAT
COUNTERBORE IN THE CYLINDER
HEAD TO THE TOP OF VALVE GUIDE.
3-11 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION II – CYLINDERS
3-13 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
FUEL PUMP
727 E-H1-H2-H3 Fuel Pump Drive Gear – End .016L
Clearance .045L .065L
781 E-H1-H2-H3 Fuel Pump Drive Gear and .0010L
Accessory Housing .0030L .005L
782 H4-H5-P-AB-AC Fuel Pump Drive Gear Bushing .001T
and Accessory Housing .004T (A)
783 H4-H5-P Fuel Pump Drive Shaft Gear – .006L
End Clearance .064L .074L
784 H4-H5-P Fuel Pump Drive Shaft Gear and .001L
Bushing .004L .006L
785 P1 Injector Drive Gear and
Accessory Housing Cover .0036L
Bushing .0048L .006L
786 P1 Injector Drive Gear – End .002L
Clearance .020L .030L
787 P1 Injector Idler Gear and Magneto .0005T
Idler Ball Bearing .0004L (A)
788 P1 Injector Idler Shaft and Magneto .0001T
Idler Ball Bearing .0005L (A)
789 AB Injector Drive Shaftgear and .001L
Accessory Housing Bushing .003L .005L
790 AC Fuel Pump Drive Shaftgear and .001L
Accessory Housing Bushing .003L .005L
791 AB Injector Drive Shaftgear – End .006
Clearance .036 .048
792 AC Fuel Pump Drive Shaftgear – .006
End Clearance .036 .048
VACUUM PUMP & TACHOMETER
737 E-H1-H2-H3 Vacuum Pump Gear and .0010L
Accessory Housing .0025L .006L
738 E-H1-H2-H3 Vacuum Pump Gear – End .016L
Clearance .045L .065L
Reference No. 739 to follow Reference No. 7000.
793 H4-H5-P Vacuum Pump Shaftgear Bushing .0015T
and Accessory Housing Cover .0035T (A)
794 H4-H5-P Vacuum Pump Shaftgear
Bushing (At Cover) and Vacuum .002L
Pump Shaftgear .004L .006L
795 H4-H5-P Vacuum Pump Shaftgear .0015T
Bushing and Accessory Housing .0035T (A)
796 H4-H5-P Vacuum Pump Shaftgear
Bushing (At Accessory Housing) .0020L
and Vacuum Pump Shaftgear .0045L .006L
797 H4-H5-P Vacuum Pump Shaftgear – End .008
Clearance .030 .050
798 AB-AC Vacuum Pump Drive Gear and
Vacuum Pump Spline Coupling .008
– End Clearance .045 .065
SSP-1776-5-PT3 3-14
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
PART III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
VACUUM PUMP & TACHOMETER (CONT.)
799 AB-AC Vacuum Pump Drive Gear .001T
Bushing and Accessory Housing .003T (A)
7000 AB-AC Vacuum Pump Drive Gear
Bushing and Vacuum Pump .002L
Drive Gear .004L .006L
739 E-H1-H2-H3 Tachometer Drive Gear and .0010L
Accessory Housing .0025L .006L
7001 E-H1-H2-H3 Tachometer Drive Gear – End .000
Clearance .030L .040L
7002 E-H1 Tachometer Driven Gear and .0015L
Adapter .0035L .005L
7003 E-H1 Tachometer Cover and Adapter .001T
.003T (A)
7004 E-H1 Tachometer Gear – End .001L
Clearance .040L .060L
7005 H1-H2-H3 Electric Tachometer Idler Gear – .005L
End Clearance .052L .065L
7006 H1-H2-H3 Electric Tachometer Driven .005L
Gear – End Clearance .027L .047L
7006 H4-H5-P-AB-AC Electric Tachometer Driven .007L
Gear – End Clearance .025L .047L
7007 H1-H2-H3 Electric Tachometer Idler Gear .001L
Shaft and Idler Gear Bushing .0025L .004L
7008 H1-H2-H3 Electric Tachometer Driven .0015L
Gear and Adapter .0035L .006L
7009 AB-AC Tachometer Drive Idler Gear
Bushing and Tachometer Drive Bushing To Be Burnished In Place
Idler Gear
7010 AB-AC Tachometer Drive Idler Gear
Bushing and Tachometer Drive .001L
Idler Shaft .003L .004L
7011 AB-AC Tachometer Drive Idler Gear – .005L
End Clearance .014L .024L
7012 H1-H5-P-AB-AC Electric Tachometer Driven Gear .001L
and Accessory Housing Cover .003L .004L
GOVERNOR
7013 ALL Governor Drive Idler Gear
Bushing and Governor Drive .000L
Idler Shaft .002L .004L
7014 ALL Governor Driven Gear and .001L
Governor Drive Adapter Bushing .003L .004L
7015 ALL Reduction Gear Governor and
Magneto Housing and Magneto .002T
and Governor Drive Bushing .004T (A)
7016 ALL Governor Drive Idler Gear and
Governor Drive Idler Gear .001T
Bushing .003T (A)
7017 ALL Governor Adapter and Governor .001T
Drive Adapter Bushing .003T (A)
3-15 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
MAGNETO, GENERATOR, & STARTER
7018 AB-AC Magneto Drive Idler Gear and .001T
Magneto Drive Idler Bushing .003T (A)
7019 AB-AC Magneto Drive Idler Shaft and .001L
Magneto Drive Idler Bushings .003L .005L
7020 AB-AC Reduction Gear Housing
Magneto Drive Bushings and .000
Magneto Drive Idler Shaft .002L .004L
7021 AB-AC Magneto Drive Adapter and .001T
Magneto Adapter Bushings .003T (A)
7022 AB-AC Magneto Drive Gear and .001L
Magneto Adapter Bushings .003L .005L
7023 E-H1-H2-H3 Magneto Drive Bushing and .001T
Magneto Gear .0005L .001L
7024 E-H1-H2-H3 Magneto Drive Bearing and .0001T
Support .0007L (A)
7025 H4-H5-P Magneto Drive Idler Gear Hub
Bushing and Magneto Drive Bushing Must Be Burnished In Place
Idler Gear Hub
7026 H4-H5-P Magneto Drive Idler Gear Hub
Bushing and Magneto Drive .001L
Idler Shaft .003L .004L
7027 H4-H5-P Magneto Drive Idler Gear Hub – .005L
End Clearance .014L .024L
7028 H4-H5-P Magneto Drive Shaft and
Accessory Housing Cover .0020L
Bushing .0045L .006L
7029 H4-H5-P Magneto Drive Shaft and .0025L
Accessory Housing Bushing .0045L .006L
7030 H4-H5-P Magneto Drive Shaft Sleeve and .001T
Magneto Drive Shaft .004T (A)
7031 H4-H5-P Magneto Drive Shaft Sleeve and .001T
Magneto Drive Coupling .004T (A)
7032 H4-H5-P Magneto Drive Shaft Gear – End .002L
Clearance .020L .030L
7033 E-H1-H2-H3 Generator Driven Gear Bushing .001T
and Accessory Housing .003T (A)
7034 E-H1-H2-H3 Generator Driven Gear and .002L
Bushing .004L .006L
7035 E-H1-H2-H3 Generator Driven Gear – End .005L
Clearance .049L .060L
7036 H1 Generator Drive Idler Gear and
Bushing (Hi-Speed) Bushing Must Be Burnished In Place
7037 H1 Finished I.D. of Idler Gear 1.000
Bushing 1.001 1.002
7038 H1 Generator Drive Countershaft .0015L
and Bushing .0035L .005L
7039 H1 Generator Drive Idler Gear – .004L
End Clearance .010L .020L
SSP-1776-5-PT3 3-16
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
MAGNETO, GENERATOR, STARTER (CONT.)
7040 E1-H1-H3 Angle Generator Drive –
Generator Driven Gear Bushing .001T
and Generator Housing .003T (A)
7041 E1-H1-H3 Angle Generator Drive –
Generator Driven Gear and .002L
Bushing .004L .006L
7042 E1-H1-H3 Angle Generator Drive –
Generator Housing and .001L
Generator Drive Gear .003L .004L
7043 H4-H5-P-AB-AC Generator Drive Gear Bushing .0015T
and Accessory Housing Cover .0035T (A)
7044 H4-H5-P-AB-AC Generator Drive Gear Bushing
(At Cover) and Generator Drive .002L
Gear .004L .006L
7045 H4-H5-P-AB-AC Generator Drive Gear Bushing .002T
and Accessory Housing .004T (A)
7046 H4-H5-P-AB-AC Generator Drive Gear Bushing
(At Accessory Housing) and .0025L
Generator Drive Gear .0045L .006L
7047 H4-H5-P-AB-AC Generator Drive Gear – End .010
Clearance .038 .050
7048 H4-H5-P-AB-AC Starter Drive Gear Bushings and .002T
Adapter .004T (A)
7049 H4-H5-P-AB-AC Starter Drive Gear Bushings and .002L
Starter Drive Gear .004L .006L
7050 H4-H5-P-AB-AC Starter Drive Adapter and .0005L
Accessory Housing Cover .0025L (A)
7051 E1-H1-H2-H3 Oil Relief Plunger and Oil Relief .0015L
Valve Plug .0035L .005L
H4-H5-P-AB-AC Oil Relief Valve Plunger and .001L
Sleeve .003L .005L
ACCESSORY DRIVE
7053 H4-H5-AC Accessory Idler Gear Bearing .0001L
and Accessory Drive Gear .0007T (A)
P Accessory Drive Gear Bearing .0001L
and Accessory Drive Shaft .0007T (A)
AB Accessory Idler Gear Bearing
and Supercharger and Accessory .0001L
Drive Gear .0007T (A)
7054 P-AB Supercharger and Accessory .001T
Drive Gear and Bushing .003T (A)
7055 H1-H5-P-AB-AC Accessory Idler Gear Bearing
and Accessory Drive Shaft .0005T
Adapter .0005L (A)
7056 P-AB Supercharger and Accessory
Drive Gear Bushing and .0005L
Accessory Drive Shaft .0017L .004L
3-17 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
ACCESSORY DRIVE (CONT.)
7056 P-AB Finished I.D. of Supercharger
and Accessory Drive Gear 1.3295
Bushing 1.3305 1.3312
7057 P-AB Supercharger and Accessory .004L
Drive Gear – End Clearance .012L .017L
7058 P Accessory Drive Shaft and .001T
Bushing .003T (A)
P Finished I.D. of Accessory Drive .750
Shaft Bushing .7515 .752
7059 P-AB Supercharger Drive Shaftgear
and Accessory Drive Shaft .002L
Bushing .004L .006L
7060 P-AB Supercharger Drive Shaftgear .0038L
and Supercharger Shaft Bearing .0050L .008L
7061 P-AB Supercharger Drive Shaftgear –
End Clearance (Use 1 Spacer if .011L
Necessary to Maintain Fit) .020L .020L
7062 P-AB Impeller and Supercharger Air .040L
Inlet Adapter – Clearance .070L
7063 P Intermediate Supercharger Drive .0040L
Shaftgear and Bushing .0055L .0075L
7064 P-AB Accessory Housing and
Intermediate Supercharger Drive .001T
Shaftgear Bushing .003T (A)
7065 P-AB Intermediate Supercharger Drive .002L
Gear and Bushing .004L .006L
7066 P Intermediate Supercharger Drive .011L
Gear – End Clearance .026L .030L
AB Intermediate Supercharger Drive .009L
Gear – End Clearance .020L .024L
7067 AB Accessory Housing Adapter and .0006L
Bearing .0006T .0016L
7068 AB Supercharger and Accessory .0002T
Drive Gear Support and Bearing .0013T (A)
7069 AB Supercharger and Accessory .001T
Drive Gear Support and Bushing .003T (A)
7070 P-AB Supercharger Shaft Bearing and .0005L
Supercharger Housing .002L (A)
7071 AB Supercharger and Accessory
Drive Gear and Accessory Drive .001L
Shaft – End Clearance .015L .020L
7072 AB-AC Oil Pressure and Scavenge Pump
Idler Gear Bushing and Fuel
Injector or Fuel Pump Drive .001L
Shaftgear (As Applicable) .003L .005L
7073 AB-AC Oil Pressure and Scavenge Pump .001T
Idler Gear and Bushing .003T (A)
SSP-1776-5-PT3 3-18
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
ACCESSORY DRIVE (CONT.)
7074 P1 Throttle Shaft and Supercharger .001L
Air Inlet Housing Bushing .003L .005L
7074 AB Throttle Shaft and Supercharger .0005L
Air Inlet Housing Bushing .0025L .005L
7075 H2-H3 Propeller Flange Two Locator .5000
Holes .5005 .5008
Oil Pumps
3-19 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION III – GEAR TRAIN
SSP-1776-5-PT3 3-20
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION III – GEAR TRAIN
Tachometer Drives
3-23 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION III – GEAR TRAIN
Magneto Drives
SSP-1776-5-PT3 3-24
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION III – GEAR TRAIN
Supercharger Housing
3-31 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV – BACKLASH
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
807 E-H1-H2-H3 Oil Pump Drive Gear and .004
Crankshaft Timing Gear .015 .020
808 E-H1-H2-H3 Oil Pump Impellers .008
.015 .020
E-H1-H2-H3 Oil Pump and Scavenge Pump .008
Impellers .015 .020
825 ALL Crankshaft Timing Gear and .004
Camshaft Gear .015 .020
829 ALL Propeller Shaft – Reduction
Gear – Total Backlash (At 4 ft.
Radius) .50
846 E-H1-H2-H3 Camshaft Gear and Magneto .004
Gear .015 .020
847 E-H1-H2-H3 Tachometer Drive Gear and .004
Crankshaft Timing Gear .015 .020
848 E-H1 Tachometer Driven Gear and .004
Tachometer Drive Gear .015 .020
849 ALL Stationary Gear and Stationary .002
Gear Drive Plate .005 .010
850 ALL Ring Gear and Ring Gear Drive .001
Plate .004 .010
851 E-H2-H3 Generator Drive Gear and .004
Generator Driven Gear .015 .020
852 E-H1-H2-H3 Oil Pump Drive Gear and
Accessory (Fuel Pump) Drive .004 .020
Gear .015
853 E-H1-H2-H3 Oil Pump Drive Gear and .004
Vacuum Pump Drive Gear .015 .020
854 ALL Pinion Gear and Stationary Gear .004
.0077 .012 (C)
855 ALL Pinion Gear and Ring Gear .003
.0065 .012 (C)
856 ALL Governor and Magneto Drive
Gear and Governor Drive Idler .004
Gear .015 .020
857 AB-AC Governor and Magneto Drive
Gear and Magneto Drive Idler .004
Gear .015 .020
858 ALL Governor Drive Idler Gear
(Bevel Gear End) and Governor .004
Driven Gear .008 .015
859 H1 Camshaft Gear and Generator .004
Drive Idler Gear .015 .020
860 H1 Generator Drive Idler Gear and .004
Generator Driven Gear .015 .020
861 E1-H1-H2-H3 Electric Tachometer Idler Gear .004
and Driven Gear .015 .020
862 E1-H1-H2-H3 Electric Tachometer Idler Gear .004
and Tachometer Drive Gear .015 .020
SSP-1776-5-PT3 3-32
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV – BACKLASH
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
863 E1-H1 Angle Generator Drive Gear and .002
Generator Driven Gear .004 .010
864 E1-H1 Angle Generator Drive Gear and .003
Generator Drive Gear Spline .007 .009
865 P1 Generator Drive Gear and .004
Magneto Drive Idler Gear .015 .020
H4-H5-P-AB-AC Generator Drive Gear and .004
Tachometer Drive Idler Gear .015 .020
866 P1 Electric Tachometer Drive Gear
(Magneto Idler Hub) and .004
Tachometer Driven Gear .015 .020
H4-H5-P-AB-AC Tachometer Drive Idler Gear .004
and Tachometer Driven Gear .015 .020
867 H4-H5-P Tachometer Drive Idler Gear .004
and Magneto Drive Shaftgear .015 .020
868 H4-H5-P Magneto Drive Shaft (Spline)
and Magneto Drive Shaftgear .001
(Spline) .015 .008
869 H4-H5-P Magneto Drive Shaftgear
(Spline) and Magneto Drive .001
Coupling (Spline) .005 .008
870 H4-H5-AC Rear Crankshaft (Spline
Bushing) and Accessory Drive .002
Gear (Spline) .0073 .018
P-AB Rear Crankshaft (Spline
Bushing) and Accessory Drive .002
Shaft (Spline) .0073 .018
871 H4-H5-AC Accessory Idler Gear and Starter .004
Drive Gear .008 .015
871 P-AB Supercharger and Accessory
Drive Gear and Starter and .004
Accessory Drive Gear .008 .015
872 H4-H5-P-AB-AC Accessory Drive Gear and .004
Generator Drive Gear .015 .020
873 H4-H5-P Accessory Drive Gear and .004
Vacuum Pump Shaftgear .015 .020
874 H4-H5-P Vacuum Pump Shaftgear and Oil
Pressure and Scavenge Pump .004
Gear .015 .020
875 E Scavenge Pump Driven Gear .004
and Accessory Drive Gear .015 .020
876 E Scavenge Pump Impellers .008
.015 .020
877 P-AB Supercharger and Accessory
Drive Gear and Intermediate .006
Supercharger Drive Shaftgear .015 .020
878 P-AB Supercharger Drive Shaftgear
and Intermediate Supercharger .006
Drive Gear .015 .020
3-33 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV – BACKLASH
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
879 P-AB Intermediate Supercharger Drive
Shaftgear (Spline) and
Intermediate Supercharger Drive .000
Gear (Spline) .002 .005
880 P1 Fuel Injector Idler Gear and .004
Magneto Drive Shaftgear .015 .020
881 P1 Fuel Injector Drive Idler Gear .004
and Fuel Injector Idler Gear .015 .020
882 P1 Injector Drive Shaft (Spline) and .0005
Fuel Injector Pump (Spline) .0056 .008
883 P1 Magneto Drive Shaftgear
(Spline) and Fuel Injector Drive .002
Shaft (Spline) .006 .008
884 AB-AC Magneto Drive Idler Gear
(Bevel End) and Magneto .004
Driven Gear .008 .015
885 AB-AC Magneto Driven Gear (Spline)
and Magneto Drive Coupling .001
(Spline) .004 .007
886 AB-AC Magneto Drive Coupling
(Spline) and Magneto Coupling .001
(Spline) .004 .007
887 H4-H5-P-AB-AC Starter Jaw (Spline) and Starter .002
Drive Gear (Spline) .005 .010
888 AB-AC Accessory and Starter Drive and
Oil Pressure and Scavenge Pump .004
Idler Gear .015 .020
889 AB-AC Oil Pressure and Scavenge Pump
Idler and Oil Pressure and .004
Scavenge Pump Gear .015 .020
890 AB Fuel Injector Drive Shaftgear
(Spline) and Fuel Injector Drive .003
Coupling (Spline) .007 .012
891 AB Fuel Injector Drive Coupling
(Spline) and Fuel Injector Pump .002
(Spline) .005 .010
892 AB-AC Oil Pressure and Scavenge Pump
Gear (Spline) and Vacuum .003
Pump Coupling (Spline) .0065 .010
893 AB-AC Vacuum Pump Drive Gear
(Spline) and Vacuum Pump .003
Coupling (Spline) .0065 .010
894 AB Vacuum Pump Drive Gear and .004
Fuel Injector Drive Shaftgear .015 .020
895 H4-H5-P-AC Vacuum Pump Shaftgear and .004
Fuel Pump Drive Shaftgear .015 .020
SSP-1776-5-PT3 3-34
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV- BACKLASH
Accessory Drives
3-35 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV – BACKLASH
Accessory Drives
SSP-1776-5-PT3 3-36
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV – BACKLASH
Accessory Drives
3-37 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV – BACKLASH
Accessory Drives
SSP-1776-5-PT3 3-38
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV – BACKLASH
Accessory Drives
3-39 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV – BACKLASH
Accessory Drives
SSP-1776-5-PT3 3-40
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV – BACKLASH
Accessory Drives
3-41 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV – BACKLASH
Accessory Drives
SSP-1776-5-PT3 3-42
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV – BACKLASH
Accessory Drives
3-43 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV – BACKLASH
Accessory Drives
SSP-1776-5-PT3 3-44
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV – BACKLASH
Accessory Drives
3-45 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION IV – BACKLASH
Accessory Drives
SSP-1776-5-PT3 3-46
SERVICE TABLE OF LIMITS
PART III – GEARED ENGINES
SECTION V – SPECIAL TORQUE REQUIREMENTS
TABLE VI
JAM NUT OR STRAIGHT THREAD O-RING BOSS
Tube Size Thread Torque Ft. Lbs.
-03 3/8 – 24 8–9
-04 7/16 – 20 13 – 15
-05 1/2 – 20 14 – 15
-06 9/16 – 18 23 – 24
-08 3/4 – 16 40 – 43
-10 7/8 – 14 43 – 48
-12 1-1/16 – 12 68 – 75
-14 1-3/16 – 12 83 – 90
-16 1-5/16 – 12 112 – 123
-20 1-5/8 – 12 146 – 161
-24 1-7/8 – 12 154 – 170
-32 2-1/2 – 12 218 – 240
SSP-1776-5-PT3 3-54
SERVICE TABLE OF LIMITS
STANDARD TORQUE (CONT.)
UNLESS OTHERWISE LISTED
TABLE VII
METAL TUBE FITTINGS
Wrench torque for tightening AN-818 Nut (pound inches) Minimum bend radii
measured to tubing
Aluminum-alloy tubing Steel tubing Aluminum-alloy tubing centerline. Dimension in
Dash Nos. Tubing (Flare MS33583) for use inches
Ref. OD inches on oxygen lines only
Minimum Maximum Minimum Maximum Alum.
Minimum Maximum Steel
Alloy
-2 1/8 20 30 75 85 -- -- 3/8 --
-3 3/16 25 35 95 105 -- -- 7/16 21/32
-4 1/4 50 65 135 150 -- -- 9/16 7/8
-5 5/16 70 90 170 200 100 125 3/4 1-1/8
-6 3/8 110 130 270 300 200 250 15/16 1-5/16
-8 1/2 230 260 450 500 300 400 1-1/4 1-3/4
-10 5/8 330 360 650 700 -- -- 1-1/2 2-3/16
-12 3/4 460 500 900 1000 -- -- 1-3/4 2-5/8
-16 1 500 700 1200 1400 -- -- 3 3-1/2
-20 1-1/4 800 900 1520 1680 -- -- 3-3/4 4-3/8
-24 1-1/2 800 900 1900 2100 -- -- 5 5-1/4
-28 1-3/4 -- -- -- -- -- -- -- --
-32 2 1800 2000 2660 2940 -- -- 8 7
TABLE VIII
TORQUE CONVERSIONS
In. Lb. Ft. Lb. Nm In. Lb. Ft. Lb. Nm In. Lb. Ft. Lb. Nm
5 0.42 0.56 100 8.33 11.30 1000 83.33 113.00
10 0.83 1.13 200 16.67 22.60 2000 166.70 226.00
20 1.67 2.26 300 25.00 53.90 3000 250.00 339.00
30 2.50 3.39 400 33.33 45.19 4000 333.30 451.90
40 3.33 4.52 500 41.67 56.49 5000 416.70 564.90
50 4.17 5.65 600 50.00 67.79 6000 500.00 677.90
3-55 SSP-1776-5-PT3
SERVICE TABLE OF LIMITS
CHART MODELS
L VO, TVO-435 (ALL)
L1 VO-435-B, TVO-435-F
L2 TVO-435-A
V VO, IVO, TVO, TIVO-540
V1 TVO, TIVO-540
NOTE
In “Chart” column, a number appearing after a letter shows exceptions to the basic model.
(A) These fits are either shrink fits controlled by machining, fits that may readily be
adjusted, or fits where wear does not normally occur, in each case the fit must be held
to the manufacturing tolerance.
(B) Side clearance on piston rings must be measured with face of ring flush with piston.
(D) These dimensions shown are measured at bottom of piston skirt at right angles to
piston pin.
(E) Permissible wear of the crankshaft (rod and main bearing journals) to be minus 0.0015
on the diameter.
(L) Loose fit; wherein a definite clearance is mentioned between the mating surfaces.
• Deleted NOTES that reference S.I. 1243 in Piston • Revised burnishing instructions for connecting rod
Application Table bushing in reference number 600
• Added Ref. number 930 to Section V table and figure for • Revised the Mfr. Min. & Max. Clearance for Piston Ring
torque value for brass union nut on stainless steel injector Gap (Compression) Nitrided Cylinders (Choke Barrels)
fuel lines and primer lines (Both Ends) and Piston Ring Gap (Oil) in reference number 607
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
500 L All Main Bearings and .0015L
Crankshaft .0045L .0060L
L1-V Main Bearings and Crankshaft .0011L
(Except Front) .0041L .0050L
V Front Main Bearing and .0011L
Crankshaft .0041L .0050L
L1 Front Main Bearing and .0015L
Crankshaft .0045L .0050L
ALL Diameter of Main Bearing 2.3745
Journal on Crankshaft 2.376 (E)
L Crankcase Bearing Bore 2.566
Diameter (All) 2.567 2.5685
V Crankcase Bearing Bore 2.6865
Diameter (All) 2.6875 2.6890
501 ALL Connecting Rod Bearing and .0008L
Crankshaft .0038L .0050L
ALL Diameter of Connecting Rod 2.1235
Journal on Crankshaft (2-1/8 in.) 2.125 (E)
ALL Connecting Rod Bearing Bore
Diameter (2-1/8 in.) (Measured 2.2870
at Axis 30° on Each Side) 2.2875
502 ALL Connecting Rod – Side .004L
Clearance .010L .016L
503 ALL Connecting Rod – Alignment .010 in 10 Inches
504 ALL Connecting Rod – Twist .012 in 12 Inches
505 ALL Crankshaft Run-Out at Center
Main Bearings
Mounted on No. 1 and 4
Journals Max. Run-Out No. 2
and 3 Journals .005 .0075
Mounted on No. 1 and 3
Journals Max. Run-Out No. 2
Journal .003 .0045
Mounted on No. 2 and 4
Journals Max. Run-Out No. 3
Journal .003 .0045
506 ALL Crankshaft and Crankcase Front .006L
End Clearance .015L .025L
508 ALL Crankshaft Propeller Flange
Run-Out .002 .005
510 ALL Crankshaft Timing Gear and .0000
Crankshaft .0015T (A)
511 ALL Tappet Body and Crankcase .0010L
.0033L .004L
ALL O.D. of Tappet .7169
.7177 .7166
ALL I.D. Tappet Bore in Crankcase .7187
.7200 .7203
4-1 SSP-1776-5-PT4
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION I – CRANKCASE, CRANKSHAFT AND CAMSHAFT
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
512 ALL Tappet Plunger Assembly and .0010L
Body – Hyperbolic .0067L .0087L
513 ALL Tappet Socket and Body .002L
(Hyperbolic) .007L .009L
514 ALL Camshaft and Crankcase .002L
.004L .006L
515 ALL Camshaft – End Clearance .002L
.009L .015L
516 ALL Camshaft Run-Out at Center .000
Bearing Journal .001 .006
517 V Counterweight Bushing and .0013T
Crankshaft .0026T (A)
518 V Counterweight Roller – End .007L
Clearance .025L .038L
519 V Counterweight and Crankshaft .003L
Side Clearance* .013L .017L
520 V Counterweight Bore and Washer .0002L
O.D. .0030L (A)
521 V I.D. of Counterweight Bushing .7485
.7505 .7512
522 V O.D. of Counterweight Roller
(P/N 73338) (See latest revision .5255
of Service Instruction No. 1012) .5260
541 ALL Rear Crankshaft Spline Bushing .0002T
and Crankshaft .0015T (A)
* - Measure below roller next to flat.
SSP-1776-5-PT4 4-2
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION I – CRANKCASE, CRANKSHAFT AND CAMSHAFT
Dimensions Clearances
Mfr. Min. Mfr.
& Max. Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max.
600 ALL Connecting Rod and Connecting Bushing P/N LW-13923 to be burnished in place
Rod Bushing Bushing P/N 01K28983 is not burnished in place
ALL Finished I.D. of Connecting Rod 1.1254
Bushing 1.1262
601 L Length Between Connecting Rod 6.4985
Bearing Centers 6.5015
V Length Between Connecting Rod 6.7485
Bearing Centers 6.7515
602 ALL Connecting Rod Bushing and .0008L
Piston Pin .0021L .0025L
603 ALL Piston Pin and Piston .0003L
.0014L .0018L
ALL Diameter of Piston Pin Hole in 1.1249
Piston 1.1254
ALL Diameter of Piston Pin 1.1241
1.1246
604 V Piston and Piston Pin Plug .0002L
.0010L .002L
V Diameter of Piston Pin Plug* 1.1242
1.1247
605 ALL Piston Pin and Piston Pin Plug .0005L
(Nitrided and Chrome Cylinders) .0025L .005L
V Diameter of Piston Pin Plug* .5655
.5665
L Diameter of Piston Pin Plug** .7605
.7615
L Diameter of Piston Pin Plug** .8405
(Thin Wall Pin) .8415
*See latest revision of Service Instruction No. 1267.
**See latest revision of Service Bulletin No. 316
606 ALL Piston Ring and Piston – Side
Clearance (Top Ring Comp.) .0025L
Half Wedge .0055L .008L (B)
ALL (AS APPLICABLE) Piston Ring and Piston – Side
Clearance (2nd Ring Comp.) Full .000
or Half Wedge .004L .006L (B)
ALL Piston Ring and Piston – Side .002L
Clearance (Oil Regulating) .004L .006L (B)
ALL (AS APPLICABLE) Piston Ring and Piston – Side .003L
Clearance (Oil Scraper) .0055L .007L (B)
ALL (AS APPLICABLE) Piston Ring and Piston – Side
Clearance (3rd Ring Comp.) Half .000
Wedge .004L .006L (B)
607 ALL Piston Ring Gap (Compression)
Chrome Cylinders (Straight .020
Barrels) .030 .047
ALL Piston Ring Gap (Compression)
Nitrided and Chrome Cylinders .045
(Choke Barrels) .065 .067
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
607 ALL Piston Ring Gap (Oil .015
Regulating) (All Barrels) .040 .047
ALL (AS APPLICABLE) Piston Ring Gap (Oil Scraper) .015
(All Barrels) .030 .047
For Choke Barrels – Ring gap is measured within 4 inches from bottom. Ring gap at top of travel must not be less than
.0075.
For All Other Barrels – Ring gap is measured at top limit of ring travel.
Cylinder Barrel
Engine and Piston Application Min. Piston Diameter
Max.
Clearance
Engine Chart Type of Maximum Piston Skirt &
Code Letter Piston Number Top Bottom Type of Piston Surface Diameter Cyl.
608 67266, 71553, 73620 4.8395 4.8540 Forged-Round C 4.8805 .0225L
608 L
73932 4.8395 4.8540 Forged-Round N 4.8805 .0225L
609 75984 4.8395 4.8590 Forged-Cam C 4.8805 .018L
610 75984, 76172* 4.8395 4.8590 Forged-Cam N 4.8805 .018L
71940, 72249, 72578,
V 73947*, 73976 5.0905 5.1040 Forged-Round C 5.1305 .0225L
71940, 72249, 73947,
73976 5.0905 5.1040 Forged-Round N 5.1305 .023L
74242, 75617 5.0790 5.1090 Forged-Cam C-N 5.1305 .018L
78203, 78762,
LW-10207*,
LW-10208 5.0790 5.1090 Forged-Cam C-N 5.1305 .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
both diameters; this sum, divided by 2, represents the average diameter of the cylinder.
*=High Compression.
Maximum taper and out-of-round permitted for cylinder in service is .0045 inch.
To find the average out-of-round, measure 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. Difference between diameters must not exceed .0045 inch.
Piston diameter at top is measured at top ring land (between top and second compression ring grooves) at right angle to
piston pin hole; diameter at bottom of piston is measured at the bottom of the piston skirt at right angles to the piston
pin.
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
611 L Exhaust Valve Seat and Cylinder .0065T
Head (Flat Seat) .010T (A)
ALL Exhaust Valve Seat and Cylinder .0075T
Head (Allison Seat) .011T (A)
ALL O.D. Exhaust Seat (Allison Seat) 1.9355
1.937
L O.D. Exhaust Seat (Flat Seat) 2.0965
2.098
ALL I.D. Exhaust Seat Hole in 1.926
Cylinder Head (Allison Seat) 1.928
L I.D. Exhaust Seat Hole in 2.088
Cylinder Head (Flat Seat) 2.090
612 ALL Intake Valve Seat and Cylinder .0065T
Head .010T (A)
L O.D. Intake Seat (Allison Seat) 2.1675
2.169
L O.D. Intake Seat (Flat Seat) 2.3145
2.316
V O.D. Intake Seat 2.2885
2.290
L I.D. Intake Seat Hole in Cylinder 2.159
Head (Allison Seat) 2.161
L I.D. Intake Seat Hole in Cylinder 2.306
Head (Flat Seat) 2.308
V I.D. Intake Seat Hole in Cylinder 2.280
Head 2.282
613 ALL Exhaust Valve Guide and .001T
Cylinder Head .0025T (A)
ALL O.D. Exhaust Valve Guide (1/2 .6633
in. Exhaust Valve) .6638
L O.D. Exhaust Valve Guide (7/16 .5933
in. Exhaust Valve) .5938
ALL I.D. Exhaust Valve Guide Hole
in Cylinder Head (1/2 in. .6613
Exhaust Valve) .6623
L I.D. Exhaust Valve Guide Hole
in Cylinder Head (7/16 in. .5913
Exhaust Valve) .5923
614 ALL Intake Valve Guide and Cylinder .001T
Head .0025T (A)
ALL O.D. Intake Valve Guide .5933
.5938
ALL I.D. Intake Valve Guide Hole in .5913
Cylinder Head .5923
615 ALL Exhaust Valve Stem and Valve .0035L
Guide .0053L (A)
4-7 SSP-1776-5-PT4
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION II – CYLINDERS
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
615 ALL O.D. Exhaust Valve Stem .4957
.4965 .4937
Service allowable limits of .4937 is
applicable only to inconel or
nimonic valves.
L O.D. Exhaust Valve Stem (7/16 .4332
in. Exhaust Valve) .4340
ALL Finished I.D. Exhaust Valve .5000
Guide (1/2 in. Exhaust Valve) .5010
L Finished I.D. Exhaust Valve .4360
Guide (7/16 in. Exhaust Valve) .4370
½ inch diameter exhaust valves may have exhaust valve guides that are .003 in. over the maximum inside diameter limit,
anytime up to 300 hours of service. After 300 hours of service, inside diameter of exhaust valve guide may increase .001
in. during each 100 hours of operation up to the recommended overhaul time for the engine, or not to exceed .015 inch
over the basic I.D. See latest revision of Service Instruction No. 1009 for recommended overhaul time.
616 ALL Intake Valve Stem and Valve .0010L
Guide .0028L .006L
ALL O.D. Intake Valve Stem .4022
.4030 .4010
ALL Finished I.D. Intake Valve .4040
Guide .4050
617 ALL Valve and Valve Cap Clearance .000
.004L .005L
618 ALL Dry Tappet Clearance .028
.080
619 ALL Valve Rocker Shaft and Valve .0001L
Rocker Bushing .0013L .0025L
ALL Finished I.D. of Valve Rocker .6246
Shaft Bushing in Cylinder Head .6261 .6270
620 ALL Valve Rocker Shaft and Valve .0007L
Rocker Bushings .0017L .004L
ALL O.D. Valve Rocker Shaft .6241
.6245 .6231
ALL Finished I.D. of Rocker Arm .6252
Bushing .6263 .6270
621 ALL Valve Rocker Bushing and
Valve Rocker Bushing Must Be Burnished In Place
622 ALL Valve Rocker Shaft Bushing and .0022T
Cylinder Head .0038T (A)
ALL Valve Rocker Shaft Bushing .7380
Hole in Cylinder Head .7388
623 ALL Valve Rocker and Cylinder .002L
Head – Side Clearance .020L .024L
625 ALL Intake and Exhaust Valve Guide .914
Height .954
MEASURE THE VALVE GUIDE HEIGHT
FROM THE VALVE SPRING SEAT
COUNTERBORE IN THE CYLINDER
HEAD TO THE TOP OF VALVE GUIDE.
SSP-1776-5-PT4 4-8
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION II – CYLINDERS
SSP-1776-5-PT4 4-10
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
FUEL PUMP
782 L-V Fuel Pump Drive Shaftgear .001T
Bushing and Accessory Housing .004T (A)
783 L-V Fuel Pump Drive Shaftgear – .006
End Clearance .064 .074
784 L-V Fuel Pump Drive Shaftgear and .001L
Bushing .004L .006L
VACUUM PUMP
793 L-V Vacuum Pump Shaftgear
Bushing and Accessory Housing .0015T
Cover .0035T (A)
794 L-V Vacuum Pump Shaftgear
Bushing (At Cover) and Vacuum .002L
Pump Shaftgear .004L .006L
795 L-V Vacuum Pump Shaftgear .0015T
Bushing and Accessory Housing .0035T (A)
L1 Vacuum Pump Shaftgear .0025T
Bushing and Accessory Housing .0045T (A)
796 ALL Vacuum Pump Shaftgear
Bushing (At Accessory Housing) .002L
and Vacuum Pump Shaftgear .0045L .006L
797 L-V Vacuum Pump Shaftgear – End .008
Clearance .030 .050
799 L1 Vacuum Pump Drive Gear .002T
Bushing and Accessory Housing .004T (A)
7000 L1 Vacuum Pump Drive Gear
Bushing and Vacuum Pump .0025L
Drive Gear .0045L .006L
7078 L1 Vacuum Pump Drive Gear and .0013L
Cover .0033L .005L
7079 L1 Vacuum Pump Drive Gear – End .010
Clearance .032 .037
TACHOMETER
7002 L1 Tachometer Driven Gear and .001L
Adapter .003L .0045L
7006 L-V Electric Tachometer Driven .007
Gear – End Clearance .025 .047
7012 L-V Electric Tachometer Driven
Gear and Accessory Housing .001L
Cover .003L .004L
7088 L1 Tachometer Adapter and .0005L
Accessory Housing .0025L .0035L
MAGNETO
7025 L-V Magneto Drive Idler Gear Hub
Bushing and Magneto Drive Bushing Must Be Burnished In Place
Idler Gear Hub
7026 L-V Magneto Drive Idler Gear Hub
Bushing and Magneto Drive .001L
Idler Shaft .003L .004L
4-11 SSP-1776-5-PT4
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
MAGNETO (CONT.)
7027 L-V Magneto Drive Idler Gear Hub – .005
End Clearance .014 .024
7028 L-V Magneto Drive Shaft and .002L
Accessory Housing Cover .0045L .006L
7029 L-V Magneto Drive Shaft and .0025L
Accessory Housing .0045L .006L
7030 ALL Magneto Drive Shaft Sleeve and .001T
Magneto Drive Shaft .004T (A)
7031 ALL Magneto Drive Shaft Sleeve and .001T
Magneto Drive Coupling .004T (A)
7032 L-V Magneto Drive Shaftgear – End .002
Clearance .020 .030
7039 L1 Magneto Drive Idler Gear – End .002
Clearance .030 .040
7080 L1 Magneto Drive Idler Gear
Bushing and Magneto Drive .001L
Idler Shaft .003L .004L
7081 L1 Magneto Drive Idler Gear and
Magneto Drive Idler Gear .0005T
Bushing .0025T (A)
7082 L1 Magneto Drive Gear Bushing .002T
and Accessory Housing .004T (A)
7083 L1 Magneto Drive Coupling and .001L
Accessory Housing Bushing .003L .004L
7084 L1 Magneto Drive Gear and .001L
Accessory Housing Bushing .003L .004L
GENERATOR
7043 L-V Generator Drive Gear Bushing .0015T
and Accessory Housing Cover .0035T (A)
7044 L-V Generator Drive Gear Bushing
(At Cover) and Generator Drive .002L
Gear .004L .006L
7045 L-V Generator Drive Gear Bushing .002T
and Accessory Housing .004T (A)
7046 L-V Generator Drive Gear Bushing
(At Accessory Housing) and .0025L
Generator Drive Gear .0045L .006L
7047 L-V Generator Drive Gear – End .010
Clearance .038 .050
STARTER
7048 L-V Starter Drive Gear Bushing and .002T
Adapter .004T (A)
L1 Starter Drive Spacer Bushing .002T
and Adapter .004T (A)
7049 L-V Starter Drive Gear Bushings and .002L
Starter Drive Gear .004L .006L
L1 Starter Drive Spacer and Starter .0015L
Drive Adapter Bushing .003L .004L
SSP-1776-5-PT4 4-12
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION III – GEAR TRAIN
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
STARTER (CONT.)
7050 L-V Starter Drive Adapter and .0005L
Accessory Housing Cover .0025L (A)
7089 L1 Starter Drive Gear – End .007
Clearance .011 .015
7090 L1 Bendix Drive Shaft (Slip
Coupling) and Accessory .0015L
Housing Bushing .0045L .005L
ACCESSORY DRIVE
7053 L-V Accessory Idler Gear Bearing .0001L
and Accessory Drive Gear .0007T (A)
7054 V Accessory Drive Gear and .001T
Bushing .003T (A)
7055 L-V Accessory Idler Gear Bearing
and Accessory Drive Shaft .0005T
Adapter .0005L (A)
7056 V Accessory Drive Gear Bushing .0005L
and Accessory Drive Shaft .0017L .004L
7057 V Accessory Drive Gear – End .004
Clearance .012 .017
7086 L1 Accessory Drive Shaftgear .002T
Bushing and Accessory Housing .004T (A)
7087 L1 Accessory Drive Shaftgear and .002L
Accessory Housing Bushing .004L .006L
7091 L1 Dual Accessory Idler Gear and .001L
Idler Shaft .003L .0045L
7092 L1 Dual Accessory Idler Gear – End .009
Clearance .018 .023L
7093 L1 Dual Accessory Drive Gear – .005
End Clearance .062 .077
7094 L1 Dual Accessory Drive Gear and .0013L
Adapter .0028L .0034L
4-13 SSP-1776-5-PT4
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION III – GEAR TRAIN
Oil Pumps
SSP-1776-5-PT4 4-14
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION III – GEAR TRAIN
4-15 SSP-1776-5-PT4
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION III – GEAR TRAIN
Bendix Drive
4-19 SSP-1776-5-PT4
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION III – GEAR TRAIN
SSP-1776-5-PT4 4-22
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION III – GEAR TRAIN
4-23 SSP-1776-5-PT4
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION IV – BACKLASH
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
808 L1 Oil Pump Impellers .005
.015 .020
L-V Oil Pump and Scavenge Pump .008
Impellers .015 .020
825 ALL Crankshaft Timing Gear and .004
Camshaft Gear .015 .020
866 L-V Electric Tachometer Drive Gear
(Magneto Idler Hub) and .004
Tachometer Driven Gear .015 .020
867 L-V Generator Drive Gear and .004
Magneto Drive Idler Gear .015 .020
868 L-V Magneto Drive Shaft (Spline)
and Magneto Drive Shaftgear .001
(Spline) .005 .008
869 L-V Magneto Drive Shaftgear
(Spline) and Magneto Drive .001
Coupling (Spline) .005 .008
L1 Magneto Drive Shaft (Spline)
and Magneto Drive Coupling .001
(Spline) .0045 .0075
870 L-V1 Rear Crankshaft Spline Bushing .002
and Accessory Gear (Spline) .0073 .018
L1 Rear Crankshaft Spline Bushing
and Accessory Drive Quill Shaft .004
(Spline) .0073 .018
V Rear Crankshaft Spline Bushing
and Accessory Drive Shaft .002
(Spline) .0073 .018
871 L-V Accessory Drive Gear and .004
Starter Drive Gear .008 .015
L1 Accessory Drive Gear and .002
Starter Drive Gear .016 .022
L1 Starter Drive Shaftgear and .000
Starter Drive Gear (Spline) .002 .004
872 L-V Accessory Drive Gear and .004
Generator Drive Gear .015 .020
L1 Alternator Drive Shaft (Spline)
and Vacuum and Magneto Drive .001
Shaft (Spline) .004 .006
L1 Alternator Drive Shaft (Spline) .001
and Alternator (Spline) .005 .007
873 L-V Accessory Drive Gear and .004
Vacuum Pump Shaftgear .015 .020
874 L-V Vacuum Pump Shaftgear and Oil .004
Pressure Scavenge Pump Gear .015 .020
884 L1 Magneto Drive Idler Gear and .006
Magneto Driven Gear .014 .020
L1 Magneto Drive Gear and .006
Magneto Idler Drive Gear .014 .020
SSP-1776-5-PT4 4-24
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION IV – BACKLASH
Dimensions Clearances
Mfr. Mfr.
Min. & Service Min. & Service
Ref. Chart Nomenclature Max. Max. Max. Max.
895 L-V Vacuum Pump Shaftgear and .004
Fuel Pump Drive Shaftgear .010 .015
896 L1 Oil Pump Drive Gear and .006
Tachometer Drive Shaftgear .014 .020
897 L1 Tachometer Drive Gear and .002
Tachometer Drive Shaftgear .006 .010
898 L1 Magneto Gear (Spline) and .001
Magneto Drive Shaft (Spline) .0045 .0075
899 L1 Starter Drive Shaftgear (Spline)
and Vacuum, Magneto Shaft .001
(Spline) .004 .007
8001 L1 Accessory Drive Quill Shaft
(Spline) and Accessory Drive .004
Gear (Spline) .0073 .011
8002 L1 Vacuum Pump Drive Gear
(Spline) and Shaft Vacuum .001
Pump Magneto Drive (Spline) .004 .007
8003 L1 Vacuum, Oil Pump Drive
Shaftgear and Vacuum Pump .005
Drive Gear .015 .020
8004 L1 Dual Accessory Drive Gear and .004
Idler .015 .020
8005 L1 Starter Drive Gear and Bendix .016
Drive (Slip Coupling) Gear .026 .031
8006 L1 Dual Accessory Idler Gear and .004
Vacuum Pump Drive Gear .015 .020
4-25 SSP-1776-5-PT4
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION IV – BACKLASH
SSP-1776-5-PT4 4-26
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION IV – BACKLASH
4-27 SSP-1776-5-PT4
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION IV – BACKLASH
SSP-1776-5-PT4 4-28
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION IV – BACKLASH
Bendix Drive
4-31 SSP-1776-5-PT4
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION IV – BACKLASH
Magneto Drives
SSP-1776-5-PT4 4-32
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION IV – BACKLASH
Accessory Drives
SSP-1776-5-PT4 4-34
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION V – SPECIAL TORQUE REQUIREMENTS
Ref. Chart Thread Size Nomenclature Torque Limits
900 L 3/8-24 Connecting Rod Nuts 480 in. lbs.
V 3/8-24 Connecting Rod Bolt and Nut –
Tighten to This Length 2.255-2.256
901 ALL 1/2-20 Oil Pump Shaft Nut 360-480 in. lbs.
903 ALL 3/8-24 Magneto Nut (To attach drive
member to magneto) – Steel Bushing
300 in. lbs.
904 ALL 10-32 Screw Plate Nuts (To attach ignition
cable outlet plate to magneto)
15 in. lbs.
905 ALL (using a silicone gasket) 1/4-20 Rocker Box Screws 35 in.-lbs.
ALL (using a cork gasket) 1/4-20 Rocker Box Screws 50 in.-lbs.
906 ALL 5/16-18 Exhaust Port Studs (Driving Torque)
40 in. lbs. min.
ALL 5/16-18 Nuts to Attach Exhaust Stacks to
Cylinder Head 160-180 in. lbs.
907 ALL 18MM Spark Plugs 420 in. lbs.
909 L-V 5/8-32 Alternator Pulley Nut 450 in. lbs.
L1 5/8-32 Alternator Nut (Quill Shaft) 474 in. lbs.
910 L1 1/4-28 Alternator Output Terminal Nut 85 in. lbs.
911 L1 10-32 Alternator Auxiliary Terminal Nut
30 in. lbs.
913 L1-L2-V 1/16-27 NPT Piston Cooling Nozzle in Crankcase
100 in. lbs.
914 V-V1 1/8-27 NPT Injector Nozzle in Cylinder Head
60 in. lbs.
919 ALL 1/4 Hex Head Hose Clamps (Worm Type)
and Below 20 in. lbs.
ALL 5/16 Hex Head Hose Clamps (Worm Type)
and Above 45 in. lbs.
919-1 ALL “T” Bolt Hose Clamps
Initial Torque . . . . . . . . . . . . . . . 35 in. lbs.
Retorque After Run-In . . . . . . . . 25 in. lbs.
920 ALL Cylinder Head Drain Back Hose
Clamp 10 in. lbs.
921 L2-V1 Exhaust Clamp – Coupling – V-Band
(See latest revision of Service
Instruction No. 1238)
928 ALL 3/8-16 Cylinder Hold Down Studs
(Crankcase Driving Torque) 100 in. lbs.
ALL 1/2-13 Cylinder Hold Down Studs
(Crankcase Driving Torque) 250 in. lbs.
929 ALL 3/8-16 Cylinder Hold Down Nuts 300 in. lbs.
ALL 1/2-13 Cylinder Hold Down Nuts 600 in. lbs.
930 ALL 5/16-32 Brass union nut on stainless steel
25-50 in.-lbs.*
injector/primer fuel line (Both Ends)
* It is also permissible to tighten the fuel line union nut finger tight, then continue tightening the nut with a wrench an
additional 30 to 60 degrees (1/2 to 1 flat of the nut.) Torque in excess of 50 in.-lbs. can result in damage to the parts.
Cylinder Hold Down and Crankcase Parting Flange Nuts’ Tightening Procedures – See latest revision of Service
Instruction No. 1029.
933 L-V Accessory Drive Shaft Nut 75-125 ft. lbs.
934 ALL Crankshaft Gear Retaining Nut 150 ft. lbs.
SSP-1776-5-PT4 4-36
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
SECTION V – SPECIAL TORQUE AND SPRINGS
TABLE VI
JAM NUT OR STRAIGHT THREAD O-RING BOSS
Tube Size Thread Torque Ft. Lbs.
-03 3/8 – 24 8–9
-04 7/16 – 20 13 – 15
-05 1/2 – 20 14 – 15
-06 9/16 – 18 23 – 24
-08 3/4 – 16 40 – 43
-10 7/8 – 14 43 – 48
-12 1-1/16 – 12 68 – 75
-14 1-3/16 – 12 83 – 90
-16 1-5/16 – 12 112 – 123
-20 1-5/8 – 12 146 – 161
-24 1-7/8 – 12 154 – 170
-32 2-1/2 – 12 218 – 240
SSP-1776-5-PT4 44-40
SERVICE TABLE OF LIMITS
PART IV – VERTICAL ENGINES
STANDARD TORQUE (CONT.)
UNLESS OTHERWISE LISTED
TABLE VII
METAL TUBE FITTINGS
Wrench torque for tightening AN-818 Nut (pound inches) Minimum bend radii
measured to tubing
Aluminum-alloy tubing Steel tubing Aluminum-alloy tubing centerline. Dimension in
Dash Nos. Tubing (Flare MS33583) for use inches
Ref. OD inches on oxygen lines only
Minimum Maximum Minimum Maximum Alum.
Minimum Maximum Steel
Alloy
-2 1/8 20 30 75 85 -- -- 3/8 --
-3 3/16 25 35 95 105 -- -- 7/16 21/32
-4 1/4 50 65 135 150 -- -- 9/16 7/8
-5 5/16 70 90 170 200 100 125 3/4 1-1/8
-6 3/8 110 130 270 300 200 250 15/16 1-5/16
-8 1/2 230 260 450 500 300 400 1-1/4 1-3/4
-10 5/8 330 360 650 700 -- -- 1-1/2 2-3/16
-12 3/4 460 500 900 1000 -- -- 1-3/4 2-5/8
-16 1 500 700 1200 1400 -- -- 3 3-1/2
-20 1-1/4 800 900 1520 1680 -- -- 3-3/4 4-3/8
-24 1-1/2 800 900 1900 2100 -- -- 5 5-1/4
-28 1-3/4 -- -- -- -- -- -- -- --
-32 2 1800 2000 2660 2940 -- -- 8 7
TABLE VIII
TORQUE CONVERSIONS
In. Lb. Ft. Lb. Nm In. Lb. Ft. Lb. Nm In. Lb. Ft. Lb. Nm
5 0.42 0.56 100 8.33 11.30 1000 83.33 113.00
10 0.83 1.13 200 16.67 22.60 2000 166.70 226.00
20 1.67 2.26 300 25.00 53.90 3000 250.00 339.00
30 2.50 3.39 400 33.33 45.19 4000 333.30 451.90
40 3.33 4.52 500 41.67 56.49 5000 416.70 564.90
50 4.17 5.65 600 50.00 67.79 6000 500.00 677.90
4-41 SSP-1776-5-PT4