Integral Acc Drive

OVERHAUL MANUAL
AVC O I VC=ONIING
INTEG RAL ACCESSORY DRIVE
AIRCRAFT ENGINES
s~i
ii~;- ´•Y; ´•´•i;;-´•I
APPROVED BY F.A.A.
LYC O N1 I N G VVI LLI ANI S rO RT D I VI s ION

AV C~ CORPOR AT ION
VV I LLIANISPO RT, PENN SYLVANIA 17701
2nd Edifion Part No, 60294 1 6
Oerober, 7915 PRIHTED IH US.~.

Price $23.00
652 Oliver Strget
Williamsport, PA 1110,
17701 U.b.H.
TECHNI CAL
PUBLICATION REVISION
REVISION NO. PUBLICATION PUBLICATION NO. PUBLICATION DATE
60294-6-3 Integral Accessory 60294-6 October 1975

Drive Overhaul Manaul Second Edition
furnished herewith intended to replace the corresponding page(s) of the publication indi-
The page(s) are
cated above.
Previous revisions to this publication This revision consists of:
April, 1976 6-3, 6-4 June 1996
February, 1992
OVERHAUL MANUAL TWTKOIY LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT
ENGINES
TO THE OWNER OF THIS MANUAL
IN ADDITION TO THIS MANUAL AND SUBSEQUENT REVISIONS, ADDITIONAL

OVERHAUL AND REPAIR INFORM~ON IS PUBLISHED IN THE FORM OF SERVICE
BULLETINS AND SERVICE INSTRUCrI~IONS. THE INFORMATION CONTAINED IN
THESE SERVICE BULLETINS AND SERVICE INSTRUCTIONS IS AN INTEGRAL PART
OF, AND IS TO BE USED IN CONJUNCTION WITH, THE INFORMATION CONTAINED
IN THIS OVERHAUL MANUAL.
THIS OVERHAUL MANUAL, THE ENGINE OPERATOR’S MANUAL, AND ALL AP-
PLICABLE SERVICE BULLETINS AND INSTRUCTIONS ARE ISSUED IN COM-
PLIANCE WITH FAR 21.50, AND SHALL BE USED BY MAINTENANCE PERSONNEL
WHEN PERFORMING ACTIONS SPECIFIED IN FAR 43.13.
For period of three (3) years new and revised pages for this manual will be furnished to
a
owners, who fill out the registration card and return it to Textron 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 Textron Ly-
coming Distributors or from the factory by subscription. Consult the latest revisions to Textron
Lycoming Service Letter No. L114. Textron Lycoming also publishes an Index of Service Bul le-
tins, Instructions and Letters that lists all Bulletins, Instructions and Letters in alphabetical order
by title and topic 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 iilustrations, pictures and drawings shown in this publication are typical of the subject
matter they portray; in no instance are they to be interpreted as examples of any specific engine,
equipment or part thereof.
Revised June 1996

OVERHAUL MANUAL LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
TABLE OF CONTENTS
SECTION PACE SECTION PAGE
1 INTRODUCTION 1-1 5 INDUCTION AND EXHAUST

SYSTEM
2 GENERAL DESCRIPTION
General 5-1
General 2-1 Removal from Engine 5-1
Cylinders 2-1 Disassembly
Valve Operating Mechanism 2-2 Turbocharger 5-3
Crankshaft 2-3 Bearing Clearance 5-4
Crankcase 2-3 Bearing- Radial Check 5-4
OilSump 2-3 Bearing Axial End Play 5-4
Connecting Rods 2-3 Cleaning
Pistons 2-5 Turbocharger 5-8
Cooling System 2-3 Inspection
Lubricating System 2-3 Turbocharger
Ignition System 2-3 Shaft Wheel 5-8
Induction System 2-4 Impeller 5-8
Turbocharger Controls 2-4 Sell Parts 5-8
Housings 5-8
3 GENERAL OVERHAUL PROCEDURES Repair and Replacement
Turbocharger 5-8
General 3-1 Relssembly
Cleaning Turbocharger 5-9
Degreasing 3-1 Testing 5-9
Removal of Hard Carbon 3-1 Disassembly
Inspection Induction Housing 5-9
General 3-2 Fuel Drain Lines 5-9
Bearing Surfaces 3-2 Exhaust Bypass Valve
Gears 3-2 Reassembly
Stressed Areas 3-2 Exhaust Bypass Vllve 5- 12
Screwed Fittings 5-2 FinalAssembly 5- 13
Magnetic 3-2
Repair and Replacement 6 LUBRICATION SYSTEM
Damaged Parts 5-3
Painted Parts 3-3 Removal from Engine
Replacement of Studs 3-9 Oil Cooler 6-1
Corrosion Prevention 3-3 Oil Filter 8-1
Prelubrication of Parts 3-4 Oil Sump 6-1
Olllte Bushings 3-4 Oil Pump 6-2
Pitch Alignment and Backlash Disassembly
in BevelGears 3-4 OilCooLer 6-2
Table of Limits 3-5 Oil Filter 6-2
Oil Seals and Gaskets 3-5 Oil Sump 6-2
Arbitrary Replacement of Parts 3-5 Oil Pump 6-9
Reassembly
4 IGNITION SYSTEM Oil Cooler 6-3
Oil Filter 6-9
General 4-1 Oil Pump 6-3
Engine Firing Order 4-1 Oil Sump 6-4
Magnetos 4-1
Ignition Harness 4-1 7 CYLINDERS, PISTONS AND VALVE
Spark Plugs 4-1 TRAIN
Removal from Engine
Ignition Harness 4-2 General 7-1
Magnetos 4-2 Removal from Engine
Dbzssembly Cylinders 7-1
Magnetos 4-2 Pistons 7-1
Repair and Replacement Hydraulic Lifters 7-1
Ignition Harness 4-2 Dfsassembly
Magnetos 4-3 Cylinders 7-1
Reassembly and Installation Pistons 7-3
Magnetos 4-3 Hydraulic Lifters 7-3
Timing Procedures 4-5 Cleaning 7-3
Ignition Harness 4-5 Inspection
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
TABLE OF CONTENTS (CONT.
SECTION PAGE SECTION PAGE
7 CYLINDERS, PISTONS AND VALVE 8 CRANKCASE, CRANKSHAFT AND

TRAIN (CONT. ACCESSORY DRIVES (CONT.
Inspection (Cont. Inspection (Cont.

General 7-3 Crankcase 8-4
Head 7-3 Crankshaft 8-4
Cylinder
Barrel 7-5 Camshaft 8-5
Cylinder
Valve Rocker 7-6 Connecting Rods 8-6
Push Rods 7-6 Crankshaft Counterweight
Valves 7-6 Bushings 8-6
7-7 Piston Cooling Oil Jets 8-6
Hydraulic Lifters
Valve Springs 7-7 Repair and Replacement
General 8-8
Repair and Replacement
General 7-7 Crankshaft 8-8
Spark Plug Thread Insert 7-8 Crankshaft Flange

7-8 Straightening 8-8
Grinding Valve Seats
Valve Seats 7-9 Crankshaft Oil Seal 8-9
Valve Refacing 7- 10 Stud Removal and Replace ment 8-9
Valve Guides 7- 10 Crankshaft Counterweight

Valve Rocker Thrust Washers 7-11 Bushings 8-9
Valve Rocker Shaft Bushings 7-11 Connecting Rod Bushings 8- 11
Valve Rocker Bushings 7-11 Reassembly

Crankshaft 8-11
Reconditioning Nitrided
7-11 Connecting Rods 8- 13
Cylinder Barrels
Valve Repair 7-11 Camshaft 8- 13
Crankcase 8- 14
Reassembly
Pistons 7-11 Crankshaft OilSeal 8- 14
Cylinder 7- 12 Crankcase Tightening

Installation Procedure 8-18
Pistons and Cylinders 7- 12
9 TEST PROCEDURE
Intercylinder Baffles 7- 14
Fin Stabilizers 7- 14 General 9-1
Run-in Specifications 9-2
Test Run 9-2
8 CRANKCASE, CRANKSHAFT AND
ACCESSORY DRIVES Oil Consumption Run 9-3
Oil Pressure Relief Valve 9-3
Disassembly 8-1 Idle Speed and Mixture

Adjustment 9-3
Cleaning
General 8-4
Piston Cooling Oil Jets 8-4 10 PRESERVATION AND STORAGE
General 10-1
Inspection
8-4 Exterior Surfaces 10-1
Bearings
FuelInjector 10-1
11 TABLE OF LIMITS
iii
SECTION
INTRODUCTION
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES Section
Introduction
SECTION 1.
INTRODUCTION
1-1. This manual contains the necessary information mended that the parts catalogs be used in conjunction
for the major overhaul of the Avco Lycoming integral with the manual, when reassembling the engine.
accessory drive engines. Unless otherwise noted, all
information and data in the manual will apply equally 1- 5. Service bulletins, s ervice instructions and servic e
to all models; those portions of the text applying to any letters issued from time to time whenever the en-
are
one particular model or series will be so identified. gine is modified or overhaulprocedures revised. When
received, these publications should be inserted in the
1-2. The main portion of the test is divided into sec-
rear of this manual or maintained in a separate file for
tions corresponding to the basic
engine components. ready reference.
Additional sections provided for general descrip-

are
1-6. Thefollowingprocedure shouldbefollowed if, for
tfon, general overhaul and inspection procedures, pre-
servation and storage information, and other items of any reason, parts are to be returned to the factory.
You may obtain from, but preferably have your dis-
a non-specific nature.
tributor complete, the applicable warranty or rework
form. These forms must include the engine modeland
1-3. The tools required for overhauling and inspec-
tion of the engines (excluding the ordinary mechanic’s serialnumber, number of hours inservice, the reason
tools foundin most overhaul shops) are listed in SSP-
for the parts being returned and any other pertinent
facts concerning the parts.
2172 Service Tools. Any special informationrequired
concerning these tools may be obtained by writing
1-7. In this manual all references to locations of the
to the Service Department, Avco Lycoming Division,
various components will be designated when viewing
Wflliamsport, Pennsylvania, 17701. When requesting
the engine from the The power take off end is
rear.
information concerning any of these tools, refer to
considered the front and the accessory drive end the
the tool by name and part number and not merely by
rear. The oil sump is considered the bottom. Cyl-
name.
inders are numberedfrom front to rear with odd num-
bered cylinders on the left side.

1-´•Q. Parts catalogs, for specific models, may be or-
dered from the department listed in paragraph 1-3. 1-8. The direction of rotation of the crankshaft is
Because this manual covers the entire series of en- clockwise as viewed from the rear. All references to
gines, it is almost impossible to call out attaching direction of rotation of the various accessory drives
p~rts for specific models. Therefore, it is recom- are made as viewed facing the drive.
Lu;
I It
O,i;
Figure 1-1. Typical TIGO-541 Series Engine
1-1
SECTION
GENERAL
DESCRIPTION
OVERHAUL MANUAL-AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES section 2
General Descr,ptlon
SECTION 2.
GENERAL DESCRIPTION
Descr~tion of Eng~ne Model Code
Example: TIO 541 EIB4D

J
PRE~IX DISPLACEMUVT SUFFIX
L Leftbond Engine Rototion 000* E Fbwer Sectiw, B Rot~iiji

CUbiC in.
T Turbocharged I -Nose Section
V -Vertical Hdicopter B -Acces~ory Section
H -Horizontal Helicopter 4 -counterweism Application
A Aerobatic D --Duol Magneto

L+ Note: (001) "I"lndicates integral
I -Fuel Injected accessory drive
G -Ge~xed Nose Sectlbn

to Models
reflected in this Section
S Supercharged ~pe
O opposed Cylinder
Figure 2-1. Description of Engine Model Code
2-1. This manual is designedto cover the overhaul of 2-3. The cylinder barrels are machined from a chrome
allAvco Lycoming integral accessory drive engines. nickel molybdenum steel forging with deep integral
The subject engines are horizontally opposed, wet cooling fins. The interior of the barrels are ground
sump, air cooled models. and honed to a specified finish.
2- 2. CYLINDERS. The cylinders are of air- cooled con-

2-4. ~vcoLycoming incorporates a color code painted
struction with the major parts, head and barrel, on cylinder heads designating differences in the cyl-
screwed and shrunktogether. The heads are made from inder barrels and spark plug lengths. It is essential
an aluminum alloy castingwith a fully machined com-
that personnel be familiar with this code as described
bustion chamber. Valve guides and valve seats are
i, the latest edition of Service Instruction No. 1181.
shrunk into machined recesses in the head. Rocker
shaft bearing supports are cast integrally with the head
along with housings to form the rocker boxes for both 2-5. Damage willresult with the use of incorrect pis-
exhaust and intake valve rockers. Valve rockers are ton rings or spark plug lengths. The latest edition of
placed atom angle inthe head. Intake ports are located Service Instruction No. 1037 lists the approved piston,
in the upper side of the cylinder and the exhaust ports piston ring and cylinder assemblies for all models
on the lower side, while the latest edition of Service Instruction No. 1042
2-1
sectron 2 OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Bsneral De~crlptlon
Tubahapar Bypass
Actwlor
H)6ruZo Pump 8 Drive ,Vor~e Ccntmller
FudRmpDrNe-~O
Cmrkmse Ol Heeder-Right T I
toa~Swrp
Rah~ I I I ~-a’l Faer Bypass volue

Sod(ets RshRobr
Litters
TmnrferC~wcr When Rign Bank
Hol Usin) Go/tror GoRmor I I I alCoa~u
hRockuArm&Ishngs
OilPmnn Pump
DroinCLlfp Re~cf ~bke Bypass Vdve
Spbsh QI to Rakr Prms,Volve Stum,Be
co~mx
Brain Oil ~Suchon Scnen

to Sump
Retvn Oil Moglcto
S~osh QI to Pistons, Piston Pns. Corns, Etc
to Sump DrkaGeas DrMGcan
(L1 OilSvr9
Crmltph V OiPPnsweGope
Rmva 87 Comectlcn
PktanOilJets
To RightBork
Mdn
No2Moin Na3 Mai, f Na~4MPin
Beorinp
Q~nkase al Headar-Lett
01 PushRodScd;ch
OilJah Litters ~bcuum Rmp
Left B~k Left Book 8[Xive
Push Rods
RockerPrm Bush’ngs
Splash Oil to Rocker
Slams,Efr
Dmin 01 to Sump Thru

Shroud Tubs, TIG-541
Figure 2-2. Lubrication Diagram
lists the approved spark plugs. Consult these publi- which operate the valves through push rods and valve
cations for correct application to your particular in- rockers. The hydraulic lifters automatically keep the
stallation. valve clearance at zero eliminating the need of any

valve clearance adjustment mechanism. The valve
2-8. VALVE OPERATINGMECHANISM. The camshaft springs bear againsthardened steel seats and are re-
is locatedparallel to and beiowthe crankshaft and op- tained on the valve stems by means of tapered split
erates in aluminum bearings. Ground and hardened keys. A rotator capis used on the stem end of the so-
cam lobes actuate automotive type hydraulic lifters dium cooled exhaust valve.
BREATHER SLINGER GEAR

DRIVE GEAR
(42 TEETH)
(24 TEETH) RATIO: 1.5 TO I.
I I INTERMEDIATE ACCY. DRIVE GEAR

(36 TEETH)
~-HM]RPIILIC 8 VPCUUM
-F PUMP DRIVE GEAR
CRANKSHAFT GEAR ,71 (24 TEETH) RATIO: 1.5 TO I.
(27 TEETH) ITO 1 IEll)
CW
CAMSHAFT GOV.
DRIVE GEAR CAMSHAFT GEAR
(34 TEETH) (54 TEETH)
(TACH; 0.5 TO I.)
(15 TEETH) CCW OIL PUMP DRIVE
CW (RATIO:O.5 TO1.) FUEL PUMP DRIVE
GEAR (36 TEETH) RATIO:I.O TO I.
GOV DRIVEN
PROP. GOV.
GEAR PUMP IDLER GEAR (24 TEETH)
(15 TEETH) IDLER GEAR
RATIO:.B95 TO 1. (19 TEETH)
ACCESSORY DRIVE GEAR (18 TEETH)
CCW
Figure 2-3. Gear Train Diagram TIG-541
2-2
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES section 2
General Detcrlptlon
Hydmhe Rnlp BDrm
Acceaay Cme Gear

VdveGude HbreGuide
Cy(.1a2 CI(. Na4 Turbcc~nrpcr Bypms
Cyt.inB
Vake bctuola Cbnob(e Ccntro~er
Ollrehnkarnpthrushmujtubes FwlRYnp
onve T T OISlmp
Cmnkcose d heoderri~t
Turbocharger
Dmnfo
(Ilarop
Rshrods
b/pcssro~
Lif ers~bgNbonk
Uxaltmndercover
R(a ~a O~Thmosls
bypass~dve
wt~nmfurhpgcH.1 I
bushngs 01 pressve _/L~I I ~pmp
rdiefvdve
ROP901
gogeam Ikmd (hl s~mp

Relun ol Splash oil to pstom,pis~on
pns,cmqetc. townp
lonmp
Pressve d
beanls al Pccessa~ Malne)o

T"P"P ~er*m dmpem
right honk
I I No.emaBV Na3moi~\T Na4main
bcai~
Cmkccse oil header-kft
left bank I ~kwn pump

left bank Bdnve
Pushrods
Rockerarm Ethaatvdvegude
Spbsh ol to maker aa~nss CYt No.l cylNo.3 cyl. No5
orms,voke slems,efe
Ollreturn to sump thru shmud hks
Dmn oil lo sump

thu shroud t~ks
Figure 2-4. Lubrication Diagram TIO-541-E
2-7. CRANI(SHAA;T. The crankshaft is manufactured sion rings and an oilregulating ring. The piston pin is
from a chrome nickelmolybdenum steelforging. All of the fullfloating type with a plug located in each end
journalsurfaces are nitride hardened. Freedom from of the pin. Consult the latest edition of Service Instruc-
torsional vibrationis assured by a system of dynamic tion No. 1037 for proper piston and ringcombinations
counterweights. for your particular installation.
2-8. CRANKCASE. The crankcaseor integralhousing

2-12. COOLING SYSTEM. These engines are design-
consists of two reinforced aluminum alloy castings ed to be cooled air pressure actuated by the for-
by
fastened together by means of thru bolts, studs and nuts.
ward movement of the aircraft. Close fitting baffles
The mating surfaces are joinedwithout the use of a gas- direct the airflow around the cylinder fins and the dis-
Itet, and the mainbearing bores are machined for use of air is then exhausted to the atmosphere.
charge
precisiontype main bearinginserts. Bearing supports
for the accessory drives are assembled in the crank-
case. In additionbearing supports for a reduction gear
2-13. LUBRICATION SYSTEM. Lubrication is of the
drive are assembled in the TIGO series crankcase. fullpressure wet sump type. Oil pressure is supplied
by a gear driven pump housed in the accessory drive
2-9. OIL SUMP. The engines covered in this manual end of the crankcase. See figure 2-2, 2-4 and 2-6 for
are of the wet sump type. The oil sump is fastened to diagrams of the lubrication system.
the bottom of the crankcase.
2-10. CONNECTING RODS. The connecting rods are 2-14. IGNITION SYSTEM. Dual ignition is furnished
made in the form of "K" sections from alloy steel by two -1200 series magnetos. The S6RN-1209 is a
forgings. They have replaceable bearinginserts inthe conventional magneto which is grounded out at the time
crankshaft ends and bronze bushings inthe piston ends. the engine is started. The SGLN-1208 is a retard break-
The bearing caps onthe crankshaft ends of the rod are er magneto providing a fixed retard and a long duration
retained by~ means of two bolts through each cap se- spark foreasier starting. A source of DC power and a
cured by nuts. starting vibrator are required to complete the installa-
tion. These magnetoincorporate an integralfeed-thru
2-11. PISTONS. The pistons are machined, from an capacitor in the breaker circuit for suppression of
aluminum alloy forging, with grooves for two compres- breaker point arcing and conducted radio interference.
2-3
section 2 OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Gansral Description
Mogneto drive gear

Patio Accesswy driLe gear
No. of teeth 24/202.000 lBlt~ 22501
~b. ofteeth
Breothcv s//i7ger drive gear
1242 of teeth 42 It~D. 3500)
Accesswy drive
No.ofteeth 30 Ir?o.2.500/ t- I CcCmnkshaftgwr

~b, afteeth/8 (PD 2 250/ ~b. ofteetn 271t~D. 3.375)
and vacuum
pump dnve geo~ drive gec~
Potlb ~b ofteetlt 54 (PD.6.750l
-e
No of teeth 30(1~0. 2.5001
Camshoft gorr dr~Le gear

i´• ~b.of teeth 34/t?~ 2.
No. ofteeth 24 ~0.2000/
Prop go~ ~dlergwr

-t II -E_3- I I I I
Tochwneterdrli~e
Patio.S:l
Optional
Oilpmp drive gear and
Fue/pwnp drive geor
Patlb No. orteeth 8~0.1800)
No.ofteeth 301~ 2.500/ Propgov. dr~Le gear
Rolb .895:/
Figure 2-5. Gear Train Diagram TIO-541-E
2-15. INDUCTIONSYSTEM. Theseengines areequip- pressure controller with the engine throttle mech-
anism.
ped with a Bendix RSA type fuel injection system. This
fuel meters fuel, in proportion to mass air
injector
nozzle cluster a central distribution zone.
to 2-18. The variable pressure controller ´•is actuated
flow, a
A manual mixture controland idle´•cut-off are provided. by a pre-determined spring load which is set to op-
erate through a range of 30 to 50 psi in the control
2-16. A turbocharger is mounted as an integralpart of system. The controller is set to close when the com-
the engine and provides constant air to the fuel injector presser discharge pressure is below a pre-deter-
inlet from sea level to critical altitudes. mined manifoldpressureto maintainthe turbine speed
and compressor discharge to provide the required
2-17. TURBOCHARGER CONTROLS. The controller cabin air pressure down to 255% of the normal rated
senses the outlet pressure (deck pressure) of the air power.
from the compressor and in turn regulates the oil pres-
sure which controls the position of the waste gate
2-19. The action of the turbocharger control system
valve located in the engine exhaust. Engine oilutilized is automatic and modulates continusouly as engine
for this control system is supplied to the actuator speed, power and altitude is varied. Bleed air on some
models is controlled by a sonic nozzle that limits the
througha restricted passage. The dischargepressure
is determined by positioning the linkage of the variable flow of air to the cabin.
2-4
Hydrou6c Pump BDriva
Accessory Drive Gear C

r
Valve Guide ~Exhoust\blve Glide E*hatsl Guide
Na2 Turbochorger Bypass
Cyl. (I Cyl Na 4 Cyl. Na 6 3
Vdve Aclua)or Vorioble Conholkr
Fuel Pump Drain to Z

Oil meurn to sump thru shroud I~es
Prop shah Drive Oil Surp
Aelurn al
to sump rwibearing r
Turbochorger
Cmnkase oil hwder-righl
Torqwr?elec
resdrvoit Drain b
Oil sump
Rshrodsodteb Pushmds
Lilten I I
~69hlbonh filler
-r~ihermoslolic
Torquemelerol rwlar
O
Prop drive gear front Rocker arm ~C
bushings Oilpressure ----t--cO I I Oilpump --cV
Pr~ drive gear mar bearing
relief valva 61
Generalor drive’ I R SuclBn
/-Splashoillolocker orms,vdves)ems,efc.
screen
Oilpreswre Z
gage conn Drain oil 011 sump m
SFlash oil to pisfons,pislon pins,cams,elc. ksump
Use oil Iransler cover Splpsh oil to pislons, 61
pislon p’ns,cbms,alc. 13
when nol using governor Pressure oil
r
Relurnol
lowmp Cronkpin
Camstlatl n
gov drive bearing bearings n
Tapap
Nol N1~2,384 P~$,
piston
Accessory
drivegaars
Magne~o
drivi~geors
right bodi v,
Gav I t No.lmain\T I I No.moinn;l Na’maain\J Na4main O
Cronkcase oil header-lefl

Plessure oil
Pressure al reduction plslon oil Iels Push rod sod(els E
poor jets left bank Lillers Vocum pump
m
lefl bark 8 drive
Slorler drive I /h Push mds
EXhOUSI valve guide valve valva guide

fibcker am
Splosh oil lo rocker bushings
CYL No. 1 cyl. No 3 cyl. No. 5 b~
arms,valve slems,ete
I Oilrelun lo sump Ihru shroud lubes
DminMllosunp nZ
Ihtushmudlubes 80
,Oz
"ZI
J f
~s
;n Figure 2-6. Lubrication Diagram TIGO-541 C: u
GEAR PINK! SHAFT A4/VEN GEAR
hi DRIVE GEAR PCNX? GO~ a4MN GEAR nI
R4T~3.6mr/ RATN).667-.I
b RATIO 15:1 RATK)B;I
S
n7.ac TEETH 361PD 3.~X)l NO CkC TEETH 48 IPD 5.90041
NZ w TEETH 24 (PD 20001 ~71QC TEETH 30(PD 25001
ou
GENERATOR DRIVE GEAR PI
RATIOEB:I
nr~ OF TEETH 15 IPD 1.875)
4m
9
’I
DRIVEGEAR
N2 OF TEETH lB~D 2250) c
3
ACC~ DKirVEILXER GEARS
nu2 OF TEETH 361PD30001
Na w TEETH 30 (PD 25001
/t´•YZOFlg7HIB(PD 2250/ r
k
G~AR
NO OF TEETH 27
IPD 3.3751 3
HYa9AULX:
a VAC: PUMP DRIVE f
ti
I---
GEAR
RATIO
1-- fi;
;a
NO OF TEETH30
(PD 2500)7 r
OIL ~MPLYilM GEAR B o
j O/L PUMP IDLER GZAR

NO OF TEETH 81PD
PROP SHAFT DRIVE GEAR
RATIOI:I Na C~ TEETH
u,C)
j21PDJ~Qj36) STARTER DRNESHAFTGEAR
RATIO 28:1
BEIVDIX DRIVE COUPLING GEAR Na OF TEETH 15(PD1B751
RATIO 16 489~ Na OF TEt-TH STARTER HAS AN ADDITIONAL
r -I 1 9 IPD .900/ INTERNAL REDUCTION OF g
STARTER DRIVE GEAR GENERA717R tf STARTER GEAR ENGINE RATIO 5565:1 ~P,
RATIO 28’/ RATIO I’I
FUEL PUMPIDLIIW GEAR
lva w TEETH 531PD 5.300~ Na. OF TEETH 42(PD 62501
5~
n
NO. Of TEEIH 24
IPD 2000/ m
Z
CAMSHAFT DRIVE GEAR
FUEL PUMPDRIVEGEAR G,
NO OF TEETH 54/PD 67501
RATIOI:INO. OF TEETH 30 Z
lPD 25001 m~
TACHOMETER DRIVE
RATIO 5’/(OPTIONAL I
Figure 2-7. Gear Train Diagram TIGO-541-E Series

SECTION
GENE RAL OVERHAUL

PROCEDURES
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES section a
General Overhaul Procedures
SECTION 3.
GE NERAL OVERHAU L
P RO CE DURE S
3-1. As mentioned in Section i, this manual will de- mercial solvent such asVarsol or Perm-A-Chlor. Op-
scribe in separate chaptersthe complete major over- erators are warned against the use of solvents with
haul procedures for each individual section of the en- which they are unfamiliar, since there are products
gine, thus dividing the engine, for all practical pur- onthe market which are injurious to aluminum and
poses, into a series of individual handbooks dealing in magnesium. Extreme care must be exercised if any
turn with each componentpart. Since there are various water-mixed degreasingsolutions containing caustic
prescribed overhaul practices and instructions of a compounds or soap are used, Such compounds, in ad-
non-specific nature, which apply equally to all basic dition to
being potentially dangerous to aluminum and
engine components, these general instructions will be magnesium, may become impregnated in the pores of
grouped together and described in this section, thus the metal and cause oil foaming when the engine is
eliminating repetition. returnedto service. Whenusing water mixed solutions
therefore, it is imperative that the parts be completely
3-2. No attempt shall be made to include overhaul pro- and thoroughly rinsed in clear boiling water after de-
cedures for the varioustrade accessories. These ac-
greasing. Regardless of the method and type of solution
cessories are covered by overhaul manuals published used, coat and spray allparts with lubricating oil im-
by the
respective manufacturer. Only such assembly mediately after cleaning in order to prevent corrosion.
and disassembly as required by engine installation will
be covered.
3-3. Just prior to or immediately after removing the 3-10. REMOVAL OF HARD CARBON. While the de-
engine from the airframe, remove the oil drain plug greasing solution will remove dirt, grease and soft
and drain the oil from the engine, carbon, deposits of hard carbonwill almost invariably
remain on many interior surfaces. To facilitate re-
3-4. Attachthe enginelifting cable(ST-220) to the en- moval, these deposits must first be loosened by im-
gine and remove from the airframe, mersion in a tank containing a decarbonizing solution
(usually heated). A great variety of commercial de-
3-5. Place the skid (ST-278) in the overhaul stand carbonizing agents are available, including such pro-
(ST-162). Attach engine overhaul adapter (ST-165 or ducts as Gunk, Penetrol, Carbrax, Super-Chemaco,
ST-240) and mount the assembly on the engine mount- Gerlach No. 70, and manyothers. Decarbonizers, like
ing ring (ST-161). the degreasing solutions previously mentioned, fall
generally into two categories, water- soluble and hydro-
3-6. Place the overhaul stand and skid into position carbons, and the same caution concerning the use of
and lower the engine to the stand and remove cables. water- soluble degreasers is applicable to water- solu-
The engine is now in a position to be disassembled. ble decarbonizers.
Specific disassemblyinstructions are contained in the
applicable section for each component. CAUTION
3-7. Inasmuch as visual inspection immediately fol-

lows disassembly, all individual parts should be laid Extreme caution shouldbe exercised when
out in orderly manner as they are removed from
an using a decarbonizing solution on mag-
the engine. No cleaningoperation shouldbe performed nesium castings. It is recommended that
until this initial visualinspection has been completed. the use of heated solutions be avoided un-
All loose studs, cracked cooling fins, loose or damaged less the operator is thoroughly familiar
fittings, andthe like, should be carefully noted and tag- with the particular solution being used. In
ged to prevent their being overlooked during regular addition, the operator is strongly advised
inspection. against immersing steel and magnesium
parts in the same decarbonizing tank, be-
CLEANING cause this practice often results in damage
to the magnesium parts from corrosion.
3-8. It is imperative to clean all engine parts’ thor-
oughly facilitateinspection. Two processes are in-
to
volved in cleaning engine parts; degreasing and re- 3-11. Decarbonizing will usually loosen most of the
moval of dirt and sludge (soft carbon), and the removal hard carbon deposits remaining after degreasing; the
of hard carbondeposits bydecarbonizing, brushing or complete removal of all hard carbon, however, gen-
scraping and grit-blasting. erally requires brushing, scraping or grit-blasting.
All of these operations demand care on the part of the
3-9. DEGREASING. Degreasing is accomplished by mechanic to avoid damage to machined surfaces. In
immersing or spraying the part in a solution of white particular, wire brushes and metal scrapers must
furnace oi1(38-40 specific gravity) or asuitable com- never be used on any bearing or contact surface.
3-1
ENGINES
section o OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT
3-12. When grit-blasting parts, do not use sand or any 3-20. BEARING SURFACES. All bearing surfaces
metallic abrasives. It is recommended instead that should be examined for scores, galling and wear. Con-
mildly abrasive organic substances such as rice, baked siderabie scratching and light scoring of aluminum
wheat, plastic pellets, or crushed walnut shells be used, bearing surfaces in the engine will do no harm and
All machined surfaces must, of course, be properly should not be considered cause for rejection of the part,
and adequately masked and all openings tightly plugged provided it falls within the clearances set forth in the
before blasting. The one to this is the valve
exception Table of Limits. Even though the part comes within
seats, which may be leftunprotected when blasting the the specific clearance limits, however, it will not be
cylinder head combustion chamber. It is often advan- satisfactory for reassembly intothe engine unless in-
t~eous to grit blast the seats, since this will cut the spection shows the part to be free from other serious
glaze which tends to form (particularly on the exhaust defects. Ballbearings should be inspected visually and
valve seat), thus facilitatingsubsequent valve seat re- by roughness, flat spots on balls, flaking or
feel for
conditioning. Under no circumstances should the pis- pitting of races, and for scoring on outside of races.
ton ring grooves be grit-blasted. If necessary, soak All journals should be checked for galling, scores, mis-
the piston in petroleum solvent and scrape with a alignment and out- of-round condition. Shafts, pin, etc.,
wooden scraper. When grit-blasting housings, plug should be checked for straightness. This may be done
all drilled oil passages with rubber plugs or other in most casesby using veeblocks and adial indicator.
suitable material to prevent the entrance of foreign
matter.
3-21. GEARS. All gears should be examined for evi-
dence ofpitting and excessivewear. These conditions
3-13. The decarbonizing solution will generally re- are of particular importance when they occur on the
move most of the enamel on
exterior surfaces. All
involute of the teeth; deep pit marks in this area are
remafningenamelshould be removedby grit-blasting, sufficient cause to reject the gear. Bearing surfaces
particularly in the crevices between cylinder cooling of all gears should be free from deep scratches. How-
fins. ever, minor abrasions maybe dressed out with a
fine
abrasive cloth.
3-14. At the conclusion of cleaning operations, rinse
loose
the part in petroleum solvent, dry and remove any
of carbon or other foreign matter by air- 3-22. CORROSIONON STRESSEDAREAS. Pittedsur-
particles
blasting and a Ilberalcoating of preservative
apply oil faces in highly stressed areas resulting from corrosion
to all surfaces. can cause ultimate failure of the part. The following
areas should be carefully examined for evidence of such
INSPECTION corrosion; interior surfaces of piston pins, the fillets

at theedges of crankshaft main and crankpin journal
3-16. The inspection engine parts during overhaul
of surfaces, and thrust bearing races. If pitting e~dsts
extent that it
is dividedinto three categories; visual, structuraland on any of the surfaces mentioned to the
dimensional. The first two categories deal with struc- cannot be removed by polishing with crocus cloth or
turaldefects in the parts while the third dealswith the other mild abrasive, the part must be rejected.
size and shape.

3-23. SCREWED FITTINGS. Screwed fittings (any
3-16. Visual inspection should precede allother in- parts such as threaded fastenings or plugs) should be
to inspected for condition of threads. Badly worn or
pection procedures. Do not clean any parts prior
mutilated threads must not be tolerated; the parts
visualinspection, since indications of adangerous op-
erating condition may often be detected from the re- should be rejected. However, small defects such as
sidualdeposits of metallic particles found in some par- slight nicks or burrs may be dressed out with a small
ticular recess in the engine. file, fine abrasive cloth, or stone. If the part appears
to be distorted, badly galled, or mutilated by over-
tightening, or from the use of improper tools, it must
3-17. Structuralfailures can be determined by several be replaced with a new one.
different methods; the method employed depending on
the part involved. The following are a few of the meth-
ods employed; magnetfcparticle, dyepenetrant, pene- 3-24. MAGNETIC INSPECTION. All ferro-magnetic
trant, x-ray and various electronic devices, steelparts should be inspected by the magnetic particle
method. The successful detection of structural failure
by magnetic inspection demands skill and experience on
3-13. Dimensional inspections should be carried out the part of operating personnel. It must be remem-
in accordance with measurements and tolerances as bered that almost any fabricated steel part will show
listed in Table of Limits SSP-2070. indications of some kind, and it is important that the
operator exercise good judgment in evaluating the in-
3-19. It is strongly recommendedthat an overhauland dications. Too rigid an interpretation may result in
inspection form, containing a list of all engine com- the rejection of a sound part, while on the other hand,
ponents, be utilized when overhauling an engine.
This a part showing a dangerous indication may be returned
form should be prepared so that all overhaul and in- to service as a result of a too casual diagnosis. In
spection procedures can be checked off as they are general, areas of stress concentration must be watched
accomplished and any remarks noted. The use of this closely for fatigue cracks. These areas include such
formwill assurethat no parts are inadvertently over- locations as keyways, gear teeth, splines, roots of
looked. Also, needless repetition can be avoided. threads, small holes and fillets.
3-2
3-25. Proper judgment must also be used in deter- result. Parts from which paint has not been removed
mining the amount of current (amperage) applies; too may be repainted omitting primer coat.
little current will not sufficiently magnetize the part, 3-30. Magnesium Parts. Magnesium parts should be
while too heavy an application will permanently dam- cleaned thoroughlywith a dichromate treatment prior
age the part by overheating and burning thin areas ad- t, painting. This treatment consists of cleaning all
jacent to the electrodes. Again, skill and experi~tnce traces of oil and grease from the part by usinga neu-
on the part of the operator are of the utmost importance,
tral, non-corrosive degreasing medium followed by a
Consult the latest edition of Service Instruction No. rinse. Afterwhich the part is immersed for 45 minutes
1285 for correct amperage. in a hot dichromate solution (3/4 Ib. of sodium di-
chromate to gallon of water at 180"F. to 200"F.,
one
3-28. CORROSION-PREVENTION. Upon completion quantity as required). The part should be then washed
of inspection, coat all steelparts with preservative oil, thoroughly in cold running water, dipped in hot water
and dried in an air blast. Immediately thereafter the
REPAIR AND REPLACEMENT
part should be painted with a prime coat and engine
enamel in the same manner as prescribed for alumi-
3-27. DAMAGED PARTS. Abnormal damage such as
parts.
burrs, nicks, scratches, scoring, or galling shouldbe
removed with a fine oil stone, crocus cloth, or any 3-31. ShroudTubes. Shroudtubes shouldbethoroughly
similar abrasive substance. Following any repair cleaned and dipped in a zinc chromate primer thinned
of this type, the part should be carefully cleaned in to,praying consistency. After the primer is driedthe
order to be certainthat all abrasive has been removed shroud tube should be painted on the outside with en-
and then checked with its mating part to assure that
gine enamel.
the clearances are not excessive. Flanged surfaces
3-32. All paint applied in the foregoing operations
that are bent, warped, or nicked may be repaired by
shouldpreferably be sprayed; however, if it is neces-
lappingto a true surface on a surface plate. Again the
saryto use a brush, care shouldbe exercised to avoid
part should be cleaned to be certain that all abrasive
a" accumulation of pockets of paint.
has been removed. Defective threads can sometimes
be repaired with a suitable die or tap. Small nicks
can be removed satisfactorily withSwiss pattern files
3-33. REPLACEMENT OF STUDS. Any studs which
or small, edged stones, pipe tapped threads should arebent, broken, damagedorloose, must be replaced.
The method of removing studs depends on the type of
not be tapped deeper in order to cleanthem up, because
stud andmanner in which it is broken. The procedure
this practice will invariably result in an oversized
for removing and replacing studs is as follows:
tapped hole. If scratches or gallingare removedfrom
abearing surface of a journal, it should be buffed to a
a If there is sufficient thread area available on stud,
high finish. Generally it is impossible to repair cracks;
use a collet grip toolconsisting of atapered collet that
however, welding operations may be performed in some
threads onto stud and a housingthat slips over the collet.
parts of housings, providing the area is not a stressed
section of the part. For example, almost any area of Tighten bolt on top of the housing and draw collet into
a rocker box may bewelded, but no part of the cylinder
housing to lock puller on the stud with a tight grip.
head except the fins may be welded, b. If the collet type tool cannot be used, drill, a small
hole into the stud. Employ a pilot bushing to guide
3-28. PAINTED PARTS. Parts requiring use of paint drillinto ceMer of stud when stud is broken beneath
for protection appearance should be painted in ac-
or th, surface of the crankcase. Redrillthe hole to en-
cordance with the following recommendations using large it to accomodate the proper size extractor. Using
materialfrom the following list of approved materials. the e~tractor, remove the stud.
Thinner Toluene equivalent (AMS3180 or equiva-
or
lent Federal Spec. TT-T-548). Primer Zinc chro- c. After studs have been removed, check for size
mate (AMSB110 or equivalent Ma-P-8585). Enamel and condition of threads in stud holes to determine
Phthalate resin type (AMS3125C or equivalent MIL- whether oversize studs must be used for replacement.
E-7729). Coat threads of studs with thread lubricant. Specifi-
cation JAN-A-669 and drive stud to correct depth by
NOTE suitable stud driver.
using a
All machined bosses should be masked 3-34. CORROSION-PREVENTION. At the conclusion

before painting. Do not paint areas under of all repair operations and subsequent inspection,
hold down nuts where torque is required. coat all steel parts with preservative oil.
3-29. Aluminum and SteelParts. Parts shallbe clean- 3-35. CORROSION-PREVENTION. Prior toassembly
ed and degreased prior to painting. Apply one coat of subassemblies, all parts should be cleaned to re-
zinc chromate primer, thinned with approximately two move alltraces of preservative oil and accumulated
parts toluene, and air dry. Apply one coat of enamel foreign matter. During assembly, cover all steel parts
and bake at 2500 F. to 3000 F. for one-half hour. Enamel with a heavy coat of preservative oil. This mixture
may be allowed to air dry but an inferior finish will should be used on all machined surfaces, especially
3-3
section a OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Censral Overhaul Procedures
3-41. P~CH ALIGNMENT AND BACKLASH IN BEVE L

GEAR ASSEMBLIES. During disassembly of engines
returnedto our factory, inspection personnel ocassion-
ally find evidence of incorrectly assembled gears. This

condition appears to be wholly confined to bevel gear
assemblies wherein one of the gears had been replaced;
that is, instances where a comparatively new bevel gear
is meshed with an older worn gear. An exaggerated
example of this sort is shown in figure 3-2. Note that
the edges of the gear are not even; the one gear is too
far forward on its longitudinal axis.
3-42. During manufacture of bevel gears, the relation-

ship between the edges of the gear (or tooth length) is
carefully controlled. Because of this relationship, the
correct location of the interlocldngteeth (pitch align-
ment) of the two bevel gears can be maintainedifthe
GEAR UX;ATK)N mating edges of the gears are even.
TOO FAR ADVANCED

’N THIS DlwOTlON
3-43. In Avco Lycoming aircraft engines where bevel
gears are employed, the gear mountings are similar to
the arrangement shown in figure 3-3. That is, a lam-
inated shim is usually provided between the mounting
adapter and the housing, thus permitting each gear to
be movedin either direction,alongits longitudinal axis.
Figure 3-1. Bevel Gear Showing E~treme 3-44. Designs such as this not only provide a means
Pitch Alignment of obtaining correct backlash between the m ating gears

but also permit adjustment to correct pitch alignment,
on bearing surfaces, cylinder bores and piston rings, by correctinguneveness of the edges of the gears. The
The practice of using plain lubricating oil during as- following procedure is suggested for obtaining both
sembly is not recommended. backlash and pitch alignment cruring assembly of the
bevel gears.
3-36. PRE-LUBRICATIONOF PARTS PRIOR TOAS-
SEMBLY. Many premature failure of parts have been
traced directly to improper pre-lubrication at engine
assembly. If parts are not properly lubricated, or an
inferior lubricant is used, many of the engine parts
will become scored before the engine oilgoes through
its first cycle and has had a chance to lubricate the
engine. This, of course, will lead to premature parts
failure prior to normalservice life, and in some cases,
lead to engine fialure before normalservice hours have
been accumulated. It is of utmost importance, there-
fore, that the following recommendations be adhered
to at engine assembly. Consult the latest edition of
Service Instruction No. 1059.
3-37. Coat the camshaft lobes, face of

tappet bodies
and rocker arm tips withTexaco MolytexType "O" or
equivalent.
RECT WHEN THESE
3-38. Coat the valve stems and the interior of the s~ ARE
valve guides with Texaco Molytex "O" or equivalent.
3-39. All other parts shouldbe coated with a mi~ture

of 15q& pre-lubricant (STP or equivalent) and 850~ SAE
SHIMSATTHESE
No. 50 mineral base avaition grade lubricating oil. U~AIIONSCOMROL
BACKLASH AND
3-40. OIL~E BUSHINGS. During overhaul cleaning PITCH AUGNMEST
OF GEARS
operations it is possible to wash the oil from these
bushings; also, if abushing has been replaced and either
reamer or broached, its porosity may be affected.
Therefore, before the bushings are reassembled into

the engine they must be impregnated by immersing
them for at least fifteen minutes inengine oil that has Figure 3-2. Typical Mounting for
been heated to 1400F. Support Bevel Gears
3-4
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES Section 3
General Overhaul Procadur´•~
a. Assemble each gear and its associated parts in determine the backlash and end clearance of gears, the
clearance between mating machined parts, the clear-
its housing using such gaskets and shims as are´•speci-
by the applicable parts catalog.
fled Secure the gear ance between movingparts which are in close contact
with each other and the torque limits for various nuts,
mountings temporarily.
screws and fastenings.
b. Remove or add shimlaminations as required to
obtain correct backlash. 3-47. OIL SEALS AND GASI(ETS. When building up
an engine during major overhaul, replace alloil seals
c. Visually, by feel, determine if the edges of
and ..d 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 equalthick-
ness to the other gear to achieve pitch alignment of the 3-43. ARBITRARY REPLACEMENT OF PARTS. It
gears. is recommended that certainparts throughout the en-
gine be replaced at normal overhaul regardless of their
NOTE
apparent condition. Included among these are the fol-
lowing:
It is possible to perform step (c) prior to
step (b); that is, pitch alignment can be All engine oil hose
corrected before adjustment for backlash All oil seals
is made provided these precepts are ob- All gaskets
served. The removal or addition of an equal and
Allcirclips, lockplates retaining rings
amount of shim material from both gear Piston rings
mountings will change backlash but not All exhaust valves (except Inconel alloy valves)
pitch alignment. The removal or addition All exhaust valve retaining keys
of shim material from one gear only will
Cylinder fin stabilizers
change backlash and pitch alignment and Allbearing inserts (main and connecting rods)
the removal of shim material from one
Magneto drive cushions
gear with the addition of an equal amount Stressed bolts and fastenings
of shim material to the other gear will Camshaft gear attaching bolts
change pitch alignment but not backlash. Connecting rod bolts and nut
Crankshaft flange bolts
3-45. It is strongly recommended that all overhaul Ignition cables
facilities adapt a firm policy of checking pitch align- All laminated shims
ment of bevel gears at the same time backlash is ad- Crankshaft counterweight bushings
justed during engine overhaul Propeller shaft thrust bearing (TIGO-541)
3-46. TABLE OF The table of limits, SSP- Consult the latest edition of Service Bulletin No. 240
2070, should be consulted whenever it is desired to for information on the replacing of parts at overhaul.
3-5
SECTION
IGNITION SYSTENI
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES section
Ignition System
SECTION 4.
IGNITION SYSTEM
4-1. GENERAL. All subjectengines are equipped with 4-4. IGNITIONHARNESS. Ignitionharnesses willvary
a high tension ignition system. A brief description of for eachparticularinstallation, however, forpurposes
the system may be found in paragraph 2-14. of description, all harnesses are comprised of the
same basic components. Basically, each lead is com-
4-2. ENGINEFIRINGORDER. Theenginefiring order posed of a magneto terminal, cable and a spark plug
is 1-4-5-2-3-6. assembly.
4-3. MAGNETOS. Dual ignition is furnished by a

4-5. SPARK PLUGS. For information relative to ap-
SBLN- 1208 magneto, aretard breaker magneto, mount-
proved sparkplugs consult the latest edition of Service
ed on the left side of the engine and aSGRN-1209 mag-
Instruction No. 1042.
neto mounted on the right side.
4
3
8
i. Left Magneto Terminal 6. No. 1 Top Lead ‘.11,No. 4Bottom Lead

2. No. 5 Bottom Lead 7. No. 3 Top Lead 12. No. 2 Bottom Lead
3. No. 3 Bottom Lead 8. No. 5 Top Lead 13. No. 2 Top Lead
4. No. 1 Bottom Lead 9. Right Magneto Terminal 14. No. 4 Top Lead
5. Spark Plug 10. No. 6 Bottom Lead 15. No. 6 Top Lead
Figure 4-1. Typical Ignition Harness
4-1
Ignition System
REMOVAL FROM ENGINE moval of the drive coupling (7). This is accomplished
by removing the cotter pin(ll), nut (10),
washer (9),
4-6. IGNITION HARNESS. Remove the spark plugs and removing the drive coupling (7) and Woodruff key
leads from the spark plugs. Detach, and mark loca- (8) from the drive shaft. It is recommended that the
tions, of the various clamps securing the harness to nut be replaced on the shaft to protect the thread.
the engine. Complete the removal of the harness by REPAIR AND REPLACEMENT
removingthe outletplates from the magnetos. Remove
the spark plugs from the cylinders.
4-9. IGNITIONHARNESS. Unlessthe harness assem-
4-7. MAGNETOS. See figure 4- 2. Remove the four 5/16 bly obviously new condition and is lmown to have
is in
nuts, washers and clamps securing the magnetos to been recently installed, it is recommended that the
the engine. Remove the magnetos and gaskets. Reach harness be replacedat overhaul. Avco Lycoming does
inside the left mounting pad and remove the cushions supply individual leads in two lengths, (48 or 18 inch)
(12) and the magneto coupling (15). Reach through the finished at the spark plug endand available from your
mounting pad on the right and remove cushions (12) local distributor. The following steps will describe
and pull the drive shaft (13) from its position, the procedure for replacing a lead.
NOTE 4-10. Removal of Condemned Lead. Remove clamps

andbrackets from applicable lead assembly. Cut cable
The gears mentioned in the above para- ties from assembly and discard.
graph are associatedwith and form a part 4-11. Cut off condemned lead flushwith the outer sur-
of the accessory drive train and should not
face of the cable outlet plate. Grip eyelet of lead with
be considered apart of the ignition system.
a pair of pliers and pull short length of conductor out
They are removed at this time, however, of grommetand cable outletplate. Using a 3 inch long,
to prevent their being dropped and damaged
0. 270 inch diameter drift, applied at outer surface of
as the engine is rotated.
plate, drive out tapered ferrule and remaining pieces
DISASSEMBLY of insulation and shielding.
4-8. MAGNETOS. See figure 4-2. For the purposes 4-12. Replacement of Condemned Lead To replace
of this manualthe only disassembly requiredis the re- a condemned lead, proceed as follows:
RIGHT MAGNETO
REAR OF CRANKCASE
15 12
$H IC
i
LEFT MAGNETO
1. Right magneto 9. Washer

2. Left magneto 10. Nut
3. Clamps 11. Cotter pin
4. Washer 12. Drive cushions
5. Nut 13. Driveshaft
8. Gasket 14. Driveshaft sleeve
7. Coupling 15. Coupling
8. Woodruff key 16. Driveshaft sleeve
Figure 4-2. Magnetos and Magneto Drive Assembly
4-2
Ignition System
a. Measure the length of the condemned lead as- j. Before coupling the harness assembly to mag-
sembly. Move coupling nut back on lead assembly neto, spray entire face of the grommet with a light
and from outer end of the ferrule at the spark coat of Plastic Mold Spray. This will prevent cable
measure
end. See figure 4-3. Add 1-3/4 inches to this outlet grommet from sticking when it is necessary to
plug
measurement, remove the harness from magneto distributor block.
b. Cut the replacement leadassembly to the length NOTE

determined in step a. Mark ferrule on spark plug end
of lead with a metal stamp, scribe or rubber stamp Bendix Tools No. 11-7074, 11-7803 and
to correspond with correct cylinder number. Starting 11-7073 are procurable from Avco Ly-
at the spark plug location, thread new cable through coming. Tool No. 11-4152 is available
grommets and clamps as necessary for correct routing from Thomas Betts Co., Elizabeth, New
of cut end of cable to magneto location. Jersey under No. WT-111-M. Plastic
Remove 1. 250 inch of outer braid from end of Material Sales Co.,Fanwood, New Jersey
c.
are manufacturers of Plastic Mold Spray.
lead. See figure 4-3. Use care notto nick or cut insul-
ation when removingbraid. Use Bendixtoolno. 11- 7803
tounbraid 3/8 inch of braided shielding. See figure 4-4. 4_13. MAGNETOS. As previously mentioned, this over-
Wrap thickness of electrical tape around un-
single
a haulmanual willnot endeavor to describe the overhaul
braided strands to facilitate insertion of lead end of trade accessories. Consult the magneto manu-
through hole in cable outlet plate, facturer’ s applicable manual for overhaul procedures.
d. Remove the cable outlet plate from the magneto.
REASSEMBLY AND INSTALLATION
Support plate securely, and using suitable cutting
pliers, split and remove eyelets from the leads adjacent
to the leadbeingreplaced. When splitting eyelet, make 4-14. MAGNETOS. Seefigure4-2. AssembleaWood-
ruff key (8) in the slot in the driveshaft and install the
certain that wire strands are not cut. Removal of the
drive coupling (7) and secure with washer (9) nut (10)
eyelets on adjacent leads will allow grommet to be
pulled away from outlet plate to facilitate insertion of and cotter pin (11).
the new lead.
e. Pass the the new lead through hole

taped end of 4-15. MAGNETO INSTALLATION AND TIMING PRO´•
CEDURES. When engine build-up has progressed to a
in outlet plate. Remove electrical tape from lead and
install tapered end of ferrule under the unbraided point where allmajor sub-assemblies have been in-
strands of shielding (figure 4-4). Form strands of stalled, the magnetos may be installed andtimed to the
shielding evenly around tapered ferrule and pull lead engine.
back through cable outlet plate until the ferrule binds
in the outletwell. Positionthe BendixToolNo. 11-7074, 4-16. See figure 4-2. It is assumed that the magneto
seating tool over the wire and firmly seat the ferrule drive coupling (15), magneto drive shaft (13) and
by tappingthe seatingtool with a hammer, or by using cushions (12) have been installed.
an arbor press.
NOTE
f. Measure inch from top of ferrule and strip
1/2
remaining insulation from wire. Figure 4-5. The retardbreaker magneto isinstalled on
the left side of the engine.

g. Insert Bendix ToolNo. 11-7073 needle through
the small hole in the grommet and over stripped end
of wire, figure 4-6. Slide grommet down needle until 4-17. Remove a spark plug from No. 1 cylinder and
place a thumb the spark plug hole. Rotate the
it seats tightly against thetapered ferrule. See figure over
4-7. crankshaft in direction of normal rotation until the

compression stroke is reached, this is indicated by a
h. Cut the wire 3/8
inch from top of grommet outlet. positive pressure inside the cylinder tending to push
Double wire over. overdoubled wire until
Slideeyelet the thumb off the spark plug hole.
it is firmly seated in recess of grommet outlet. See
figure 4-8. a. (TIO-541Series). Continue rotation the crank-
shaft in direction of normal rotation until the advance

Using the "AB" groove of Bendix ToolNo. 11-
i.
4152, crimping tool, crimp the eyeletto wire. Approld- timing mark on the front face of the starter ring gear
is in exact alignment withthe small hole located at the
mately 1/32 inch of wire should extend from end of eye-
let after crimping. 2 o’clock position on the front face of the starter hous-
ing. See figure 4-9. Starter ring gear may be marked
NOTE at 20" and 25". These engines use the 20" mark.
If the previously designated crimping tool b. (TIGO- 541Series). Remove thetiming hole cover,
and sighting through the timing hole, continue to ro-
is not available, a satisfactory connection
can be made by soldering withgester Flux
tate the crankshaft until the 20" mark on the crank-
709 or equivalent and non-corrosive shaft front flange is in alignment with the crankcase
solder. After soldering, clean solder joints parting surface. The crankshaft front flange may be
marked 20-25-30.
using denatured alcohol.
4-3
Ignit(on System
1.250
ii NEEDLE
L REQUIRED
LENGTH--I
Figure 4-3. Measuring Lead Assembly Lengths Figure 4-6. Installing Grommet Over Lead Assembly
1/2 INCH COATING

SCRAPED FROM BRAID
BRAID TO EDGE
BLUE COATING iT~
OF KNURLING
Figure 4-4. Ferrule Installed Under Shielding Figure 4-7. Lead Assembly Installed in Grommet
0.500
Figure 4-5. Measuring Wire from Top Figure 4-8. Wire Doubled Over for Installation
of Ferrule of Eyelet
4-4
Ignition System
250 MARKER
TIMING REFERENCE HOLE nn0111~Yt0
tooth the distributor gear is aligned in the center
on
Toc MARK
Of the inspection window. Being sure that the gear
does not move from this position, install gaskets and
magnetos on the engine. Secure clamps, with washers
and nuts; tighten only finger tight.
4-19. Using timing light, attach the positive lead to a

suitable adapter connected to the switch terminal of
the magneto and the negative lead to any unpainted por-
tion of theengine. Rotate the magneto in its mounting
flangeto a pointwhere thelight comes on, then slowly
turn it in the opposite direction until the light goes
out. Bring the magneto back slowly until the light just
comes on. Repeat this with the second magneto.
NOTE
~c:
Some timing lights operatein the reverse

manner as described above, the light goes
out when the breaker point open.
4-20. Afterboth magnetos have been timed, check, as
described below, to ascertain that both magnetos are
are set to fire together.
4-21. Backoff the crankshaft a few degrees, the tim-
Figure 4-9. Reference Points Timing ing lightsshould go out. Bring the crankshaft slowly
Magnetos to Engine TIG-541 back in direction of normal rotation untilthe timing
reference points are in alignment. At this point, both
NOTE lights should go on simultaneously. Tighten nuts to
specified torque.
If the crankshaft is accidently turned inthe
direction opposite normal rotation, repeat 4-22. IG~IONHARNESSINSTALLATION. Assemble
the above procedure as accumulatedback- spark plugs withtighten to specified tor-
gaskets and
lash will make the final timing incorrect. que. Secure each harness to its respective magneto
by screwing the outlet plate to the mounting surface.
4-18. At this point, the engine is ready for assembly Arrange the leads, all leads should be marked with
of the magnetos. Remove the inspection plugs from its spark plug location, and secure to the engine at
both magnetos and turn the drive shafts in direction locations marked at disassembly.Attachto spark plugs.
of normal rotation until the first painted chamfered See figure 4-10 wiring diagram.
i:"
q3 I
I I
i
f~
I /I
lo Ii
I
Figure 4-10. Ignition Wiring Diagram
4-5
SECTION
INDU CTION AND

EXHAUST SYSTENI
Induction and Exhaust Systems
SECTION 5.
INDUCTION AND
EXHAUST SYSTEMS
5-1. For purposes of this manual the induction sys- REMOVAL FROM ENGINE
tem will be considered as consisting of the intake
pipes, induction housing, pressurization valve, injec-
tor nozzles, fuel injector, fuel drain Lines and fuel 5-3. TIG-541-A. See figure 5-1. Remove oil lines
drain check valve. The exhaust system willbe con- from turbocharger and controls. Loosen and remove
sidered as consisting of the exhaust manifolds, turbo- theMarmanclamps (8) securingthe exhaust manifolds
charger, exhaust bypass valve assembly and the vari- to the exhaust bypass assembly. Using wrench (ST-213),
able pressure controller, remove the 5/16 nuts and lockwashers from the ex-
haust flanges and remove the exhaust manifolds (10).
5-2. Fuel injectors, for the purposes of this manual, Remove the four bolts and nuts securingthe exhaust by-
will be covered only to the extent of removing from pass valve assembly (9) to the compressor housing and
and assembling to the engine. Overhaul of the fuelin- remove the exhaust bypass valve assembly. The turbo-
jectors is covered in the applicable Bendixpublication. charger, supports, brackets and struts may be re-
2
3
f t
t~ r I"
12 tlL jl;: I
II
10
I. Induction housing 7. Waste gate acutator

2. Intake pipe 8. Marman clamps
3. Fuel injector 9. Exhaust bypass valve
4. Adapter housing 10. Exhaust manifold
5. Hose 11. Turbocharger bracket
6. Variable pressure controller 12. Magneto baffle
Figure 5-1. 3/4 Left Rear View Typical TIG-541-A Series
5-1
section 5 OVERHAUL MANUAI-AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
1. Hose (actuator to controller)

2. Strut (turbocharger)
3. Support (turbocharger strut)
3´•
L
~4 2. ~il 4. Bracket (turbocharger)
5. Exhaust by-pass valve assembly
6. Turbine oil drain tube
7. Strut (compressor mounting bracket)
8. Strut (compressor mounting bracket)
9. Compressor drive pulley
10. Hose clamps
6
LEFT SIDE
11. Hose outlet to adapter)

(turbocharger II
12. Bracket (turbocharger and compressor)
13. Support (turbocharger and compressor)
14. Hose (crankcase to actuator)
12
15. Bracket(compressor mounting)
16. Fuel drain check valve
17. Strut(turbocharger) 20
18. Exhaust manifold
19. Marman clamps
20. Hose (actuator to turbine oil inlet) fYI~rdl4
17
19 2
RIGHT SIDE
Figure 5-2. Views of Typical Turbocharger Mounting ("E" Series) TIO-541-E1A4, -E1B4
5-2
OVERHAUL MANUAC -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES Section 5
Induction and exhaust Systems
a. Remove oil line from controller to actuator (1)

andoil line from actuator to turbine oilinlet (20). Un-
fasten oil line from crankcase to actuator (14) at the
d actuator. This line will be easier to remove from the

crankcase after the turbocharger assembly is removed.
Loosen hose connecting turbine oil drain tube (6) to
the crankcase.
g~
f b. By removing the nuts and bolts, identified by X

on figure 5-2, the turbocharger, supports, brackets,
and struts will remove as an assembly.
5-7. Turbocharger and Exhaust Manifolds ~IO-541-

E1C4, -E1D4, TIGO-541-E1A). figure 5-3. Al- See
´•1 thoughthe figure shows the rear of the TIGO-541, the
arrangement at the rear is similar enough to call out
removal procedure for subject engines. Remove the
oil lines from turbocharger and controls. Loosen and
remove the v-band couplings (2 and 5) securing the
exhaust manifoldstothetransition assembly (7). Using
wrench (ST-163) removethe 1/2 inch self locking nuts
fromthe exhaust flanges andremove the left and right
exhaust manifolds (1 and 6).
5-8. Removethe fourbolts and nuts securingthe tran-

sition assembly(7) to the turbocharger and remove the
transitionassembly and the exhaust bypass valve as-
sembly (4). By removing the nuts and bells securing
the turbocharger, supports etc, to the crankcase, it
f 4 b 6 be removed as an assembly and disassembled on

the bench.may
1. Exhaust manifold left
5-9. ALlModels. Seefigure 5-10. Remove the 1/4 inch
2. V-band coupling bolts, lockwashers and washers at intake pipe flange
3. V-band coupling andpull intake pipes (1) and sealrings (2)from the in-
4. Exhaust bypass valve duction housing (8). Remove flanges (9) from pipes.
5. V-band coupling
6. Exhaust manifold right 5-10. ALlModels. See figure 5-4. Remove cross shaft
7. Transition assembly
linkage shields (13 and 15), injector and controller
connecting rods (1 and 9) and cross shaft assembly
Figure 5-3. Rear View of Typical TIGO-541 (14). Remove the tube assemblies (2 and 11). Remove
flelEible lines (6, 7 and 8)
moved from the engine as an assembly anddisassem-
bled on the bench. 5-11. Remove variable pressure controller (5) and
sonic nozzle assembly (4) from those models em-
5-4. Loosen clamps on hose (5) connecting turbo- ployingthis feature. Remove controller adapter (3) and
charger to adapter assembly (4). Remove the cap- fuelinjector (10). Discardthe gaskets. Remove the in-
screws securing the turbocharger mounting bracket duction housing (12).
(11) to the engine and remove the bracket and turbo-
charger assembly from the engine. Remove the mag- 5-12. See figure 5-11. Loosen fuel drain lines from
neto baffle plate (12). nipples in cylinder head and from the check valve (1)
onthe crankcase. Remove the various clamps andre-
5-5. Turbocharger and Exhaust Manifold CTIO-541- move the fuel drain lines. Remove the check valve
E1A´•Q, -E1B4). See figure 5-2. Remove oil linesfrom assembly (1).
turbocharger and controls. Loosen and remove the
Marman clamps (19) securingthe exhaust manifold to DISASSEMBLY
the exhaust bypass valve assembly (5). Using wrench
5-13. Turbocharger. For overhaul of the turbocharger,
(ST-163) remove the 1/2 inch self loc~ng nuts from
the exhaust flanges and remove the exhaust manifold.
thefollowing special tools must be available:
a. A furnace, oven or hot oil bathwhich canbe tem-

5-6. Remove the four bolts and nuts securing the ex- perature controlled between 3500F. and 3750F.
haust bypass valve assembly (5) to the compressor
housing and remove the exhaust bypass valve assem- b. An arbor press, and dial indicators.
bly. The turbocharger, supports, brackets and struts
may be removed from the engine as an assembly and 5-14. Clean exterior ofturbocharger with a pressure
disassembled on the bench. This is accomplished in spray of cleaning solvent before disassembly. As each
the following manner: part is removed, place in a clean, protective container.
5-3
Section 5 OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Induction and Ewhaust Systems
5-15. Prior to disassembling, mark the position of mounting plate) and one and one-quarter inch indicator
the compressor and turbine housings in relation to the extension rod, (see figure 5-7) to the turbocharger oil
center housing, so they may be reassembled in the drain mounting pad (figure 5-8). The mounting~plate
and indicator can be securedwith the bolts which were
same position.
removed to gain accessto the oil drain hole.
5-16. See figure 5-5. Remove the bolts and clamps
securing the compressor and turbine housings to the 5-19. Radial Bearing Check. After securing the dial
center housing. Note that compressor housing on
properly, move the rotating shaft forward and
indicator
T-1879 andT18A21 are securedby a V-band coupling. shaft in
away from the indicator. Use care to move the
Tap the housings with a soft hammer if necessary to thesame direction as the dial indicator travels. Equal
break loose. Place the center housingassembly in the
ends
pressures should be applied to the shaft at both
holding fixture (ST-133). simultaneously. The total dial indicator displacement
5-17. Before completing the disassembly the following should be less than 0. 009 inch; if the measured move-
ment is 0. 009 inch or more, the cartridge rotating as-
procedure should be followed to determine whether it
is necessary to replace or repair the thrust bearing, sembly must be repaired or replaced. The minimum
radial bearings, and rotating assembly of the center should be no less than 0. 004 inch.
housing rotating assembly.

5-20. Axial End Play Bearing Check. Fasten a dial
5-18. BEARING CLEARANCE. Fastenadialindicator indicator tothe center housing so that the indicator tip
rests on the end of the rotating shaft on the compressor
(plunger type with one inch travel) using a mounting
side (figure 5-9). Movethe shaftaxiallyback and forth
plate, (see figure 5-6 for dimensions to fabricate a
0’14
"s´•
3 /P
O
f
i,ds~ Q9
bU
"f~
~psc
L --7
Ye 8
i´• ’r
i9
i-
15
,-~2"’\
12
14 13
8. Hose actuator to crankcase
1. Injector connecting rod
2. Tube assembly Induction housing to controller 9. Controller connecting rod
3. Controller adapter 10. Fuel injector
4. Sonic nozzle assembly (not used on -E1B4) 11. Tube assembly Injector to pressurizing valve
5. Variable pressure controller 12. Induction housing
B. Hose controller to crankcase 13. Linkage shield

7. Hose waste gate to controller 14. Control shaft assembly
15. Linkage shield
Figure 5-4. Fuel Injector and Controller Linkage
5-4
19.
12 /1
t j,18
:’1
,9
26
J
22~ 22
27
14´•
C 5
)6
r o
\15
L/
1. Bolt 10. Center housing 19. Thrust plate assembly

2. Washer 11. Impellerlocknut 20. "0" ring
3. Clamp 12. Impeller 21. Washer
4. Compressor housing 13. Thrust spacer 22. Retaining ring
5. Bolt 14. Thrust collar 23. Bearing
6. Lockplate 15. Shaft wheel assembly 24. Backplate
7. Turbine housing 16. Piston snap ring 25. Pin
8. Drive screw 17. Machine screw 26. Lockwasher
9. Nameplate 18. Lockplate 27. Pin
Figure 5-5. Turbocharger Assembly T-1823 Exploded View
5-5
section s OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Induction end Ewhaust Systems
13/32" DRILL
5-23. Back Plate Removal(Early models of T-1823).
R.
This back plate assembly (26 and 24, figure 5-5) is no
longer employed. It has been replaced by a shroud wheel
R. BoRE TO FIT DIAL
assembly which is clamped to housing. However, for
INDIC~TOR-UM those models still employing the backplate assembly
2 1116" WITH SET SCREW the following procedures may be followed:
OR U~K NUT
lllJ2Y a. For overhaul facilities not equipped to machine
c
off plate.
i. Remove center housing (10) from holding fix-

13/4* Cc3/B* OR 112"
ture ST-133 andsecure to table of standard drill
press.
Figure 5-6. Mounting Plate for Attaching

Dial Indicator
by hand; the total indicator reading should be between

0. 004 and0. 009 inch. If the totalindicator reading ex-
ceeds 0. 009 inch, the cartridge rotating assembly must
be repaired or replaced.
5-21. See figure 5-5. To remove the impeller (12) hold

the shaft wheel assembly (15) in a suitable fixture. X
Place an Alien wrench in the Alien screw located in
the end of the shaftwheel to holdthe shaft from turning
while removing the impeller nut (11) from the shaft
wheelassembly. Heat the remainder of center housing
group (13 through 28) in furnace, oven or oil bath to a
temperature of 3500F. to 375"F. (m~urimum) for not
longer than 10 minutes. If a hot oil bath is used, im-
merse the impeller only. No other form of heatingthese
parts is accep’table.
CAUTION
Use reasonable care to avoid overheating

or other damage to impeller vanes.
5-22. See figure 5-5 or 5-15. Disassemble rotating

assembly (center housing group) in the sequence shown
in the figures. See paragraph 5-23.
Figure 5-8. Dial Indicator Mounted on
Oil Inlet Pad
drill plate, (ST-135) on top of back-

2.
A~semble
plate and locate sothat drill bushings in the plate
are directly over a flat on the hex surface on the
bottom of the backplate.
3. Align a 3/8 inchend cutting, end mill (Standard)

so that it just touches the threads on backplate.
Set stop on drill press so that end mill will pass
through hex surface and no more.
4. Position end mill with drill bushing in back-

plate fixture, and mill both holes to drill press
stop.
5. Remove end milland install standard 3/8 inch

drillindrillpress spindle. Moving toward the
outside of the backplate from the previously
drilled holes, drillthree more holes in a straight
line on both sides of backplate (24).
6. Employing a standard cold chisel, split the back

plate by driving the chisel from outside edge of
Figure 5-7. Dial Indicator With Extension backplate (24) toward the center following line of
5-6
Induction and Exhaust systems
7. Secure center housing securely in a suitable

fixture, and insert wrench (ST-134) between
center housing (10) and backplate (24). This is
accomplished by spreading the wrench handles
apart. Squeeze the handles together and assemble
detail 7 of the wrench overthe handles. Tighten
adjusting screw securely. This will prevent the
r~"a( handles ofwrenchfrom spreadingwhen pressure
is applied, thus loosening grip on hex surface.
8. Using a No. 4 Nicholson rawhide hammer (or

equivalent), strike wrench handles several
sharp
blows to loosen backplate (24). When plate is
loose, unscrew from center housing and discard.
Also, discard the lock plate located under lier
surface.
Figure 5-9. Dial Indicator Mounted on Housing b. For overhaul facilities equip’p~d to inachine off
backplate,
drilled holes. When backplate has been split on
both sides, the hex surface on backplate may be 1. Mount center housing (10) in a three jaw,
turned by a special split type wrench, (ST-134). universal lathe chuck.
/2 6
/3
~6F o
ci
’2
13
4Q´• rJ-----~f
O
O O
18
o
f
14
15i16
II
C3)
1. Intake pipes 7. Spacer 13. Washer

2. Seal rings 8. Induction housing 14. Screw
3. Injector nozzle 9. Intake pipe nange 15. Pressurizing valve cover

4. Sealring 10. Gasket 16. Pressurizing valve spring
5. 11. Seat assembly 17. Valve and diaphragm
Lockplate
g, Hex head bolts 12. Lockwasher 18. Pressurizing valve seat
Figure 5-10. Induction Housing Assembly and Pressurizing Valve
5-7
13 3. Reposition the cutter and making horizontal

12 cuts, machine the hexdown untilmerely a thread
II shell remains.
10
4. Breakremainingthread she11 with any suitable
7-~k´•. ~ir tool and remove. Remove and discard lockplate
d
I
I ~-;C-8
under hex.
I
y LI
C, i CLEANING
I
5-24. Turbocharger. Before cleaning, visuallyinspect

parts for signs of burning, rubbing or other damage
which might not be evident after cleaning.
I
2 1 Y NOTE
4 \a I If there is any evidence of failed bearings,

the entire unit must be overhauled.
5-25. Soak all parts in clean carbon solvent for 20 to

25 minutes. After soaldnguse a stiff brush and remove
particles. Dry parts thoroughly with filtered,
all dirt
moisture-free, compressed air at approximately 20
psig.
I
5t /i,41~-’ Use
area.
WARNING
cleaning solvent in a well-ventilated

Avoid breathing fumes. Keep away
from open flames.
5-26. Remove all carbon which has deposited in the

drain annulus behind the rear bearing strut and back
surface of center housingwall. A screwdriver or sim-
ilar blunt instrument may be used. It is not neces-
sary to completely clean the carbon from the threaded
1. Fuel drain check valve assembly area in the turbine seal. Remove only enough to expose
2. Tube assemblies to cylinders the thread surfaces. Interior surfaces of center housing
3. Tees may be sand blasted or shot peened with glass beads.
4. Fuel drain between tees
5. Tube (tee to induction housing) 5-27. Buff the seal hub and shaft journals Lightly with
6. Tube (tee to fuel pump) 600 grit paper to remove shellac or carbon deposits.
7. Reducer
INSPECTION
8. "0" ring
9. Plunger 5-28. Turbocharger. Parts must show no signs of
10. Spring damage, corrosion or deterioration. Threads must
11. Gasket
not be nicked, stripped or crossed.
12. Valve housing
13. Nipple 5-29. SHAFT WHEEL ASSEMBLY. Turbine wheel
14. Elbows must show signs of rubbing, and vanes must not be
no
torn or eroded to a feather edge. Shaft must show no

Figure 5-11. Typical Fuel Drain System signs of scoring, scratches or seizure with bearings.
CAUTION 5-30. IMPELLER. Must show no nicks or signs of

rubbing, and must be completely free of dirt or other
It is imperative housing is
that center foreign matter. Impeller bore must not be galled.
running true in the chuck, allmachining as
5-31. SEAL PARTS. Must show no signs of rubbing
operations described hereinafter require or scoring on running faces.
true running of the housing.
5-32. HOUSINGS. Must show no signs of contact with

2. Position lathe cutter at center hole in back-
rotating parts. Oiland air passages must be clean and
plate (24), and machining from OD of center hole free of obstructions.
to OD of backplate remove all metal to face of
hex on bottom side of backplate. REPAIR AND REPLACEMENT
NOTE 5-33. Turbocharger. Polish or burnish out minor sur-

face damage. Use silicon carbide abrasive cloth for
The cutter must not touch any of the pro- aluminum parts and crocus abrasive cloth for steel
trudfng surfaces of the center housing. parts.
5-8
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES section s
10 20 )/3 :9
j---~ -3l
p~;b /16
i__i~. (9´•
354
8 9
II I2 20
q~i;
zjl22B 15 23 17
14 21
1. Nut 8. Spring 18. Spring

2. Lockwasher 9. Spring 17. Flat head pin
3. Cylinder 10. Shaft 18. Clevis
4. "0" ring 11. Gasket 19. Bypass valve housing
5. Adjusting screw 12. Plate 20. Bolt
8. Piston 13. Heat shield 21. Flat head pins
7. Shaft retainer 14. Cotter pins 22. Turnbuckle
15. Locknut(TIO-541-A, -E1A4, -E1B4 only) 23. Washer
Figure 5-12. Exhaust Bypass Valve Exploded View
5-34. Replace the following parts: O-rings, Zockplates, of Felpro (C5-A) or equivalent to bolt threads and tight-
gaskets and retaining rings. Replace all damaged en to 100-110 inch pounds. The housings of the T-1879
bolts. and T-18A21 turbochargers are secured with a v-band

coupling.
NOTE
5-41. TESTING. The turbocharger does not require
If bearings show signs of scores, nicks, special tests after overhaul. After unit is reinstalled
shellac deposits, or foreign matter imbed- on engine, follow instructions in following paragraph.
ment, replace.
5-42. Immediately prior to mounting the unit, prime
5-35. Turbocharger. Check each partprior to instal- the lubrication system as follows: Invert turbocharger,
lation to ensure cleanliness. As parts are assembled, fill center housing with new, clean oil through oil inlet
cover all openings to prevent entry of dirt or foreign strainer. Turn rotatingassembly by handto coatbear-
matter, ings and thrust washer with oil.
NOTE a. Coatthreads ofattachingbolts or studswith high
temperature thread lubricant (Felpro C5A). Secure

If any foreign particle falls into turbo- turbocharger to its mount. Connect ducts and make sure
charger during reassembly, remove parti- all connections are air tight.
de immediately, even though extensive
disassembly is required, b. Flush oil through oil inlet line and ensure that line
is cleanandunobstructed. Fillengine andoil inlet line
5- 38. Lubricate O- rings with a light coat of liquid soap with new, clean lubricating oil, and connect line. Con-
of "Molykote, Type Z" before installation, nect oil return line.
5-37. Assemble rotating assembly in reverse order 5-43. INDUCTION HOUSING ASSEMBLY. See figure
of disassembly. See figure 5-5 or 5-15. 5-10. Remove pressurizing valve assembly. Dis-
assemble and inspect pressurization valve assembly
5-38. Lubricate OD of bearings before assembly. (15-18). Inspect diaphragm for perforations etc. Re-
move induction housing seat assembly (11) and discard
5-39. Orient the center housing assembly to the tur-
bine housing and secure with lockplates and bolts.
oil seal. Usingwrench(ST-190) remove, clean and in-
spect injector nozzles (3). Discard oilseals (4) and
Tighten to 100-110 inch pounds,
lockplates (5).
5-40. Orient the center housing to the compressor 5-44. FUEL DRAINLINEASSEMBLIES. Disassemble
housing and secure. Note that T-1823 center housing drain lines, clean and inspect. See figure 5-11. Dis-
is secured with lockplates and bolts. Apply a thin coat assemble, clean and inspect checkvalve assembly (1).
5-9
Section 5 OVERHAUL MANUAL-AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
’B"
WITH 50-60 PSI PRESSURE IN
CYUNDER,ADJUST CLOSED
POSITION OF VALVE SO CLEAR- ’A’
8
p~NCE"B"lso.oos-o.025
SEE TEXT
je
0_
AFTER ADJUSTING CLOSED

POSITION IB*AND WITH ZERO
PRESSURE IN CYLINDER AD-
JUST FULL OPEN STOP
SCREW (I)TO PROVIDE
2 3 4
CLEARANCE OF 0.80-0.90
AT’n’
I.ADJUSTING SCREW
3.FLAT HEAD PIN
ILOCKNUT
4.CLMS
Figure 5-13. Exhaust Bypass Valve Opened and Closed Positions TIG-541-A, -E1A4, -E1B4
60-SOPS/pressu/e/i7cy//ixr’w /--Affw od/i~st/i7p ondw~j33 ~3"

ad/i/st of M7/ve so pre~wreh ed/i/st stop
that cleoronce ~rew toprav/ii~7.73-.75 of back
token up
ru/n th/j´•shaft to ed/i/st
"B"
vo/ve ~spni7g
b Tum sc~´•ew to
afbufterf4 vo/ve
fw
Figure 5-14. Exhaust Bypass Valve Opened and Closed Positions TIGO-541, TIO-541-E1C4, -E1D4
5-10
OVERHAUL MANUAL -AVCO LYCOM1NG INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES section s
5-45. EXHAUST BYPASS VALVE. Although the phy- only on the type used on the TIG-541-A, -E1A4 and
sical appearance of parts may vary, the disassembly -E1B4. Also the spring (16) is attached on the TIO-
of all subject valves is similar and figure 5-12 will 541-E1C4, -EU)4 and TIGO-541 and shown in figure
serve to demonstrate. Note that locknut (15) is used 5-14,
4 5 6
768
14
8 13 C\U I 1 2 7
11 12 10
i. Thrust spacer 8. Piston ring

2. "0" ring 9. Wheel assembly
3. Backplate assembly 10. Shroud wheel
4. Thrust collar ii. Retaining ring
5. Inboard thrust washer 12. Center housing assembly
6. Bearing 13. *Outboard thrust washer
7. Washer 14. Impeller
15. Locknut
Detail part of backplate assembly.
Figure 5-15. Turbocharger Center Housing and Rotating Assembly (T-1879 and T- 18A21)
5-11
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL
ACCESSORY DRIVE AIRCRAFT ENGINES
sactlon 5
Induction and Exhaust Systams
ria,
;r
i’!
q,.
,J,´• ´•Sf~
tis~
7~´• :t~.´•
n
8
Figure 5-18, Obtaining Clearance ofThrottle Lever

Figure 5-16, Fixture 31-319 Installed and Showing
Cross Shaft Lever in Closed Throttle Position, in Closed Position,
5-46, See figure 5-12, Remove cotter pins and flat 5-51, Remove adjusting screw (5) and discard "O" ring
headpins (17) from clevis (18), Leave turnbuckle (22) (4),
onshaft (10) to retain internal actuator springs (8 and
REASSEMBLY
9),
5-52, Use all new gaskets, "0" rings, packing, ex-
5-47, Remove cylinder assembly (3), heat shield (13) pander, cotter pins etc, and any parts that may have
with plate (12) from housing (19) and discard gas- been damaged,
ket (11),
5-53, See figure 5-12, Install adjustment screw (5) and
5-48, Remove piston (6) with packing and expander, "0" ring (4)in cylinder (3),
Discard packing and expander, 5-54, Install new packing and expander in piston (6) and
using (ST-129) installpiston. Lubricate with engine oil,
5-49, Remove retainer (7) and springs (8 and 9)by com- B, paskine. does not fold when inserted,
pressing retainer and sliding off shaft end slot,
5-55, Installturnbuckle (22) on shaft (10) and install
shaft through plate (12) and attach springs (8 and 9)
5-50, Remove cotter pins and flat head pins from turn-
with retainer .(7), Install heat shield (13) to plate,
buckle (22) and shaft (10),
.-r r--
u"-j´•-~.´• r
nC´•’
ItlftL;~i
‘s~´•l´•´•
-LI;
-I~
i 3;L‘
,i
~i
´•t
~311
d
t-
Screw at Injector Figure 5-19, Obtaining Clearance of Throttle Lever
Figure 5-17, Setting Idle Adjusting
in Full Open Position,
Stop Pin,
5-12
5-56. Installcylinder assembly to valve body (19) and inder hold down 3/8 inch studs and nuts. Secure with
torque to 60 80 inch pounds. two (P/N 383-B) nuts. If unable to secure with nuts
because of insufficient thread, hold the fixture by
5-57. Assemble clevis (18) to lever armwith flat head hand. The fixture in position is shown in figure 5-16.
pin (17) washer andcotter pin. Fully engagethreads of

clevis and turnbuckle. Temporarily installflat head 5-69. Back off idle stop adjusting screw untilit just
touches the injector stop pinwhen the throttle butter-
pins (21) connecting clevis and turnbuckle.
fly is fully closed. Check clearance with a piece of
5-58. (TIO-541-A, -E1A4, -E1B4). Install spring (16) shim stock or an.0015 inch feeler gage. See figure
to lever arm and stud. ~IGO-541, TIO-541-E1C4, 5-17.
-E1D4). Znstall spring (16) to lever arm and boss on
actuator. 5-70. Place gage (ST-318) overinjector stop pin with
side marked ".040" down and between pin and end
of idle stop adjusting screw. Do not turn from full
5-59. See figure 5-13. ~IO-541-A, TIO-541-E1A4,
-E1B4). Apply 50 60 psi pressure to cylinder and closed setting at this time. See figure 5-18.
adjust closed position ("B") of the valve by rotating

turnbuckle counter-clockwise to fully close the butter- 5-71. Align hole in ballend of injector connecting rod,
hole in shaft control lever and hole in fixture.
fly. Back off turnbuckle clockwise until clearance cross
"B" is 0. 005 0. 025 inch. Insert pins (2), and secure Insert fixture pin through allthree holes. See figure
with cotter pins. Tighten lockbut (3) to 80 100 inch 5-16. With throttle lever held firmly against gage on
pounds, injector, adjust the connecting rod length (maintain-
ing approximately equalthread engagements on both
5-60. Withzeropressure inthe cylinderadjustthefull ends) and attach to throttle lever. Remove fixture
openstop position, with the adjustingscrew (1) topro- (ST-319) and attach injector connecting rod to the
vide clearance of 0.80- 0. 90 inch at "A". Tighten cross shaft control lever. Remove gage (ST-318).
locknut to 60 80 inch pounds.
5-72. Replace gage (ST-318) oninjector stop pin with
5-61. ~IO-541-E1C4, -E1D4, TIGO-541). figureSee the side marked 025" up. This is the desired clear-
5-14. With 50 60 psi pressure to cylinder adjust closed ance between the pad of the throttle arm and the in-
position of the valve by rotating turnbuckle counter- jector stop pinwith thethrottle lever in full openposi-
clockwise to fully close the butterfly. Back off the turn- tion. Move shaft control lever forward to put
cross
buckle until clearance is Il. 005 0. 015 inch. Insert injector throttle lever in full open position and main-
tain a constant pressure betweenthe throttle arm pad
pins and secure with cotter pins,
and the gage while completing the following step. See
5-62. With zero peessure in the cylinder adjust the figure 5-19.
open stop position by turning the adjusting screw to
provide clearance of Il. 73 0. 75 inch. 5-73. Remove the controller connecting rod at the
controller end. Push the controller arm against the
5-63. For procedure to disassemble, overhaul, cali- full boost stop pin (forward). See figure 5-20. With
brate and reassemble the variable pressure controller the controller arm in this position and the throttle
consult AiResearch Industrial Division Publication No. lever in the position obtained in the preceding step,
TP-21. adjust the controller connecting rod (maintaining ap-
pro~cimately equalthread engagement on both ends) to
FINAL ASSEMBLY match hole locations in both the controller arm and
the connecting rod. Attach the connecting rod to the
5-64. See figure 5-10. Reassemble injector nozzles controller arm andremove the gage from theinjector
(3) using new oil seal (4) and lockplate (5). Employ stop pin. See figure 5-21.
wrench (ST-190) for tightening nozzles. Reassemble
pressurization valve assembly in housing. Secure 5-74. Installthe sonic nozzle assembly (4, figure 5-4)
those models employing this feature.
housing (8) to the crankcase with four hex head bolts on
(6), washers and spacer. Assemble intake pipes (1).

5-75. TIG-541-A. See figure 5-1. Install magneto
5-65. See figure 5-4. Install gasket and fuel injector baffle (12) andturbocharger bracket (11). Installturbo-
(10) to induction housing (12). Assemble gasket and charger. Assemble exhaust bypass assembly (9) to
adapter assembly (3) to the fuel injector. Install var- turbocharger intake. Assemble exhaust manifold as-
iable pressure controller (5) to housing. Place hose sembly to exhaust ports. Note that the twu gaskets are
clamp on adapter housing. assembled with the flat sides toward the cylinder port
and the raised interlocking face sides facing the mani-
5-66. Install tube assemblies (2 and 1) figure 5-4 and fold. Assemble gaskets and secure the manifold as-
install control shaft assembly (14). Installthe con- sembly to the exhaust bypass valve assembly with
nectfng rods in the following manner: Marman clamps (8).
5-67. Remove injector connecting rod from both the 5-76. TIO-541-E1A4, -E1B4. See figure 5-2. Assem-
cross shaft control lever and the throttle lever. ble the oil hose (14) to crankcase. This is easier to in-
stall before the brackets and supports are assembled.
5-68. Positionthe cross shaft control lever usingfix-
ture ST-319 thus: Mount the fixture over no. 4 cyl- 5-77. Assemble turbocharger bracket (4) to crank-
5-13
´•:-i~86 c
:´•:a
"f ´•c,41~j L1-.re
I
--6´•1~
cJ
it ~s i
i
I-i-T-~
f~s
Figure 5-20. View Showing Controller Arm in Full Figure 5-21. View Showing Connecting Rod Secured
Boost Position to Controller Arm in Full Boost Position
case.Assemble turbocharger and compressor support 5-81. TIC~541, TIO-541-E1C4, -$1B4. See figure
(13),compressor mounting bracket (15) and turbo- 5-3. Assemble theturbocharger, transition assembly,
charger and compressor (12) to the crankcase. exhaustbypass valve andexhaust manifoldsin reverse
order ofdisassembly.
5-78. Reinstall struts in the reverse order as dis-
assembled from the turbocharger assembly. Position 5- 82. PRESSURIZATION VALVE SEAT. The pressuri-
the turbocharger assembly with the compressor out- zation valve seat is removed and replacedin the follow-
let entering the hose (11) and the compressor wheel
i,g manner.
housing into the bracket (12). Fasten all struts and
supports. a. Tap valve seat with a 3/8-24 tap.
5-79. Assemble exhaust bypass valve assembly (5)
to the turbine inlet. Assemble hose (14) to actuator. b. Inserta3/8-24x 2-1/4inch boltthrougha socket
and screw into the threaded hole in seat. Tighten bolt
Assemble hose (20) from actuator to turbine oil inlet,
Fasten hose connecting turbine oil drain (6) to crank- against socket until seat is removed.
case.
c. Place a new pressurization valve seat in the
5- 80, Assemble exhaust manifolds in the same manner driver, fabricated as shown in figure 5-22 and drive
as described in paragraph 5-75. to a firm seat in the housing.
4"
I"
8I .435 DIA. BORE
KNURL
3"DIA.
4 I-REQ’D iOOL STEEC
T.465 DIA. C’BORE
HDN. a GR.- R/C 60-62
Figure 5-22. Driver To Install Pressurization Valve Seat
5-14
SECTION
LUBRICATION
SYSTENI
OVERHAUL MANUAL-AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES Section 6
Lubrication System
SECTION 6.
LU BRI C~ATION SYSTE M
6- I. For purposes of this manual the lubrication system 6-4. Oil Filter and Adapter Assembly (TIO-541-A).
will consist of the oil sump assembly, oilpump, oil See figure 6-3. Remove the oil filter and adapter as-
filter and oil cooler. sembly (7) by removing the three hex head bolts and
1/4 inch nut securing it tothe crankcase. Discard the
REMOVAL FROM ENGINE
gasket (10).
6-2. Oil Cooler (TIO-541-A Series). See figure 6-1. 6-5. Oil Filter and Oil Filter Housing Adapter (TIO-
Remove the hex headbolt (4) washer (5) andbracket (6). 541-E, TIGO-541-E). See figure 6-4. Remove the oil
Remove the attaching parts (3) and remove the oil filter assembly (2) and housing (1) by removing the
cooler assembly (1) and gasket (2). three hex headbolts and 1/4 inch nut securing it to the
crankcase. Discard the gasket (11).
6-3. Oil Co6ler (TIO-541-E). See figure 6-2. Remove
the oil cooler damper assemblies (land 9) from the
oil cooler and cylinder head. Remove the oil cooler 6-6. OilSump. See figure 6-5 (TIO-541-E). Remove
heat shield (8) and remove the oil cooler (7), gasket the oil suction screen cover (21), gaskets (20-18) and
(2), oil cooler spacer assembly (3) and gasket (4). screen (19).
i -r
jl
I
lr .~C´•
(1
2
i. Oil Cooler Assembly
2. Gasket
3. Attaching parts
4. Bolt
’?r 5. Washer
6. Bracket
Figure 6-1. Oil Cooler Assembly (TIO-541-A Series)
6-1
s´•ctlon 6 OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Lubrication Syatam
3
co o: J1
r
o o
a
\~e ´•a
Q,
II
i
tb II
i. Damper assembly 5. Spacer 8. Gasket

2. Baffle 6. Gasket 9. Heat shield
3. Oil cooler 7. Temperature valve 10. Damper assembly
4. Gasket 11. Ignition lead support
Figure 6-2. Oil Cooler Assembly (TIO-541-E Series)
6-7. A11Models. Remove thebolts securing the sump cooler temperature control valve (6) and gasket (5)
to the crankcase and lift away from the crankcase. from the oil cooler spacer (3) employed on the E series.
6-12. OilFilter (TIO-541-A). Seefigure 6-3. Remove
6-8. OilPump. See figure 6-5. It is assumed that
temperature by-pass valve (1) and gasket
the oil cooler
the tachometer drive shaft (9) (where applicable)
(2). Loosen the center stud (6) attaching the fiber as-
and the camshaft gear baffle (2) have been previously
sembly to the adapter (9). Discard the replacement
removed.
assembly (7) and gasket (10).
8-9.(TIO-541-E). Remove the oil suction tube as- 6-13. OilFilter (TIO-541-E, TIGO-541-E). See figure
sembly (17) and gasket (16) from the oil pump. 6-4. Remove the oilpressure relief valve assembly (7,
8, 9 andl0). Loosenthe bolt assembly (4) attaching the
6-10. A11Models. Turn the camshaft gear (1) so that filter assembly to the housing (1) and discard the re-
the slot in the gear is in a horizontal position. Cut the placement assembly (6) and gasket (11).
lockwire and remove the 5/16 inch bolts (12) and dis-
6-14. OilSump (TIO-541-A, TIGO-541-E). See figure
engage the oil pump driveshaft from the slot in the cam- 6-5. Remove all plugs and the oilseal (28). Remove
shaft gear. The entire assembly can now be removed.
the oil suction screen assembly (25, 26 and 27). Dis-
card oil seal and gaskets.
DISASSEMBLY
6-15. OilSump (TI(1541-E). Seefigure 6-5. Remove
B-ll. OilCooler. See figure 6-2. Nodisassembly of the all plugs. Remove cover (21), gaskets (18 and 20) and
oil cooler is requiredother than the removal of the oil screen (19).
6-2
C
:S~v
~5_ "L"~
,,~eP):i;t
J:
T 5 6
L)i~ai c~
control valve 6. Center stud

I. Temperature
2. Gasket adapter assembly
7. Oil filter and
8. Plug
3. Replacement element assembly
4. Oil filter housing 9. Adapter assembly
5. Gasket 10. Gasket
Figure 6-3. Oil Filter and Oil Cooler Bypass Temperature Control Valve (TIQ-541-A Series)
6-16. Oil Pump. See figure 6-5. Remove the hex head filterreplacement element package (3) into housing (´•1)
and the assembly to the adapter, using a new
bolts securing the cover (8) to the body (5). Note that secure
the impellers (7 and 13) will be loose in the body, re- gasket (5), with the center stud(6). Tighten center stud
move the impellers. Remove the cotter pin (4) from the
to 20-25 foot Ibs. torque. Place a new gasket(l0) on the
oil pomp idler shaft (15) and remove the idler shaft mounting pad and secure the oil filter and adapter as-
from the body. Pull the drive shaft (3) from the body, sembly to the crankcase.
6-22. Oil Filter(TIO´•541-E, TIGO´•541-E). See figure

CLEANING
6-4. Assemble the oilpressure relief valve seat (8),
valve spring(9), gasket (10), and plug (11) in the oil
6-17. Clean all parts in accordance with the general filter housing adapter (1). Place a new housing adapter
instructions outlined in Section 3.
gasket (12) on mounting pad and install the oil filter
ZNSPEC TION housing adapter (1) on crankcase. Install"O" ring seal
(2) on the recess at the open end of the filter housing
6- 18. Inspect all parts in accordance with the general (6). Place the filter bolt assembly (5) using a new copper
instructions outlined in Section 3. gasket (4) in the filter housing. Place filter element
(3) over bolt and install on filter housing adapter.
REASSEMBLY Tighten filter bolt to 30-35 foot pounds torque.
NOTE
6-19. Oil Cooler (TIO-541-A). See figure 6-1. As-
semble the oil cooler assembly (1) and gasket (2) and On the TIO-541-E and TIGO-541-E some
secure to the crankcase with twelve bolts, lockwashers of the earlier model engines were manu-
and washers (3). Attach the ignition lead support (6) factured without the recess machined at the
lockwasher (5) and secure with bolt (4). open end of the oil filter housing. There-
fore: the "0" ring seal and aluminum re-
6-20. Oil Cooler (TIO-541-E). See figure 6-2. As-
taining ring must be used. For more in-
semble the oil cooler temperature control valve (6) into formation concerning the oil filter seal
the oil cooler spacer (3) using a new gasket (5). Install consult Service Bulletin No. 397.
the oil cooler spacer gasket (4) oil cooler spacer (3),
oil cooler gasket (2) and oil cooler assembly (7) on the The TIO-541-E and TIGO-541-E may be equipped
mounting pad. Install the heat shield(8) and the upper with the spin-on filter as described in Service In-
and lower damper assemblies (1 and 9). struction No. 1319. The converter plate gasket (13)
must be replaced at time of overhaul. The gasket should
6-21. Oil Filter (TIO-541-A). See figure 6-3. As- be cemented onto the converter plate (14) with 3M
semble oil cooler bypass temperature valve (1) into Industrial Adhesive No. 847 or equivalent. Install the
the adapter (9) using a new gasket (2). Assemble oil converter plate (14), converter plate stud(15) on the
6-3
Revised April, 1976
12O
2
se~4
3:O 14B ’3
Is
I
8
e
~LY\a
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I ~6
i. Filter housing adapter 6. Filter housing 12. Housing adapter gasket

2. "0" ring seal 7. Replacement element kit 13. Converter plate gasket
3. Filter element 8. Relief valve seat 14. Converter plate
4. Copper gasket 9. Relief valve spring 15. Converter stud
5. Bolt assembly 10. Gasket 16. Spin-on filter
11. Relief valve plug
Figure 6-4. Oil Filter Assembly (TIO-541-E, TIGO-541-E)
oil filter housing adapter. Tighten stud to 50-60 foot on the longest of the hex head bolts (12) and install this
pounds torque. Lubricate the spin-on oilfilter(l6) with assembly through the larger hole´•in the oil tube as-
clean engine oil and install on converter plate stud. sembly flange. Note that the bolt and sleeve assembly
Tighten filter to 18-20 foot pounds torque. Do not ex- must be installed from an off center position. Attach
ceed the maximum torque of 20 foot pounds, the bolt to the oilpump assembly and complete securing
the tube assembly with a 1/4-20 hex head bolt through
6-23. Oil Pump (All Models). See figure 6-5. As- the second hole in the flange. Install the other two
semble a new oil seal (6) into the pump body (5). In- 5/16 inch bolts (12) securing the oilpump assembly to
stall the idler shaft (15) into the body and assemble the case and lockwire.
the cotter pin (4). Install the drive shaft(3) into the
body and assemble the drivingimpeller (7) over the oil 6-26. Oil Sump (TIO-541-A, TIGO-541-E). Assemble
pump drive shaft (3) and the driven impeller (13) over the oil suction assembly (25, 26 and 27) and all
screen
the idler shaft(l5) meshing the impellers. Place the plugs. Install an oil seal (28) over the oil pump inlet
cover (8) on the body assembly and secure with bolts dowe1(29). Assemble the sump assembly to the crank-
and lockwire. Turn the camshaftgear (1) until the slot case.
in the gear is in a horizontal position and engage the

drive shaft (3) into the slot. 6-27. (TIO- 541-E). plugs that were removed
Install all
at disassembly and secure assembly to the
the sump
6-24. (TIO-541-A, TIGO-541-E). Secure the oil pump crankcase. Assemble a gasket (18) over the oil suc-
assembly to the case using the three 5/16 inch hex tion screen (19) andinstall the screen through the pad
head bolts (12) and lockwire. in the sump and into the oil suction tube assembly (17),
be certain the screen is not distorted when entering
6-25. (TIO-541-E). Assemble a gasket (16) on the oil the flange of the tube assembly. Assemble the gasket
suction tube assembly (17). Assemble a sleeve (24) (20) and cover (21) on the pad.
6-4 Revised April, 1976

8 Q
6
24~
5
o
7\~24 *C
1
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3\ ;~ag
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oP q
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/16 Z
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´•-27
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0-26 1
r
29 Z~
C~ r´•´• ~CT L~
22-----0
a
23~g Z:
´•k~o
-<t>c20 ;a
i. Ca!ushalt gear ii. Retaining ring i 20. Gasket

2. Camshaft gear baffle 12. 5/16-18 hex head shaft 21. Cover
3. Oil pump drive shaft 13. Driven impeller 22. Casket 7
14. 23. Plug
4. Cotter pin Dowel Zm
5. Oil pump body 15. Oil pump idler shaft 24. Washer O
r
6. Oil seal ring 16. Gasket 25. Oil suction screen Z
7. Driving impeller 17. Oil suction tube 26. Gasket
8. Oil pump cover 18. Casket 27. Plug
9. Tachometer drive shaft 19. Oil suction screen 28. Oil seal ring If
10. Thrust washer 29. Oil pump inlet dowel u,
h Figure 6-5. Oil Pump and Oil Sump Assemblies

SECTION
CYLINDERS, PISTONS
AND VALVE TRAIN
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES S~ction 7
Cylinder~.
´•nd Vllve Tr´•ln
SECTION 7.
CYLINDERS,’PISTONS AND
VALVE TRAIN
7-1. The piston, being a reciprocating part, is nor- spring(31) and sleeves (24) ina safe location and dis-
mally grouped with the crankshaft in the theoretical card the seals.
breakdown of the engine into basic components. How- 7-9. Remove the cylinder base hold down nuts (4 and
ever, from a practical standpoint and for purposes of 5) and remove the cylinder by pulling directly away
this manual, it is felt that the piston should be con- from the crankcase. Catch and hold the piston as, it
sidered with the cylinder insofar as overhaul proce-
leaves the cylinder. Remove the rocker shafts (Z 1) from
dures are concerned. The basic configuration of the
the cylinder head and discardthe oil seal ring (1). Set
engine requires the removal and reassembly of the pis- the cylinder aside for further disassembly.
tons at the same time the cylinders are removed or
replaced. 7-10. PISTON. See figure 7-2. Remove the pistonpin
plugs (5) from the piston pin(4) and with the aid of the
7-2. Also, for the purposes of this manual, the valve
piston pin puller (64843) pull pin from piston and re-
train will be considered as all parts of the valve oper-
move piston.
ating mechanism beyond the camshaft beginning with
the hydraulic lifter assembly. NOTE
7-3. Although the cylinder assemblies on the various The connecting rod must be supported to
models differ, basic overhaulprocedures are the same
prevent damage to the rod and the crank-
for all cylinder assemblies. The overhaulprocedures
case. Figure 7-3 shows two methods of
described in this section will be applicable to all en-
supporting the rods.
gines except as noted.
7-11. RYDRAULIC LIFTERS. See figure 7-1. Remove
REMOVAL FROM ENGINE adapter (29) and gasket from the crank-
the shroud tube
case and remove the hydraulic Lifter assembly (29)
7-4. At this point it is assumed that the intake pipes, from the crankcase.
exhaust manifolds, ignition harness, spark plugs, oil

drain back tubes, fuel drain lines and exhaust valve NOTE
guide oil lines (where applicable) have been removed.

The valve rockers, hydraulic lifters and
7-5. Remove the fuel drain line nipples and exhaust pushrods must be replaced in the same lo-
valve guide oil line connectors, tees and elbows (where cation from which they were removed.
applicable). Using the intercylinder baffle tool (64885)

turn the baffle retaining hook so that it disengages the DLSASSEMBLY
retainer. Remove the intercylinder baffle and hook
7-12. CPI~INDERS. See figure 7-1. Place cylinder
from between the cylinders.
overthe holding block (6452 6-2), assemble valve spring
7-6. CYLINDERS. See figure 7-1. Remove rockerbox compressor (ST-266) on cylinder, and compress valve
cover (19) and gasket (17). Also the rocker shaft covers springs (11 and 12) far enoughto remove the retaining
(26) and gaskets. keys (14).
NOTE
7-7. Rotate the crankshaft to place the piston at top
center of the compression stroke. With the piston in
this position both valves are closed and the piston is If valve keys are stuck tight in spring seat,
extended away from the crankcase to avoid damage a light blow with a leather mallet on top of
when the cylinder is removed. the compressor will release keys.
7-8. Pushthe valve rockershafts outwardsufficiently 7-13. Remove all valve spring seats (10 and 13) and
to allow clearance for the removal of the valve rockers valve springs (II and 12) from the rocker box, keep-
(15) and thrust washers (20). Remove the rotator cap ingparts for each valve separate. Hold valves by stem
and remove the cylinder from the holding block. Now
(22) from the exhaust valve stem. Remove the push rods
tubes (27). reach inside and remove the valves from the barrel.
(23)by grapsing and pulling from the shroud
Turn each shroud tube 900 in either direction, this
Ifdifficulty is experienced in pulling the tops of the
Vahes through the guides (9), clean the carbon from
will release the detent on the shroud tube from the
the stem and then remove.
spring. Remove the tubes by first removing them from
the sealseats in the cylinder head andthen withdraw- CAUTION
ing from the crankcase retainers. Remove the seals
(25) and sleeves (24) from the cylinder head end and Do not drive the valves through the valve
the seals from the crankcase. Place washers (30), guides.
7-1
-3 ~,0"
4 5 6 7 s4~
51~
h, q
a I
9 r
z
to
13
II
12
1415
a3
~16
32
z
a a
P~ Z~
’r
26
I 61
25
27 Q 25 24 23
1 izf
30k
8
29
20 21 u,
o
F
19 18
(bb19
1. Oil seal ring 11. Valve springs tauxiliary) 22. Valve stem cap
~n
2. Valves 12. Valve springs touter) 23. Push rod a
3. Valve seats 13. Valve spring seats tupper) 24. Sleeve
FF;
4. Plain nut, 3/8-24 14. Valve re’taining key 25. Seal
5. Plain nut, 1/2-20 15. Valve rockers 28. Rocker shalt cover
6. Cylinder fill stabilizers (A series) 16. Valve rocker bushing 27. Shroud tube 61
7. Spark plug insert 17. Rocker box gasket 28. Hydraulic lifter
8. Reciter shalt busllings 18. Rocker box screws 29. Shroud tube adapter ,m,
9. Valve guides 19. Rocker box cover 30. Washer
10. Valve spring seals (lower) 20. Thrust washers 31. Shroud tube spring
21. Valve rocker shafts 32. Thrust buttons
Figure 7-1. Cylinder and Valve Train Assembly

OVERHAUL MANUAL-AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES section 7
Cylinders. Plstono.
and Valve Train
CLEAN~G
7-16. Clean all cylinder, piston and valve train parts

in accordance with the general instructions described
3 in Section 3.
MSPECTION
7-17. Inspect allcylinder, piston andvalve trainparts

in accordance with the generalinstructions described
in Section 3.Specific instructions will be found inthe
;d’ C
;ie~--- following paragraphs.
7-18. CYLINDER HEAD (VISUAL INSPECTION). Ex-

amine the cylinder head thoroughly, checking for the
following possible defects.
b LwJe, scored, pitted or otherwise damaged

valve seats. OMark for replacement).
t~ b. Loose or damaged studs. (Replace with 0. 003,

Il. 007 or Il. 012 oversize studs).
´•~A
h
:ia~ij
9----C~
,r?-’" n
1. Piston
8----s~
6.
7.
Connecting rod
2. Compression rings Bushing
3. Oil regulating ring 8. Connecting rod bolt
4. Piston pin 9. Nut
5. Piston pin plug 10. Bearing
Figure 7-2. Piston, Piston Rings and

Connecting Rod
7-14. PISTONS. Usingthe piston ring expander (64713),

remove therings from the pistons. Remove the rings
in order, starting at the top andwor~ng down Be care-
ful not to scratch or score piston while removing rings.
7-15. HYDRAULIC LIFTERS.Place the hydraulic lifter

assembly in the fi~rture (ST-233) and remove the spring
clip from the body. Remove the socket and plunger as- O C;36
sembly. In the event that the fixture is not available,
the assembly may be disassembled as follows. Insert
a suitable tool into the socket and push in the plunger
assembly until enoughoil is forced out of the vent hole

to release the pressure on the spring clip. Using a
pair of pliers, remove the spring clip being careful
as the spring clip will release with great force. Fi~gLre 7-3. Method of Supporting Connecting Rods
7-3
Cyllnd´•rs, P1´•ton~.
and Valve Train
(c) No more than four blended fins on the push

rod side of the head. No more than sixblended
fins on the anti-push rod side of the head.
MAX. FIN REMOVAL

(d) In addition to the above, it is recommended
TO THIS LINE ONLY.’
that fluorescent penetrant inspection of the
a
NEVER ENTER--
BASE METAL.
cylinder be made. Pay particular attention to
the following areas. Cracks in these areas
Figure 7-4. Maximum Fin Removal can progress apoint where a cylinder might
to
fail completely. Any cracks in these areas,
c. Loose or damaged spark plug hell-coil inserts. regardless of length or depth, are cause for
(Mark for replacement with oversize insert). rejection of the cylinder.
(1) Between the 13th and 20th cylinder fin

d. Loose, cracked or scored valve guides. (Mark
(counting from top) on exhaust port side
for replacement). of cylinder.
Nicked, scored or dentedmounting
e. pads. (Intake
(2) The area around the lower spark plug
and exhaust ports, rocker box covers).
counterbore.
f. Cooling fins. The followingstandards shall pro-

3. Cylinder Head Dome Area. See figure 7-5.
vail insofar as acceptance or rejection of cylinder heads
Cracks in the sparkplug fillet radius in direction
are concerned.
of valve seat are not acceptable. Cracks in the
spark plug fillet radius, in direction away from
i. Cracked fins,
valve seat (see shaded area in figure 7-5) are
acceptable up to i. 75 inch diameter.
(a) Fin adjacent to the exhaust port flange.
7-19. CYLINDER HEAD (DIMENSIONAL INSPEC-
(1) Stop drilling, a 3/16 inchdiameter hole TION). Check the ID of each intake valve guide tit is
’ecommendedthat exhaust valve guides be replaced at
through the end of the crackis permissible
providing the end of the crack is at least 1/4 overhaul) with the appropriate flat plug rejection gage
inch from the base of the metal. (ST-81). Check the diameter and out-of-roundness of
the guide bore by checking with the gage at a mini-
mum of twopositions 90" apart. If the gage enters the
(2) Fin removal to eliminate crack and re-
duce vibrating mass is permitted provided: guide at any of the positions tested, mark the guide for
replacement. Check the ID of the four rocker shaft
aa Maximumremoval is no more than bushings in the cylinder head, using the flat plug re-
one half the total fin width.
bb. Maximum removalis inaccordance

with figure 7-4.
cc. No burrs or sharp edges are per-

mitted.
dd. Minimum fillet atthe root of the re-

moved portion of the fin is one quarter
inch radius. Minimum corner at top of
fin adjacent to the removed portion is
one half inch radius.
CRACKS IN MEAREA OF SPARK
i
I
PLUG HOLESARE ACCEPTABLE
(b)
Fins other than the above may be accepted ONLY IN SHADED AREAS
provided not more than one crack per fin and
its depth is no closer than 1/4 inch from the
base of the metal and a fin stabilizer is used
to reduce vibration and further deepening of
the crack.
~iV
2. broken bent fins.
3r
Physically damaged, or
(a) The blended area for any one fin shall not
exceed 3/8 square inches, nor 3/8 inch in
depth.
(b) No more than two blended areas on any one
fin. Figure 7-5. Inside View of Cylinder Head
7-4
Cylinders. Pistons.
and Valve Train
I barrel consists of the following measurements (the

numbers in parenthesis refer to the applicable refer-
ence numbers in the Table of Limits):
a Fit between piston skirt and cylinder (519).
b. Maximum taper of cylinder walls (520).
.i
OU1 Lnl IIYO rrul
c. Maximum out-of-roundness (521).
d. Bore diameter (522).
NOTE
All measurements involving cylinder bar-

rel diameters must be taken at a minimum
of two positions 90" apart in the particular
roume plane being measured. All measurements
of nitrided barrels must be made in the
Il´•ISIYI IUILD U~ IN
1H1~ IICtl~ YUIT .r straight portionbelow the startingpoint of

IOILDIIY.
IruovcD the choke, or at least two inches below the
top of the barrel.
7-22. PISTON (VISUAL INSPECTION). Examine the
top of the piston for excessivepitting, cavaties or sur-
face distortion. The latter may be evidence of deton-

ation, particularly if the piston has been in service for
a relatively short time. Other critical points which
must receive thoroughvisual examination are the pis-
ton ring lands and grooves, piston pin holes, and piston
Figure 7-6. Inspection of Nitrided Barrels pin hole bosses.
7-23. PISTON (DIMENSIONAL INSPECTION). Make

jection gage (64613). Be sure to use the end of the
marited the following dimensional checks on each piston (the
gage marked "Cyl. Head". The opposite end,
numbers in parenthesis refer to the applicable ref-
"Rocker Bushing" is 0. 0015 inchlarger in diameter by
erence numbers in the Table of Limits).
virtue of the greater wear limit allowed on the valve
rocker bushing. As in the case of the valve guides,
Side clearance between piston ring and piston
a
check for out-of-roundness by trying the gage at sev-
(514, 515 and 516). Pistons for Avco Lycoming op-
eral different points on each diameter being checked.
posed engines are ground with a slight taper from
7-20. CYLINDER BARREL (VISUAZI INSPECTION). th, skirt to the head, with the exception of the lands
Tn addition to a thorough inspection of the cylinder bar- between the top compression and oil control rings,
relto ascertain its general condition, make the fol- which are ground parallel. The clearance on wedge
lowing specific checks: type. compression rings, therefore, must be measured
as shown in figure 7-7 in order to obtain a true check
of
a. Cooling Fins. Itis recommended that notches
the side clearance.
or nicks be profiled with a hand grinder or file. A
cracked cylinder barrel is cause for rejection of the hole (512).
b. Inside diameter of piston pin
cylinder.
b. Cylinder Skirt. Replace any cylinder having a
c. Clearance between piston skirt and cylinder and
bent, cracked or broken skirt. piston diameter at top and bottom (519).
c. Check mounting flange for cracks, nicks or

7-24. PISTON PIN AND PISTON PIN PLUGS. Check
warping.
OD of pistonpin againstID of hole inpiston (reference
d. interior of barrel for scoring or corro-
Inspect
FEELER GAGE
sion. Minor damage can be repaired by regrinding or
honing; deep scoring or pitting, however, is cause for
rejection of the cylinder.
e. Inspect interior of nitrided barrel for barrel
glaze and a possible ring wear step at the point where

the piston reverses travelat the top of the stroke. Re-
pair of these items is fully described in Service Instruc-
tion No. 1047.
7-21. CYLINDER BARREL (DIMENSIONAL INSPEC- Figure 7-7. Method of Checking Piston
TION). See figure 7-6. Dimensional inspection of the Ring Side Clearance
7-5
sactlon 7 OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Cyllnder´•, Pi´•tons,
and Valve Train
for physical damage, damage due to burning or cor-

rosion. Valves that indicate damage of this nature
must not be reused.
NOTE
Exhaust valves (except Inconel exhaust

valves) should never be reused. Inconel
FACE OF VALVE MUST RUN exhaustvalves maybe reusedif they com-
TRUE WITH STEM WITHIN ply with requirements of this inspection.
.00 15
7-28. Check runout of valve face. See figure 7-8.
Total runout must not exceed.0015 inch. Do not re-
use any valves that exceed this limit.
7-29. Measure edge thickness of intake valve heads.

See figure 7-8. If, after refacing, "A" is less than the
limit shown in Table 7-1, the valve must not be re-
used.
i
T
Figure Valve, Showing
7-8. Locations for
Checking Run-Out and Measuring
Edge Thickness
512, Table of Limits). Measure fit between piston and

plugs and check OD of plugs (reference 513, Table of
Limits). Examine interior surfaces of piston pin for
corrosion or pitting.
7-25. VALVE ROCKERS. Damaged, badly worn, pit-
ted or scored tips and push rod sockets warrant re-
Iq?- ,.r´• 1´•
placement of the rocker. Check the ID of the rocker ´•rJc;;~,l

bushing at several different positions with a flat plug
rejection gage (64613). This is a double-end gage; be
sure to use the end marked "Rocker Bushing". If the
gage enters the bushing at any point, mark the bushing

for replacement.
7-26. PUSH RODS. Inspect push rods for wear or

looseness of ball ends. If ball ends are loose, replace Figure 7-10. Method of Checking Edge
the rod. Rod must be straight within .010 inch. Thickness With Dial Indicator
7-27. VALVES. Remove the valves from the cylinder NOTE

and clean to remove soft carbon and examine visually
The edge of intake valve heads are gen-
erally formedas shown infigure 7-9. The
VALVE FACE. DO NOT INCLUDE
thickness "A" can best be measured with
WHEN MEASURING THICKNESS it be
an optical comparator; however, can
measured with sufficient

accuracy by
means of a dial indicator and a surface
plate, as shown in figure 7-10.
7-30. Using an optical magnifier, examine the valve in

the stem andthe tip for evidence of cracks, nicks,
area
toolmarks, or other indications of damage. Damage

of this nature seriously weakens the valve, making it
A
liable to failure. Any valve having a nick, with ragged
1/16
inch in length should not be
Y edges more
reused. A nick
than
tool mark of any sort in the keeper
or
groove of an exhaust valveis sufficient reason for not
Figure 7-9. Section Thru Edge of Valve reusing the valve.
7-6
OVERHAUL MANUAI-AVCO LYCQMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES section 7
Cyllndert. Pl~tonr.
end V´•lve Tr´•ln
300-0’ 1 450-01
29"-X)’ I ~-440-30’
15" 150
75"
INTAKE ‘ORIGINAL OUTLINE OF SEAT~ EXHAUST
MODEL Ont~) "B" (Exhaust) ,,c" (Intake) "D" (Exhaust)
TIG-541-A 2.344/2.334 1.826/1.816 .093/.074 .106/.091

TIO-541-E 2.344/2.334 1.826/1.816 .093/.074 .106/.091
TIGO-541 2.344/2.334 1.826/1.816 .093/.074 .106/.091
Figure 7-11. Valve Seat Dimensions for Reconditioning
7-31. If superficial nicks and scratches on the valve well hardness check marks which are round and even.
indicate that the valve might be cracked, it should be The area covered by spalling will vary with different
of the the lifter must
inspected by the magnetic particle or dye penetrant lifters but regardless degree,
method. Dye penetrant procedures should be carried be replaced.
out strictly within the recommendations of the manu-
facturer of the penetrant. 7-35. Scoring The lifter face is scored when small
scratch-like lines are found on the surface. These
marks are usuellv found near the outer edge of the
TABLE 7-1 face andwill appear to radiate from the center. Other
scoring marks may be present and extend to the cen-
Valve Min. Permissible Engine Serie~ ter of the lifter face. Any lifter face, with this con-
Part No. Edge Thickness dition in evidence, must be replaced.

"A"
7-36. Lifter’Face Wear The operation of this lifter

73117 .085 inch TIG-541-A
provides that the lifter rotates during wiping action of
78347 .085 inch TIO-541-E
the cam. This will form a groove, or path. This path
78671 .085 inch TIGO-541
will extend all the way across the face and deeper
-13087 .085 inch TIO-541-E
TIGO-541
penetrations will be noted at the center of the face. If
thewear is excessive, it will be noticeable to the touch
if a fingernail is rubbed across the lifter face. This
condition required replacement of the lifter body.
7-32. Critical areas include the face and top both of
which should be examined for pitting and excessive 7-37. If for any reason anew camshaftis to be instal-
wear. pitting on valve faces can sometimes be
Minor l,d in theengine, or the cam lobes are conditioned by
removed by regrinding; otherwisethe valve should be regrinding, all of the hydraulic lifters must be dis-
rejected. Replace any valve that has operated with carded and replaced with new hydraulic lifters.
a collapsed hydraulic lifter, regardless of the num-
ber of hours on the valve. Checkthe clearance between
7-38. VALVE SPRINGS. Check the condition of all
the valve stem and guide (reference 528, Table of
valve springs on a suitable spring tester, using the
Limits for exhaust valves, and reference 529 for in-
loads and deflections as given in references 800 and
take valves). Table of Limits.
801,
7-33. HYDRAULIC LIFTERS. Inspect the hydraulic
lifters for evidence of the following wear patterns. REPAIR AND REPLACEMENT
7-34. Spalling If the face of the lifter shows small 7-39. General instructions forthe repair of cylinder,
nicks orindentations near the center of the face, it is piston andvalve train parts will be foundin Section 3.
considered pitted or spalled. The pitting will constitute Specific instructions follow, possible revisions will be
small irregular holes, not to be confused with Rock- found later in the section.
7-7
Pietons,
and Valve Train
mandrel should then be rotated in a c lockwise direction
untilthe insert disappears from sight. When this posi-
REPLACE SEAT IF 15´• NARROWING tion is reached, the turning action should be stopped
WHEEL and the tool withdrawn. The top of the insert will be
WHEEL PRODUCES
GRINDING STEP 111’ 1111111 ´•1 approrrimately half turn from the face of the boss.
one
HERE However, if it is not, the tool should be reassembled

and the insert turned until it is about one half turn
from the face of the boss.
VALVE SEAT 7-45. The tang of the insert can be broken off with
PILOT
needle-nose pliers at the location of the notch. Then
using the expanding tool (64593), secure the insert
VALVE GUIDE
firmly in the spark plug holes. The limit of expan-
wion can be kept within the thread gage limits byfix-
ing the stop nut on the expanding tool at the correct
Figure 7-12. Rejection of Valve Seat position. After expanding the insert, it may be staked
by assemblingthe staking sleeve over the mandrel until
7-40. SPARK PLUG THREAD INSERT. Spark plug the sleeve meets the boss. A slight blow on the top of
thread inserts which were rejected during inspection the sleeve willimpress a slight chamgered edge around
the periphery of the tapped hole. The staking sleeve
are removed and replaced as described in the following
paragraphs, may then be removed and adjusting screw released,

and the expanding mandrel removed from the insert.
7-41. Insert the extracting tool (64595) in the spark
plug hole that the edges of the tool cut into the top
so
7-46. GRINDING VALVE SEATS. See figure 7-11.
thread of the insert. Then rotatethe tool in a counter- The ID of thevalve guide is used as apiloting surface
clockwise direction, unscrewing the insert from the for all valve seat reconditioning operations. Grind
holes, valve seats, using suitable grinding equipment, to 30"
angle on intake valve seats and 45" angle on exhaust
7-42. A new insert may be installed by use of the in- valve seats. Grind to the dimensions called out in
figure 7-11. Proceed in the following manner:
sertingtool (64594). Withdraw the nrandrel part of the
toolbeyond the recessed section of its sleeve. The in-
sert may then be assembled into the recess and the 7-47. On intake valve seats, use a 15" grinding wheel
mandrel advanced to engage its slotted end with the to grind the top surfaces of the valve seat to produce
the outer face diameter (dimension "A"). Bringthe face
tang of the insert. Rotate the mandrel clockwise and
of the intake valve seats to the specified width (dim-
press forward slightly; this will engage the insert in
threaded end of sleeve. Continue to rotate the mandrel ension "C") by narrowing thethroat with a 75" wheel.
while holding the sleeve thus securing the insert firmly
wound 7-48. Onexhaust valve seats, use a 15"
grindingwheel
on the inserting tool.The insert may then be
through the threaded portion of the sleeve within one to grind the top surface of the valve seats to produce
half turn from the end of the coil the outer face diameter (dimension "B"). The width of
the exhaust valve seats should now conform to dimen-
7-43. The adjustable brass screw on the sleeve tends sion "D".
to act as abrake, preventingthe insert from unwinding.
It is important that the insert be kept tight on the man- 7-49. If seat wear has progressed to the extend that
drelto facilitate its assembly in the threads of the cyl- the entire face of the 150 narrowing wheel must be
inder head. The insert should bewound so that the ad- brought into contact with the seat in order to achieve
the specified diameter, the seat must be replaced.
j scent turns of the insert are in contact with each other.
This willeliminate the possibility of crossed threads. (See figure 7-12).
NOTE 7-50. VALVE SEAT REMOVAL AND REP LACEMENT.

Valve seats that are loose, damaged or wornto the ex-
When inspection reveals the necessity of tent that they cannot be reground to the dimensions
shown in figure 7-11 must be replaced.
replacing aspark plug hell-coil insert, it
must be replaced with a.010 inch over-
size insert. A .010 inch bottoming tap
(84596-1) is available.
7-44. When screwing the insert into the hole in the

cylinder head, be sure that the first coil picks up the
first thread. As the tool is turned, the insert will ad-
vance into the hole. When the face of the sleeve is
approximately 1/16 inch from the face of the boss, FLAT I~SNRS (2)
the inserting tool should be held tightly by the handle YCNGE ePaa
and the sleeve rotated counter-clockwise with the other
hand, freeingthe left half-turnof the insert. Be sliding
the sleeve towardthe top of the mandrel, the end of the
insert can be seen projecting above the boss. The Figure 7-13. Valve Seat RemovalTool
7-8
OVERHAUL MANUAL-AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES s~ction
Cy~indarr.
~nd V´•lve Tr´•ln
TABLE
VALVE SEAT REPLACEMENT TOOLS
Engine Model Intake Valve Seat Exhaust Valve Seats
Recess Cutter Pilot Replacement Drift Recess Cutter Pilot Replacement
0-541-A Series ST-51 ST-66 ST-64 ST-54 ST- 67 ST-65
541-E Series ST-51 ST-66 ST-64 ST-54 ST-257 ST-65
541 Series ST-51 ST-66 ST-64 ST-54 ST-257 ST-65
length, tapered shank driver ST-62 used with all recess cutters.
drive adapter ST-63.
ement fixture ST-232.
NOTE
DESIRED (I´• MAX.ANGLE)
When it is necessary to replace intake or I1ITCJ(E VPLVE EXWAUST VALVE
exhaust valve seats, the recessin the cyl-

inder headmust be cut .010, .020 or .030
oversize and the corresponding oversize I´•)1AX. I I I rl´•LIAX.
seat installed.
7-51. VALVE SEATS. Place the valve seat replace-

ment fixture (ST-232) suitable surface and fasten
on a
securely. Fabricate a removaltool in accordance with

the materials and dimensions shown in figure 7-13.
7-52. Heat cylinder to a temperature of 6000F. and

secure to fixture. Soak the sponge of the removal tool
in cold water. Insert the tool down through the valve
seat, the seatwill shrinkand clingtothe sponge. With-
draw the tool being careful not to cock the seat. This ACCEPTABLE
entire procedure should be performed as swiftly as IrlTJXt v~uvF EXHAUST VALVE
possible after removing the cylinder from the heat.
7-53. Measure the ID of the valve seat recess in the

cylinder head. Compare the measurementwith the ori-
Binal manufactured diameter of the recess (see Table
of Limits) and determine which oversize seat is to be
installed.
7-54. Refer to Table 7-2 and select the proper cut-

ter andpilot. Installthe pilotin the cutter, tighten and
install cutter in special drive. Install on drill press
and proceed to cut the recess in the cylinder head to
proper size. Note that the pilot engages the ID of the
valve guide hole in the cylinder head. Remove no more
metal from the bottom of the recess than is necessary NOT ACCEPTABLE
to clean up the major diameter.
INTOXE Vil~E EXHAUST VALVE
7-55. In the event the seats are to be cut by hand, in-
stall the hand drive adapter (ST-63) over the special
drive and using a "T" handle proceed to cut the re-
cesses as described in the preceding paragraph
7-56. Heatcylinder to 4009 F. to 425"F. and secure to

replacement fixture. Chill seat and place on replace-
ment drift (refer to Table 7-2) for correct drift and
drive seat into the recess in the cylinder head by tap-
SE*TING
ping end of drift with hammer.
7-57. Proceed to grind the faces of the newly installed
valve seats as described in paragraphs 7-46 through Figure 7-14. Acceptable, Desired and Not
7-48. Acceptable Valve Contact with Seat Face
7-9
Cylinders. Pistons.
and Valve Train
NOTE TABLE 7-3
Whenever a new valve seat is installed, it VALVE GUIDE REPLACEMENT TOOLS

is required that its matching valve guide
be replaced. This will assure concentric GAGE SIZE
grinding of the new seat.
Valve Guide Hole
7-58. VALVE REFACING. Place valve in a suitable in Cylinder Head
valve refacing machine (Snap-On VR-300) or equiva-
lent. Set refacer to 30" for intake valves and 45" for 5913/. 5923 hole)
exhaust valves. Using a soft #80 grit wheel, remove
no more metal than is necessary to clean up pits in the 64571 Standard
valve face or to correct any apparentwarping condition. 164507 .005 oversize 64678-
Round off with a hand stone any sharp orburred edges 164509 .010 oversize 64678-
left around the valve face after refacing; this is best 164511 .020 oversize 6467
accomplished while valve is turning in the refacing 164639 1 .030 oversize 6467&´•
machine.
6613/. 6623 hole)
7-59. VALVE GUIDE REPLACEMENT. Damaged or
64940 Standard 64924
worn valve guides are removed and new guides installed
8 .005 oversize 64924-1
in accordance with the procedures described in the fol-
64929 .010 oversize 64924-2
lowing paragraphs. Referto Table 7-3 forvalve guide 30 .020 oversize 64924-
replacement tools. 64931 .030 oversize 64924-
7-60. Screw the nut of the valve guide puller (ST-49) 6933/. 6943 hole)
to the head of bolt (3/4-16). Place the retainer over
valve guide inside of rocker box Insertthe bolt (3/4- -259 Standard
16)into the retainer and valve guide. From the cyl- ;259-5 .005 oversize ST-258-5
Lnder barrel end insert the bolt (3/8-24) into the end -259-1 .010 oversize ST-258-1
of the 3/4 inch bolt. Tighten the 3/8 bolt until snug -259-2 .020 oversize ST-258-2
-259-3 .030 oversize ST-258-3
against the valve guide. Turn the nut in rocker box in
a clockwise direction untilvalve guide is free of cyl-
inder head. Valve Guide ID
14 All intake valves 64684
7-61. Check eachvalve guide hole in the cylinder head T- 155 .4995/. 5005 exhaust valve
with the applicable valve guide hole plug gage. If the Pilot diameter .4828/. 4833 ST- 143-1
gage enters the hole more than 1/8 inch it will be nec- Pilot diameter .4778/. 4783 ST-143-2
essary to ream the hole andinstall an oversize guide.

If the gage enters the hole easily or seems loose in the ent Fixture 64644
hole, it is evident that an oversizeguide has already n Drift (Intake) 64505

been installed and the nextlarger guide must be used. Drift (Exhaust) 64923
alve Guide Puller ST-49
7-62, Mount valve guide replacement fixture (P/N BREAK INNER EDGE
64844) on drill press table. Fasten cylinder securely
.005L015 AFTER
in place on the fixture and set fixture to proper angle
INSTALLATI
for the valve guide being installed (11" 45 minutes for
intake valve, 120 40 minutes for exhaust valve).
7-63. Determine the proper size reamer, mount the

reamer in the drill press spindle and ream the valve
VALVE GUIDE
guide hole in the cylinder head. Checkthe reamedhole
CYLINDER HEAD
with the appropriate plug gage (see Table 7-2).
7-64. Heat cylinder to 4000F. to 4250F., chill valve

guide. Place guide on proper valve guide installation
drift, insert the guide in the hole of the cylinder head.
Drive the guide to a firm seat with sharp hammer blows
on the endof drift. After the cylinder has cooled, ream
the valve guide with the appropriate valve guide ID
reamer. Check the finished ID of the guide with the
appropriate valve guide ID plug gage.
7-65. On all newly installed valve guides, break the

inner edge of the upper (rocker box) end of the guide as Figure 7-15. Breaking Inner Edge of
shown in figure 7-15. Exhaust Valve Guide
7-10
cylinders. Pistons,
and Valve Train
7-66. VALVE ROCKlERTHRUST WASHERS. Excessive 7-72. REPLACEMENT OF VALVE ROCKER BUSH-
side clearance between the valve rocker and cylinder INGS. If valve rocker bushings are damaged or worn.
head (reference 533, Table of Limits) caused by ex- they can be replaced in the following manner:
eessive wear on the inner rocker shaft support boss

may be brought within limits in the following manner: 7-73. Place the valve rocker in position in the valve
rocker holding fixture (64540) and, using a suitable
a. Use the inner rocker shaft spotfacer (64862) to drift, remove the bushing from the valve rocker.
clean up the surface of the inner rocker shaft support
boss, removing no more metal than is necessary.
7-74. Usinga suitable arborpress, installa newbush-
ing in the valve rocker. Make sure the oil hole in the
b. Select and fit any two of the three undersize wash-
bushing is alignedwith the oil hole in the valve rocker.
ers that will bring the side clearance withinthe service
limits. 7-75. Burnish the housing by using an arbor press to
pass the valve rocker bushing burnisher (64541) com-
7-67. REPLACEMENT OF VALVE ROCKER SHAFT
pletely through the bushing. Remove the rocker from
BUSHING. Remove the outer and inner bushing using the fixture and check the finished ID with the valve
the rocker shaft bushing removal drift (64814). rocker bushing finish ID gage (64542).
7-68. Check each rocker shaft bushing hole in cyl- 7-76. RECONDITIONING NITRIDEDCYLINDER BAR-
inder head with a standard plug gage (64810). If plug RELS. When anitrided barrel is worn beyond service
gage enters hole more than 1/8 inch an oversize rock- limits, it can be reconditioned by chrome plating or in
er shaft bushingwill be required. If the fit of plug gage
certain cases by re-barreling. Consult Service In-
in the hole is quite loose, it is evidentthat thebushing struction No. 1047 for information relative to recon-
that was removed was an oversize bushing. Use the
ditioning nitrided barrels.
0. 005 oversize plug gage to determine what oversize
bushing should be used for replacement. When the
7-77. VALVE REPAIR. Repair to valves are limited
proper size replacement bushing has been determined,
proceed to ream bushing hole in the cylinder head. to removal ofcarbon, regrinding the fac e, and polls hing
superficial scratches. Bending processes to straight-
e" andpuddling to restorethe face must not be attem-
7-69. Placethe pilot of the outer rocker shaftbushing
hole in cylinder headreamer (64812 or 64813)through pted.
the outer hole intothe inner hole and proceedto ream
the outer hole. Place the inner rocker shaft bushing REASSEMB~LY
hole in cylinder headreamer (64832 or 64833)through
the outer hole and the inner hole. Clean 7-78. ASSEMBLY OF PISTONS. Using the pistonring
ream cylinder
and reamed holes thoroughly. expander, assemble the new rings pistons in the
on
order described in the following paragraphs.

7-70. Install new rockershaft bushings in the following
manner: Place the stop of the outer rocker shaft bush-
7-79. With the piston lying top up on the workbench,
ing installation drift (64815) betweenthe inner rocker i"stall the oil regulating ring equalizer in the first
shaft bushing boss and the outer rocker shaft bushing groove above the piston pin hole. Assemble the reh’-
boss. Assemble newbushingon drift, insert driftpilot ulating ring over the equalizer with its gap 180" op-
through boss into stop and tap bushing into place. As- positethe equalizer gap. Compress the assembly sev-
semble the new bushing on the pilot of the inner rocker
eral times with the fingers to make sure the ring lies
free and loose in the groove. Both the equalizer and
shaft bushing installation drift (64816) and position
the regulating ring are symmetrical and may be in-
bushing and pilot. Insert drift through outer bushing
into pilot and tap inner bushing into place. stalled with either side upward.
7-80. Install compression rings in the remaining top

7-71. After installing new rocker shaft bushing in cyl- grooves The compression rings are etched on one
inder head, ream the bushing inside diameter. To do side with the word ’TOP" and this side must face to-
this, place the pilot of the outer rocker shaft bushing ward the top of the piston.
ID semi-finish reamer (64819) through the outer bush-
CAUTION
ing and ream outer bushing. Place the inner rocker
shaft bus hing ID semi-finish reamer (64820) through the
If in doubt as tothe proper combination of
outer bushing and ream the inner bushing. Repeat the
rings to be used, refer to the latest revi-
same procedure, this time using theouter and inner
sion of Service Instruction No. 1037 or
finish reamer 164821and 64822). Check the finish ID
hole in the rocker shaft
contact the Service Department, Avco Lyc-
bushings with the rocker shaft
plug gage (64823). Clean the cylinder and
ID oming Division.
bushing
reamed hole thoroughly. 7-81. Upon completionof assembly of the piston rings,
check the side clearance of the rings in the piston
NOTE .grooves. Use feeler gage and straight edge as shown
in figure 7-7.
After bushings have been reamedthey must NOTE
be impregnated with oil by immersingthem
for at least 15 minutes in engine oilthat has Under no circumstances should oversize
been heated to 600C. (140"F. piston rings be used in nitrided barrels.
7-11
sactron 7 OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Cylinders, Pl~tons,
and Valve Train
mediately prior to assembly of piston and cylinder to

4 the engine, space the rings correctly and apply a gen-
erous coating of the oil mixture described in paragraph
3-39. Apply to the inside of the cylinder barreland to

piston and rings working and mixture well around the
rings and into the grooves. Starting with No. 1 cyl-
inder, proceed to install as follows:
7-85. Rotate crankshaft so that No.
1 piston, when
installed, will be top dead center on
approximately at
thefiring stroke; this is determined by bothtappets of
No. 1 cylinderbeing onthe base circle of the cam lobes.
Before any attempt is made to rotate the crankshaft,
support the connecting rods as shown in figure 7-3.
7-86. Assemble piston on connecting rod with

piston
3\(0) number, which is stamped on bottom of

piston head,
toward the front of the engine. The piston pin should
be palm or hand push fit. If the original piston pin is
tighter than a palm push fit, it is probably caused by
nicks or slight carbon in the piston pin bore of the pis-
FIRST- TIGHTEN NUTS 1,2,3 AND 4 IN CLOCKWISE
ton. If a new piston pin or piston is to be installed,
SEQUENCE, STARTING WITH NO. I. TIGHTEN select the pin to give a palm push fit at room temp-
NUTS TO 300 IN. LBS. TORQUE. erature of 15" to 20"C. (600 to 70"F. )After pistonpin
is in place and centrally located, insert a piston pin
SECOND-IN SAME SEQUENCE, TIGHTEN NUTS 1,2,3 plug at each end of the piston pin.
AND 4 TO 600 IN. LBS. TORQUE.
7-87. When the crankcasefastenings have been tight-
ened as described in Section 8, the cylinder may be
Figure 7-16. Sequence for Tightening
installed, Install in pairs beginning at the rear and pro-
Cylinder Base Nuts
ceeding toward the front. Proceed as follows.
7-82. ASSEMBLYOF CYLINDER. Seefigure?-1. Ap-
NOTE
ply loclrtite instant pipe sealant #70 to exhaust valve
guide oil line connectors, tees’ and elbows (where ap-
The two front half inch through studs of
plicable), assemble in cylinder head and tighten to 100
inch Ibs. torque. Install fueldrain line nipples incyl- each cylinder are not secured by screw
Inder head. Coat the valve guides and valves with a pre- threads; instead the center of each stud
lubricant as described in paragraph 3-38. Insert the serves as a dowel to insure crankcase
intake and exhaust valve in their respective guides. The alignment at the
bearing webs while the
Intake valve can be identified by the fact that it is slight- threaded ends protrude through the cyl-
inder mounting pads. Therefore, when
ly larger than the exhaust valve. Hold the ends of the
valve stems and place the cylinder on the applicable tightening the 1/2 inch cylinder base hold
down nuts, the opposite side must be held
cylinder holding block. Install on each valve a lower
so that the stud does not turn while torque
spring seat (10), outer and auxiliary valve spring (11
and 12) and outer valve spring seat (13). is being applied.
7-88. Place a new cylinder base seal ring (1) around
NOTE the cylinder base, assemble the piston ring compressor
(64712) over the piston rings and installthe cylinder
Assemble the dampener ends of springs over thepiston, pushingthe piston ring compressor
(close wound coils marked with dye or lac- ahead withthe cylinder barrel. As the cylinderbarrel
quer) downward or next to lower spring approaches the crankcase, catch the ringcompressor
seats, as it drops off the piston. When the base of the cylinder
is seated on the crankcase pad, secure with 3/8 inch
7-83. Compress the springs with the valve spring and 1/2 inch nuts, tightening the nuts finger tight only.
compressor a nd assemble the valve retaining keys (14). BeforetigMening any of the nuts to final torque, com-
pletethe assembly of allcylinders as described above.
NOTE
NOTE
Exhaust valves are assembled with special
keys (14) andcaps (22). Do not installcaps Before installing cylinder hold-down nuts,
until just before valve rockers are in- lubricate crankcase through stud threads
stalled. with any one of the following lubricants,
or combination of lubricants.
7-84. INSTALLATION OF PISTONS AND CYLINDERS.
See that all preservative oil accumulation on cylinder 1. 90~6 SAESOWengineoiland 10~bSTP.
and piston assemblies is washed off with solvent and 2. Parker Thread Lube.
thoroughly dried with compressed air. Insert valve 3. 60~ SAE 30 engine oiland 40S~park-
rocker shafts in their bores in the rocker box. Im- er Thread Lube.
7-12
Cyllnderz. P,~ton´•.
end V´•lve Tr´•ln
7-92. As a finalcheck hold thetorque on eachwrench

nut for about five seconds. If the nut does not turn, it
may be presumed to be tightened to correct torque.
7-93. Install some type of vented plug in spark plug
’i
holes to prevent entrance of foreign matter and to allow
the engine to be easily turned.
7-94. See figure 7-1. Install hydraulic lifters (28) in

2
the crankcase and assemble the shroud tube adapter
gasket and shroud tube adapter (29) on the crankcase.
7-95. Assemble new shroudtube oil seals (25) intheir

retainers inthe crankcase and assemble another shroud
tube seal (25) over the cylinder head end and cen-
ter a sleeve (24) over the seal.

r10-541-AIA
7-96. Assemble shroud tube spring (31) over the inner

ends of the two shroud tubes (27) so that the detent
nothces in the spring are approximately 900 removed
fromthe detents onthe tubes. Place shroudtubewash-
Fm NO 28
FIN NO 27
,7
k-´• a FINNOIG
6 NOll
NOIO
ALL OTHER MODELS
1, Baffle assembly 4. Retainer hook

2. Baffle assembly 5. Baffle retainer
3. Baffle assembly 6. Grommet
7. Button plug
3el
369
Figure 7-17. Intercylinder Baffles
No.l
7-89. When all cylinders have been initially installed

on the crankcase as described in paragraph 7-88, be-
gin tightening all cylinder base nuts as describedbelow,

usingthe proper cylinder base nut wrenches and handle
in conlunction with a suitable torque indicator. Torque
fiua
wrenches employing the flexible beam design are
recommended in preference to those using the hyd- ~F*IN014
raulic principle or a dial indicator with rack and pinion.
7-90. Tightenthe 1/2 inchcylinderbase holddown nuts

in the sequence and tothe torque shownin figure 7-16.
NOTE
Because the front two through studs at each O

cylinder pad are not secured by screw
threads, the opposite hold down nuts on
these studs must be tightened simultane-
ously.
7-91. Tighten the 3/8 inch cylinder base hold down
nuts to 300 inch pounds torque. Sequence is optional. Figure 7-18. Cylinder Head Fin Stabilizers
7-13
s´•ctron 7 OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Cyllndera,
and Valva Train
era (30) (maximum of two), to bring minimum over- clearance is out of limits adjust by using a longer of
lap between the spring and detent2ugs to 1/8 inch, over shorter push rod. Refer to Table 7-4 for part number
end of each tube. Insert tube ends into the seals in the and length of push rods.
crankcase. Holdboth shroudtubes with detentat inner
end at unlocked position and insert the outer ends of 7-100. When alldry tappet clearances have been de-
the tubes in the cylinder head. See that the seals are termined, coat allparts in the rockerbox as described
seating squarely and turn each shroud tube 900, thus in paragraphs 3- 37 through 3- 39 andinstall the rocker
locking the tubes by engaging the detents with the notch- box cover gaskets (17) and covers (19) and secure with
es in the spring, self locking screw (18).
7-97. Select the properpush rods (23), dip in oil mix- 7-101. (TIO-541-E and TIGO) Coat valve rocker shaft
ture described inparagraph 3- 39 and insertfull length cover studs with non-hardening Permatex #2 or equi-
through the shroud tubes. Press tightly against outer valent and coat both sides of gasket with POB sealer
end to check spring tension and free travel of the hy- or equivalent. Installgasket and cover(26) and secure
draulic lifter assembly. with one self sealing, slotted head screw, one washer
and one nut.
7-98. Slide rocker shafts (21) back and install valve
rockers (15) and thrust washers (20). TIGO series 7-102. (TIO´•541-A)Assemble gasket andvalve rocker
install a thrust button(32) in each end of rocker shaft, cover and secure with self sealing, slotted head cap
Before installing exhaust valve rocker place rotator screws.
cap (22) over the exhaust valve stem. Slide rocker

shaft back into position. If the clearance between the 7-103. MTERCYLINDER BAFFLES. Seefigure 7-17.
valve rocker and cylinder head cannotbe broughtwith- Note that the baffles differ according to
intercylinder
in limits (see Table of Limits) by the use of standard engine model. baffles, proceed as follows:
To install
washers, clean up the worn valve rocker support boss Place the baffles in place beneath andbetween the cyl-
as described in paragraph 7-66 and use any of the inders, running the hook up between the cylinder bar-
selective fit undersize washers to bring the clearance rels. Place a retainer in placebetween the cylinders,
within limits, and with the aid of a baffle installation tool (64885),
bringthe retainer hook through the slot in the retainer,
NOTE When hook is far enough above the retainer, turn and
hook over the bridge between the retainer slots.
The valve rockers, intake and exhaust,
differ on the TIG-541-A. The valve rockers 7-104. CYLINDER READ FIN STABILIZERS (TIO-
on the TIO-541-E and the TIGO-541 series 541-A1A only). Clean the stabilizers and affected fin
are the same for intake and exhaust. area thoroughly to remove all traces of grease, dirt
of other foreign matter.
7-99. Check dry orunloadedtappet clearanceby push-
ing in on push rod end of valve rocker and measuring 7-105. Apply Dow CorningSilastic 140 adhesive to the
the clearance between end of valve rocker and valve fin stabilizers and press surfaces together in the lo-
stem tip. Clearance should measure .040/.105. If cations described in figure 7-18.
TABLE 1-4
PUSH ROD ASSEMBLIES
Model Push Rod P/N
541-A 73580 (Intake) 13. 790-13. 803

541-A 73581 (Intake) 13. 817-13. 830
0-541-A 73582 (Intake) 13. 844-13. 857
541-A 73568 (E~xhaust) 13. 505-13. 518
541-A 73569 (Exhaust) 13. 532-13. 545
541-A 73570 (Exhaust) 13. 559-13. 512
541-E, TIGQ-541-E 76180 (Intake or Exhaust) 13. 955-13. 912
541- E, TIGO´•541-E 16181 (Intake or Exhaust) 13. 992- 14. 009
541-E, TIGO-541-E 76182 (Intake or Exhaust) 14. 029- 14. 046
541- TIGO-541-E 76183 take or Exhaust) 14. 066- 14. 083
7-14
SECTION
CRAN KCAS E,
CRAN KSHAFT AND
ACCESSORY DRIVES
Crmkc´•te. Crankshaft.
and ACCaa40ry DrlVaa
SECTION 8.
CRA´•NKCAS E, C RANKSHAFT
AND ACCESSORY DRIVES
DISASSEMBLY 8-8. (TIO-541). See figure 8-5. Remove the external

hex headplug (6) andgasket (5). Remove the propeller
8-1. (TIO-541). Remove the starter ring gear and idler gear shaft (4), idler gear (2), thrust washer (1)
support assembly (1, figure 8-3) from the crankshaft and propeller driven gear (3).
propeller flange by tapping lightly on the rear face of
the support. The alternator drive belt should also be 8-9. (A11Models). Removethe camshaftassembly and
removed from the engine at this time. on the TIG-541 series remove the circlips (27, figure
8-3) and remove the governor drive gear (23, figure
8-2. (TIO-541). See figure 8-1. Removethe oil pres- 8-3).
sure relief valve assembly (1 or26), the dip stick
(5 or 6) and the oil filler extension (7 or 8). Remove 8-10. Remove the crankshaft assembly. See figure
all threaded plugs so cleaning will be facilitated. Re-
7-2. With the crankshaft properly supported at the
move oil seals andengine mounts. Remove crankshaft
main bearings, remove the nuts (9) from the connecting
oil seal retainer (17) and oil seal (22). Remove the
rod bolts (8) and disassemble the connecting rod by
peripheral fastenings, the lifting eyes (9 or 11) and lightly tapping the bolts. ~fter removing the rods,
the lifting strap (19). Remove the nuts from the through
discard the inserts and reassemble the cap and rod.
bolts.
This is essential as the rods and caps are not inter-
changeable. The number of the cylinder is stamped

NOTE
on the side of both the rod and cap and it should be re-
installed on the correct throw.

The crankshaft oil seal retainer(l7) men-
tioned in the preceding paragraph is not
employed on all models. 8-11. (TIO-541). See figure 8_3. Remove the acces-
sory drive gear (16) from the crankshaft gear (12).

8-3. (TIGO-541). Seefigure~-a. Removetheoilpres- Unscrew the hex head bolts (15) remove the lockplate
sure assembly (11) and oil bypass valve
relief valve (14) andtap the crankshaftgear (12) off the crankshaft.
housing (10). Remove the dip stick (8) and oil filler Do not remove the dowel (13) unless it is loose or
tube (5). Remove allthreaded plugs so cleaning will damaged. It will not be necessary to remove the ex-
be facilitated. Remove engine mounts. Remove the .pansion plug (2) unless it is damaged or leaking. It is
peripheral fastenings and remove the lifting eyes (1) also not necessary to remove the propeller fiange
and lifting strap (4). bushings (24, 25 and 26) unless they are loose or
damaged.
8-4. (All Models). Place the crankcase assembly on
itsright side and remove the lockwire and fastenings 8_12. (A11Models). See fi’gure 8-3 or 8-4. To remove
securing the bottom of the case. the counterweight assemblies (10), remove the cir-
clip (6), washer (7) and remove the counterweight (10)
8-5. Remove the through studs using service tool
and rollers (8) from the crankshaft.
ST-211. Pull the left half of crankcase away from the
right half. When the halves of crankcase are about 1 NOTE
inch apart, reach through the cylinder mounting pads
and push left halves of the main bearing down on the A1Z counterweights and their related parts
shaft to prevent them from falling from left half of
should be reassembled in the same loca-
crankcase. Proceed to remove the left haL~ holding tion theyoccupied onthe crankshaftbefore
the governor driven gear on the TIQ´•541 series, re-
disassembly. For example the retaining
move the gear from the crankcase half. Remove the
washers are selective ly fitted to the washer
piston cooling nozzles from the crankcase. seats. It is advisable, therefore, to mark
all counterweight parts to insure proper
8-6. (TIO-541-E andTIGO-541). See figure 8-12. Re- identification. The markings must be im-
move the cotter pin (14) and nut (13) from shaft. Re-
permanent. No scoring, etching, scratch-
move the washer (12), pulley (11), oilseal(6), drive
ing or other permanent marking of any kind
adapter (3) and gasket(2). Remove drive shaft (1) from is permissible on these parts.
the accessory drive gear.
8-7. (TIGO-541). See figure 8- 9. Remove the propeller 8-13. (TIGO-541). See figure6’l. Removethe acces-
drive shaft gear assembly (17) generator and starter sory drive gear (5) from the crankshaft gear (1). Un-
gear (16) along with the spring adapter (15) and spring screw the hex head bolts (4), remove the lockplate (3)
(14). Remove the propeller shaft (2) and component and tap the crankshaft gear (1) off the crankshaft. Do
parts. not remove the dowel (2) unless it is loose or damaged.
8-1
i~´•2
,’Oa 3 P
~K g
c~ab
,00 61
Ol,j "im
aaz~I
5
4o 2" 6 ’j8
4
Opm
~s;a
´•~’--sB´• 7
a,":
r~
CC.
0\ O 4
z
19
8eba s
n
II
k
oo
o00 12
P
Od
8 14
B ~u 8
~b´•
r
22
Od O
o
16
\1\15 13
;a
a
i. Oil relief valve (adlustable) 10. Mount, upper left ("E") 18. Support brackets ("A"’ 5;
2. Mount, upper right ("E") 11. Lifting eyes 19. Lifting strap ZI
3. Right crankcase hall 12. Through bolt 20. Piston cooling nozzle
4. Left crankcase half 13. Mount, lower left ("E") 21. Oilseal rings G)
5. Dip stick, cam action 14. Mount, left rear ("A") 22. Crankshaft oil seal
6. Dip stick, screw type 15. Through stud 23. Through bolt Z:
7. Oil filler extension, long 18. Mounts, front ("A") 24. Mount, lower right ("E")
8. Oil filler extension, short 17. Oil seal retainer 25. Mount, right rear ("A")
g~ Lifting eyes ("E") 26. Oil relief valve (non-adjustable)
Figure 8-1. Typical Crankcase Assembly TIG-541

OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES Secr~on s
Crankc´•~e. Crankrh´•tt.
and Acccatory Drlv~´•
6 7 8\ r
t
It
´•tst~ Q \i
t.~e
Q i
C
8
´•--f~ 1:
16-\´•C i
~jp
2
c´•~’’ r‘
5111
15
~,13
´•0~:
1. Lifting eyes 7. Oil filler tube chain 13. Hydraulic lifter

2. 8. Oil level gage assembly 14. Piston cooling nozzle
Lifting eye spacer
9. Mount- upper left 15. "0" ring
3. Mount upper right
4. 10. Oil bypass valve housing 16. Starter housing bushing
Lifting strap
5. Oil filler tube 11. Oil pressure relief valve assembly 17. Mount lower left
6. Oil filler tube cap 12. Mount lower left
Figure 8-2. Typical Crankcase Assembly (TIGO-541)
8-14. (All Models). Unscrew the hex head bolts, re- outside of the case and lift out the thrust washer (12)
move the Zockplates and camshaft gear from the and fuel pump drive gear (11).
camshaft.
8-17. Propeller Shaft Assembly. See figure 8-9. Re-
move the circlip (18), "0" ring (19) and pull oil trans-
8-15. See figure 8-6. Liftout thehydraulic
(TIO-541). for tube (20) from oil supply tube (1). Remove gover-
and vacuum pump driveshaft (8), the intermediate ac- drive gear (13) and locknut (12). Remove cones
cessory drive gear (7) andthe accessory idler gear (16). (9 ,d 11), prop shaft driven gear (10), thrust bearing
Remove the circlip (9) from the fuel pump idler gear (8), oil slinger (7), shim (6), thrust bearing cap (5),
shaft (14) and remove the idler gear (10) and thrust .il seal (4) and Woodruff key (3).
washer (12) from the shaft. Remove the capscrews (15)
and lockplate (3) from the shaft. Remove the circlip 8-18. Starter Drive Assembly. See figure 8-10. Re-
(9) from the outside of the case and remove the fuel move nut (9) from a shaftgear (7) and disassemble as
pump drive gear (11) and thrust washer (12). Remove shown.
the cotter pin (17) and slotted nut (18) from outside of
case and remove the breather slinger gearshaft (6). NOTE
The slinger gear (21), pinion rollers (20), thrust washer
(12) and shield (19) can be removed. Torquemeter oil pump assembly is no
longer applicable to TlGO-541 series en-

8-16. (TIGO-541). See figure 8-7. Remove the hy- gines. See Service Bulletin No. 350 for
draulic and vacuum pump driveshaft (7), the inter- detailed information.
mediate accessory drive gear (6) and the accessory
idler gear (19). Remove the circlip (8) from the fuel 8-19. Thrust Bearing Propeller Shaft Drive. See fig-
8-11. Disassemble as shown.
pump idler gear shaft (14) and lift the idler gear (9) ure
and thrust washer (17) from the shaft. Unscrew the

hex head bolts (16) and remove the lockplate (15) and 8-20. Starter Drive Adapter Assembly. See figure
circlip (13) from the 8-13. Disassemble shown in figure 8-13.
idler gearshaft (14). Remove the as
8-3
ssct~on s OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Crankcas´•,Crankshaft.
and Accessory Drives
8-21, Alternator Drive Assembly. See figure 8-14. 8-24. BEARINGS (PRECISION TYPE). All precision
Disassemble as shown in figure 8- 14. type bearing inserts used for main crankshaft bearings
and connecting rod bearings should be replaced with
new bearing inserts at overhaul.
CLEANING
8-25. CRANKCASE (VISUAL INSPECTION). Check
carefully for burrs, nicks and cracks around the bear-
8-22. All crankcases, crankshafts and accessory
drives etc, should be cleaned in accordance with the ing support webs. Check bearing bores and inspect
generalinstructions outlined inSection 3. When clean- tang slots for any roughness that might cause improper
ing the crankshaft, clean the inside of all crankpin and seating of bearing inserts. Check all drilled holes.
main bearing journals and oil passages with suitable
8-26. CRANKCASE (DIMENSIONAL INSPECTION).
brushes, after which thoroughly flush with clean sol-
vent and compressed air.
The following paragraphs on crankshaft and camshaft
dimensions will also describe dimensional require-
ments of the crankcase.
8-23. PISTON COOLINGOIL JETS. Immersethe pis-
ton cooling nozzle in petroleum solvent. Hold the ball 8-27. CRANKSHAFT (VISUAL INSPECTION). Care-
check valve off its seat in the nozzle by inserting a light fully inspect all surfaces of the shaft for cracks. Check
the bearing surfaces with particular care for galling,
copper wire or other relatively soft material through
the threaded end of the nozzle and wash thoroughly so scoringor otherdamage. Znspectoiltransfertubes for
that any dirt particles that may be under the ball seat tightness. Check propeller nange bushings for tight-
will be washed out. ness; mark for replacement any that are loose.
~i
8 9 10
7
6
4
512
422~T
6~P
7----’
21ji~i 19
20
18
1. Ring gear and support assembly 10. Counterweight "E" 19. Dowel
series employs 4 ct’wts. 20. Camshaft
2. Expansion plug
3. Plug 11. Crankshaft ct’wt. bushings 21. Hydraulic lifter
4. Front main bearing 12. Crankshaft gear 22. Woodruff key
5. Main bearing 13. Dowel 23. Governor drive gear
6, Circlip 14. Lockplate 24. Propeller nange bushing, long
7. Washer 15. Hex head bolts 25. Propeller flange bushing, short
8. Roller 16. Accessory drive gear 26. Propeller flange bushing, indexing
9. Counterweight bushing 17. Lockplate 27. CircLips
18. Camshaft gear
Figure 8-3. Crankshaft and Related Parts (TIO-541)
8-4
Crankcasc.Crankshatt.
and Accessory Driver
4j
5
5
4
2 12
’"714 it
f 9
T
20
17
5
i 8
1. Prop. shaft bearing 8. Counterweight rollers 15. Hex head bolts

2. Spline bushing 9. Counterweight bushings 16. Lockplate
3. Dowel 10. Counterweight 17. Camshaft gear
4. Crankshaft counterweight bushing 11. Crankshaft gear 18. Stepped dowel
5. Crankshaft bearing 12. Lockplate 19. Camshaft
B. Retaining ring 13. Dowel 20. Prop. drive gear rear bearing
7. Counterweight washers 14. Hex head bolts 21. Prop. drive gear front bearing
Figure 8-4. Crankshaft and Related Parts (TIGO-541)
8-28. CRANKSHAFT (DIMENSIONAL INSPECTION). resulting clearances with the Table of Limits (Ref-
Place the crankshaft in Vee blocks supported at the erence 501). Assemble the connecting rods tempor-
locations called out in Table of Limits (Reference 556) arily (using new bearing inserts) and check the crank-
and using a surface plate and dial indicator measure pin journalclearances in the same manner, see Table
the run-out at center main bearings. If this total in- of Limits, (Reference 502). If clearances do not fall
dicator reading exceeds the dimensions given in Ref- within prescribed limits, the shaft must be reground
erence 556 the shaft must notbe re-used. The crank- undersize. See Repair and Replacement section for
shaft flange run-out may be checked at this time and instructions for regrinding.
if the totalindicator readingexceeds the run-out given
in Table of Limits (Reference 607) the shaft must be 8-30. CAMSHAFT (VISUAL INSPECTION). Carefully
rejected, inspect all surfaces of the camshaft for cracks, scoring,
galling, corrosion, pitting or other damage; be par-
CAUTION ticularly careful when inspecting bearing surfaces. If
hydraulic lifter has been rejected for spalling or es-
Any attempt to straighten a bent crankshaft cessive wear, inspect the corresponding cam lobe. Any
will result in rupture of the nitrided sur- indication ofdistress, surface irregularity or feather-
face of the bearing journals, a condition that ing at the edge of the cam lobe is cause for rejection
will cause eventual failure of the crank- of the camshaft.
shaft.
8-31. CAMSHAFT (DIMENSIONAL INSPECTION).
8-29. Using newinserts at allmain bearing locations, Support the camshaft in Vee blocks at its front and
assemble crankcase halves together temporarily and rear bearing journals and check the run-out at the
measure the ID of the bearings. Measure the ODof center bearing location. See reference 539, Table of
the crankshaft main bearingjournals and compare the Limits. Slight bending operations are permissible on
8-5
section s OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Crsnkca´•e,Cr´•nkshaft.
and Accerrory Driver
the camshaft providing careful magnetic inspection fol- ner in which it weakens the metallic structure of the
lows such procedures. Measure the diameter of the connecting rod.
camshaft bearing journals and check them against the
bearings formed by the crankcase. Reference 537, 8-35. CRANKSHAFT COUNTERWEIGIIT BUSHLNCS.
Table of Limits. Wear damage to the crankshaft counterweight bush-
or
ings located in the crankshaft counterweight lugs, is

8-32. CONNECTING RODS (VISUAL INSPECTION). almost impossible to detect by normalinspection pro-
It is necessary to make a thorough visual check for cedures. Because of this situation and as damage to
galling. Galling is generally indicative of excessive the crankshaft counterweight bushings could cause fail-
speed or overboosting; and if permitted to e~dst can ure of the counterweight and/or the crankshaft, it is
result in failure of the rod. mandatory that these bushings be replaced at overhaul.
The procedure for removal and replacement of the
8-33. Galling, as shown in figure 8-15, is caused by crankshaft counterweight bushings is contained in para-
an infinitesimal movement between the surfaces of the graphs 8-50 through 8-55.
bearing insert and the connecting rod during periods
of high loading such as is produced during overspeed 8-36. Measure the out-of-roundness of all crankpin
or excessive manifold pressure operation. The visual and main bearing journals on the crankshaft and all
evidence produced by galling appears as if particles camshaft bearing journals.
of metal from one contacting surface hadwelded to the
other. The bearinginsert shown in figure 8-15 repre- NOTE
sonts atypical case of galling; while the connecting rod
bearing bore shown is an example of severe galling If a new or reconditioned camshaft is to be
and indicative of imminent failure of the conne cting rod. used on the engine, new tappet bodies must
Regardless of extent, evidence of any galling is suffi- also be used.

cient reason for rejection of the complete rod assembly.
8-37. CONNECTING RODS. Discard connecting rod
8-34. The rods andbearing inserts must be thoroughly bolts and nuts; new bolts and nuts are to be used on
clean and the examination carried out with the aid of a reassembly. Check condition of bore in large end for
8 power magnifying glass (minimum) or bench micro- seatingof the bearinginserts. Check bore in small end
scope. Do not mistake stains or discoloration for gal- bushing with connecting rod bushing plug gage (64537).
ling; surface blemishes are easily removedwith a fine If this gage enters the bushing, the bushing must be
abrasive cloth, chemical cleaner or steel woolwhile replaced.
galling cannot be removed. Galling is a distortion in 8-38. CONNECTING ROD PARALLELISM CHECK.
the metal and is comparable to corrosion in the man- See figure 8-16. Usingconnecting rodparallelism and
squareness gage (64530), insert tapered sleeves (1 and
2) in bearing holes in connecting rod. Be sure that bear-
ing capis assembled properly and securely tightened.
g’ Place arbors (3 and 4) throughsleeves and place gage

arm (5) on arbor (4). Set adjusting screw (6) on gage
arm to exact distance between arbors and lock the ad-
justing screw withthe wing nut (7). Then remove gage

arm and place it on the other end of arbor (4), and check
~u distance between arbors. For exact parallelism or

P alignment the distances checked on both sides will be
6 the same. See reference 566, Table of Limits
8-39. CONNECTING ROD SQUARENESS CHECK. See

figure 8-17. Using the connectingrod parallelism and
T squareness gage (64530) with the~gage arm removed,
4
place parallel blocks (1) on surface plate and, with
0(9e sleeves and arbors still in place in connecting rod
place ends of arbors on parallelblocks. Check clenr-
ance at points (2) where arbor rests on parallel blocks
using a feeler gage. For exact squareness or zero
twist, no clearance will eldst at the designated points.
See referen~e 567, Table of Limits.
10~
II 8-40. PISTON COOLING OIL JETS. Test the nozzle

12~1 assemblies for correct pressure in the following man-
I, Governor driven gear 7, Hex head plug ner. Using SAE 810 motor oilat a temperature of 65’
2, Governor idler gear shaft 8. Gasket to 90"F. direct a now of oil through the nozzle. The
3, Governor idler gear 9, Cover oil stream must pass from the nozzle through a one
4, Key 10, Washer inch diameter hole located on a center line through the
5, Thrust washer 11. Lockwasher nozzle and 4. 5 inches from the face of the nozzle at
6, Gasket 12. Nut 50 psi. The valve must not open below 37 psi; the valve
opening shall be defined as the point where leakage
Figure 8-5. Propeller Governor Drive (TIO-541) changes from droplets to a stream.
8-6
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES section a
Crankcase. Crankshatt.
b-B4I
V ~;4 0~9
~M
20~
1 2- ~ I Cj
-12--9
2
-----1 4
IP
1. Crankshaft gear 8. Hydraulic and vacuum pump drive gear shaft 16. Accessory idler gear
2. Dowel 9. Retaining ring 17. Cotter pin
3. 10. Fuel pump idler gear 18. Shear nut
Lockplate
4. Hex head bolt 11. Fuel pump drive gear 19. Breather shield
12. Thrust washer 20. Pinion rollers
5. Accessory drive gear
6. Breather gear shaft 13. Bushing 21. Breather slinger gear
7. Accessory drive gear tinter. 14. Fuel pump idler gear shaft 22. Camshaft gear
15. Hex head bolt
Figure 8-6. Accessory Drive Gear Train TIG-541
;biB i’
a"
4
20 17
\o
15--.71 e13
15--------~
14~
1. Crankshaft gear 11. Fuel pump drive gear

2. Dowel 12. Thrust washer
3. Lockplate 13. Retaining ring
4. Hex head bolt 14. Fuel pump idler gear shaft
5. Accessory drive´•gear 15. Lockplate
6. Intermediate accessory drive gear 16. Hex head bolt
7. Hydraulic and vacuum pump drive shaftgear 17. Thrust washer
8. Retaining ring 18. Bushing
9. Fuel pump idler gear 19. Accessory idler gear
10. Plug 20. Camshaft gear
Figure 8-7. Accessory Drive Gear Train TIGO-541
8-7
ssctlon s OVERHAUL MANUAL-AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Crankca´•c.Cran~´•haft.
r=
a a a
a
Figure 8-8. Crankshaft, Camshaft and Gears Assembled in Right Crankcase Half (TIGO-541)
REPAIR AND REPLACEMENT undersize, the crankshaft must be ground to undersize

and renitrided. Standard shafts may be ground to 0. 006
8-41. Repair all crankcase, crankshaft and recipro- inch or 0. 010 inch undersize, renitrided 0. 003 inch
eating Darts in accordance with the general instructions undersize shafts must be ground to 0. 010 inch under-
contained in Section 3. Specific instructions follow. size. Shafts must be fitted with the corresponding
undersize bearing inserts. Grinding the crankshaft is
8-42. CRANKSHAFT (BearingSurfaces). Duringover- a delicate operation requiring adequate grinding facill-
haul of the crankshaft, the operator must determine ties and a great degree of skill. A properly dressed
if it has standard or undersize bearing journals, then wheel (Carborundum (GA-54-J5-V10 or equivalent)
must be used with generous amounts of coolant. The
proceed with its overhaul accordingly. Undersize
crankshafts are identified by a code symbol stamped wheel must be fed to the journalor pin very slowly and
on the front of the flange as a suffix to the part num-
the final ground finish maintained during the complete
ber. In addition to the code symbols the letters RN are operation. This procedure must be.followed to eliminate
stamped as a suffix to the serial number indicating the possibility of grinding cracks. After grinding, the
shaft has been renitrided. The code symbols are, crankshaft must be carefully inspected by the magnetic
M03MP (main and crankpin journals 0. 003 inch under- particle method. If any cracks or checks are found, the
size) M03M (main bearing journals 0. 003 inch under- shaft must be rejected.
size) M03P (crankpin bearing journals 0.003 inch
undersize). If the ma~imum service Limits are ex- NOTE
ceeded (Reference 501 or 502, Table of Limits) standard
shafts may be polished to 0. 003 inch undersize and fit- If one crankpin bearing surface is ground
ted with 0. 003 inch undersize bearing inserts. Reni- undersize all crankpin bearing surfaces
trided 0. 003 inch undersize shafts may be polished to must Be~ground to same undersize. If one
0. 006 inch undersize and fitted with 0. 006 inch under- main beiring surface is ground undersize
size bearing inserts. Do not allow lathe speed to ex- all main bearing surfaces must be ground
ceed 150 RPM at any time during polishing operation. to same undersize. Mainbearing surfaces
may be ground without affecting crankpin
NOTE surfaces and similarly crankpin bearing
surfaces may be ground without affecting
Note that if one surface is polished to 003 the main bearing surfaces. After any grind-
or.006 undersize all corresponding sur- ing operation the crankshaft must be re-
faces must be polished to same size. nitrided. It is recommended that the shaft
Polishing to undersize is preferred to be returned to Avco Lycoming for re-
grinding because shafts that are polished nitriding.
do not require renitriding whereas any
grinding operation requires that the shaft 8-44. STRAIGHTENING CRANKSHAFT FLANGE.
be renitrided. This is necessary because (TIO-541). If the crankshaft run-outexceeds the ma?ci-
of the nonuniformity of grindingtools. The mum service Limit of.005 inch but does not exceed
possibility exists wherein the grinding 0. 018 inch TIR and the rest of the shaft is within the
wheel will cut through the nitrided surfaces limits given in the Table of Limits, the crankshaft
on one or more of the journal radii causing straightened.
flange may be
areas of stress concentrationthat can de-
velop into fatigue cracks andultimately re-

sult in a broken crankshaft. 8-45. When surface distortion of the flange has been
reduced as much as possible the front face of the flange
should then be trued by grinding. This operation is
8-43. If itis necessaryto make a standardshaft jour-
permissible, however, only if the minimum width of the
nalsurface more than 0. 003 inch undersize or a re-
fiange after grinding is not less than 0. 430 inch.
nitrlded 0. 003 inch undersize more than 0. 006 inch
8-8
Crankcase.Crankshatt,
CAUTION jacent to the failed stud must be

replaced. Consult
Service Bulletin No. 211 for procedures and tooling
Exercise extreme care during straighten- required to remove and replace studs.
ing operations in order to avoid damage to
the nitrided surfaces of the crankshaft.
8-50. Crankshaft, Counterweight Bushing Replacem ent
These surfaces, which extend without in-
(Where applicable).Wearer damage to the crankshaft
terruption from the front oil seal seat to
counterweight bushings located in the crankshaft
the crankshaft gear position are glass-
counterweight lugs, is almost impossible to detect by
hard and will crack if the shaft is bent,
normal inspection procedures. Because of this situa-
dropped or carelessly handled in any way. tion and as damage to the crankshaft counterweight
bushings could cause failure of the counterweight
8-46. At the conclusion of straightening operations,
and/or the crankshaft, it is mandatory that these bush-
the entire crankshaft must be inspected by the mag-
ings be replaced at overhaul. The procedure for re-
netlc particle method, paying particular attention to
moval and replacement of the crankshaft counterweight
bearing surfaces andthe fillet areas atthe base of the
bushings follows.
flange.
8-51. Thread the bolt of the counterweight bushing
8-47. Cadmium plate the ground surfaces of the crank-
puller through the puller plate, positioning the plate
shaft flange. The plating, which should be 0. 005 inch
so that the recess in it will be nest to the crankshaft
maximum thickness, should extend along the crank-
when the puller through the bushing
bolt is inserted
shaft only to front face of slinger,
in the crankshaft. Installthe small puller bushing over
the end of the bolt and then place the puller nut over
8-48. CRANKSHAFT OIL SEAL SURFACE. Oil leaks
the end of the bolt and tighten. As the nut is tightened
that develop at the front crankshaft oil sealcan usually
on the bolt the counterweight bushing will be pushed
be eliminated by removing nicks, scratches, or similar
out of its recess in the crankshaft counterweight
physical dam age from the oil seal area of the crankshaft
mounting ear and into the recess in the puller plate.
and by restoring its surface finish to Zike- new condition.
See figure 8-18.
Consult Service Instruction No. Illlfor procedures
and tooling required to accomplish this reconditioning.
8-52. Measure the II) of the rollerbushing hole in the
8-49. CYLINDER BASE STUD REMOVAL AND RE- crankshaft. If the hole measures 0. 9369 0. 9377 inch,
PLACEMENT. In the event of a cylinder base stud no reaming of the hole is necessary and a standard
failure, the adjacent studs areimmediately placed un- bushing may be installed. If the roller bushing hole
der a greater operating pressure and likely to be measures more than 0. 9377 inch, the next oversize
stressed beyond their elastic limit. Therefore, in the bushing mustbe installedand the hole reamed accord-
event of a stud failure, all of the hold down studs ad- ingly. See Table 8-1.
59
Yil Q
"i"9
18
19
17
1. Prop. oil transfer tube 8. Thrust bearing 15. Spring adapter

2. Prop. shaft 9. Prop. hub split cone 16. Generator and starter gear
3. Woodruff key 10. Prop. shaft driven gear 17. Prop. drive shaftgear
4. Prop. shaft oil seal 11. Prop. hub split cone 18.Retaining ring
5. Thrust bearing cap 12. Prop. shaft nut 19."0" ring seal
6. Shim 13. Governor drive gear 20. Prop. oil supply tube
7. Oil slinger 14. Spring 21. Rear thrust bearing race
Figure 8-9. Propeller Shaft, Generator and Starter Drives (TIGO-541)
8-9
s~ctlon a OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Crankcaee, Crank´•haft,
II
~-B 8
4
RIg 9
532
O~(-T
2
~I 36 7 8
9
i. Starter drive adapter 5. Thrust washer 10. "0" ring

2. Bushing 6. Seal 11. Washer
3. Dowel 7. Starter drive gear spacer 12. Lockwasher
4. Starter drive shaftgear 8. Starter drive gear 13. Nuts
9. Nut
Figure 8-10. Starter Drive Assembly (TIGO-541)
cod
’´•;5~4
1. Nut 5. Seal ring 8. Seat
2. Lockwasher 6. "0" ring seal 9. Thrust bearing
3. Washer 7. Shim 10. Rear bearing race
4. Cover 11. "O" ring seal
Figure 8-11. Thrust Bearing Propeller Shaft Drive Components
8-10
OVERHAUL MANUAL-AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES section a
Crankcase.Crankshatt.
and AccesJory Drives
13 1.1 3
O
12
O O
O
O O
UP 4 j
987
i. drive shaft 6. Oil seal 10. Woodruff key

Compressor
2. Gasket 7. Washer 11. Compressor drive pulley
8. Lockwasher 12. Washer
3. Compressor drive adapter
4. 9. Hex head bolt 13. Slotted shear nut
Bushing
5. Dowel 14. Cotter pin
Figure 8-12. Compressor Drive Assembly (TIGO-541, TIO-541-E)
TABLE 8-1 parallelism of the wedge blocks with that of the main
journals. Bushing must be parallel with.002 per inch.
Hole Size Reamer No.
Support the crankshaft in the vee blocks at journals
.9369/. 9317 None adjacent to the bushing location.
.9420/.9425 64874
8-56. CONNECTING ROD BUSHINGS. If the bushing
.9445/.9450 ST-210
in the small end of the connecting rod is worn beyond
.9470/.9475 64875
service limits, it can be replaced in the following
.9495/.9500 ST-211
manner.
.9520/.9525 64876
8-57. Clamp the connecting rod on the connecting rod
8-53. Determine the oversize reamer needed and as- bushing replacement block(64597) in such a manner
semble the reaming fixture ST-280 over the crank- that the smallbushing in the rod is in alignment with
shaft lug. Selectthe two openingsin the fixture to line the hole stamped "Remove Bushing". Using the con-
up with bushing holes and install the plugs provided to necting rod bushing removal drift (64535), drive the
line up the holes in the fixture with the holes in the bushing out of the rod. Move the connecting rod to the
crankshaft lugs. Secure the fixture by tightening the "Installand Burnish" position and clamp it securely in
set screws. See figure 8-19. Assemblethe reamer to place. Using.the replacement drift (64536), drive the
new bushing into place in the rod. Locate bushing so
a suitable brace and proceed to hand ream the hole in
the crankshaft lug to proper size, that splitis towardthe piston end of the rodand 45" off
the center line.
8- 54. Assemble the puller to the crankshaft in the same
8-58. Use a suitable arbor press and the connecting
manner as describedin paragraph 8-51, except thatthe
large puller bushing is used instead of small puller rod bushing burnisher (64580) to burnish the bushing
bushing. Place the correct size crankshaft lug and the in place. Pass the burnisher completely through the
large pullerbushing. When the pullernut is tightened, bushing. Remove the rod from the holding block and
the bushing willbe forced into placein the crankshaft. finish bore the bushing to the diameter shown in ref-
erence 510, Table of Limits. Check the bushing ID
CAUTION with finish II) gage (64767). Check alignment of the
The inside diameter of these bushings is hole in bushingwith the connecting rod parallelism and
finished at the factory and no further ma- squareness gage as described in paragraphs 8-38 and
8-39. If the assembly does not meet the requirements
chining of the bushing is necessary. Cau-
tion must be exercisedwhen installing the shown in reference 556 and 567, Table of Limits, the
entire assembly must be replaced.
bushings so that this finished ID is not
damaged. Because of possible damage to
REASSEMBLY
the crankshaft, never, under any circum-
stances, remove or install the roller 8-59. CRANKSHAFT. (TIO-541). (2, figure 8-3). If the
bushings by use of a drift. expansion plug was removed install a new plug in the
8-55. After the bushing is installed, check its align- following manner: Use the crankshaft welch plug driver
ment with the main bearings by placing the crank- (64681) to drive the plug in place with the convex side
shaft in vee blocks on a surface plate. Install~the wedge towardthe front. Be sure the plug seats firmly against
the shoulder provided the ID of the crankshaft.
blocks, Tool No. ST-212, in the bushing and compare on
8-11
sactlon s OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Cr´•nkca´•e,Crankshaft,
and Acca´•aory Drives
678 9 10
3 5
I
2
I1 !T~´•-4 Q~
´•4
sc
;s,
O
’PR\~i)´•
t.´•
~1
d a
16
f 15 14 13
12
19 18 17
1. Dowel 6. Starter slip coupling 11. Retaining plate studs 16. Bendix drive shaft
2. Starter drive housing 7. Thrust washer 12. Retaining plate 17. Thrust washer
3. Starter idler gear shaft 8. Bushing 13. Slip coupling gear 18. Dowel
4. Woodruff key 9. Starter idler gear 14. Slip coupling assy. 19. Dowels
5. Starter slip coupling 10. Starter 15. Pin
Figure 8-13. Starter Drive Adapter Assembly (TlGO-541)
8-60. If the propeller nange bushings have been re- installing thewashers and retaining rings on the other
moved from the crankshaft, new bushings must be inside of the counterweight.
stalled. Use the crankshaft flange bushing replacement
tool (ST-115) to installthe new bushings. See figure NOTE
8-3 for proper location of the bushings.
Washers are installed with the chamfered
8-61. See figure 8-3. Installthe crankshaft gear (12) side in toward the roller and the retaining
over the dowel on the shaft and secure with lockplate rings are inserted with the sharp edge
(14) and hex head bolts (15). outward (see figure &20) and the gap in
position shown in figure 8-21.
8-62. (TIGO-541). See figure 8-4. Assemble the crank-
shaft gear (11) over the dowel on the shaft and secure 8- 64. Insert one end of the counterweight retaining ring
with lockplate (12) and hex head bolts (14). gap gage(64892) between the ends of the counterweight
retaining ring. Make sure the gage is resting on the
8-63. (A11Models). Using identifying marks made on bottom of thegroove. The gage must pass between the
the various counterweight parts during disassembly, ends of the retaining ring and when rocked back and
match eachwasher with the proper seaton the counter- forth must clear the inside edge of the top of the re-
weight from which it was removed. Installwashers and taining ring. If the gage does NOT pass freely between
new retaining rings on one side of the caunterweight, the ends and underthe top of the ring, the ring is NOT
place the counterweight on its proper ear of the crank- seated properly. Be certain all rings are properly
shaft, insert the rollers, and secure the assembly by seated.
12
7 8 9
4 5 6
3
I
1
I
16 i5 14
1. Alternator drive gear 5. Alter’nator drive adapter 9. Alternator drive coupling 13. Cotter pins
2. Thrust washer 6. Gasket 10. Slotted sheer nut 14. "0" ring
3. "0’’ ring 7. Alternator adapter 11. Drive coupling adapter 15. Bushing
4. "0" ring 8. Gasket 12. Alternator 16. Dowel
Figure 8-14. Alternator Drive Assembly (TIGO-541)
8-12
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES section s
Cr~nkcate.Cranksh´•tt.
NOTE
Connecting rods are marked at manufac-

ture with the part number followed by a
letter (A through E) designating weight
groups. It is recommended that replace-
ment sets of rods be of the same weight
classification. Individualrods may be re-
a
placed by a service rod bearing the letter
t-c,
8-66. Place the crankshaft on a suitable support on
bench so that all crankpins are free for installation of
CONNECTING ROD BEARING BORE

SHOWING SEVERE GALLING
Figure 8-15. Connecting Rod Showing Damage

by Galling
~L,
8-85. Assemble two new connecting rod bolts in each
connecting rod cap and install new bearing inserts in
the connecting rods and connecting rod caps, ma~ng
sure the tang on each bearing insert enters locating
slot in cap and connecting rod. Assemble each con- E~ IIE~L L2
necting rod assembly after installing inserts; tighten

bolt nuts moderately tight. Measure the ID of each
bearing and check for clearance against measurements
taken previously on diameter of crankpin journals.
rt
2 ´•---1
2 1
4 1. Parallel blocks 2. Check points
Figure 8-17. Checking Squareness of Connecting Rod
connecting rods. Disassemble connecting rods after

checking bearing ID, thoroughly coat both the inserts
and the crankpjn journals with preservative oil, and
assemble rods on their respective crankpins. The
order of assembly should be such that the numbers
stamped on the caps and on the rods will be down
(toward sump).
8-67. Using a socket wrench, alternately tighten the

connecting rod nuts and check rod bolt stretch with the
stretchboltgage (64945). Continue totightenuntilbolts
are stretched to 2.25512.256 inches. If the stretch
limit of 2.256 inch is exceeded, the connecting rod
bolt must be replaced. Check the connecting rod side
clearance according to Table of Limits.
3 8-68. CAMSHAFT. (TIO-541). See figure 8-3. As-

semble propeller governor drive gear (23) and secure
4. Arbor with circlips (27). Assemble camshaft gear (18) and
1. Tapered sleeve
2. Tapered sleeve 5. Gage arm secure with lockplate (17) and hes head bolts (15).
3. Arbor 6. Adjusting screw
7. Wing nut 8-69. (TIGO-541). See figure 8-4. Assemble camshaft

gear (17) and secure with lockplate (16) and hes head
Figure 8-16. Checking Parallelism of Conn. Rod bolts (15).
8-13
secticn s OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Crankca´•e, Crankshaft.
PLUGS SET SCREW
8-70. CRANKCASE. (A11Models). Applythreadlubri-

cant and install those plugs which were removed to
facilitate cleaningthe oilpassages. InstalIpiston coo2-
ing jets and tighten to specifiedtorque. Reference 857,
Table of Limits.
8-71. Install new main bearing inserts for allmain IP,$b

bearings in both crankcase halves, being sure that the
tang on each bearing insert fits into the slot in the
crankcase. Bolt crankcase halves together tempor-
arily and measure the ID of each main bearing formed
by the inserts. Checkthe clearances with the measure-
ments previouslytaken on the journals. Also measure
the ID of camshaft bearings formed by camshaft
esacgniraeb
bore and check the clearanceswith the measurements
previously taken on the journals. Separate the crank-
halves.
8-72. (TIO-541). Place both crankcase halves on a

suitable support with interior of each facing upward.
Place new main bearinginserts in the center and rear
COUNTERWEIGHT COUNTERWEIGHT EAR WITH PLUGS IN PLACE TIGHTEN SET SCREW

ROLLER BUSHING ON CRAfJKSHAFT Figure 8-19. Reaming Fixture Assembled
to Crankshaft
surface of allforeign matter with Methyl- Ethyl Ketone,

Acetone, Napasco SC-200, M17 or M114 solvent.
ZI
8-74. Apply a thin film of Lubriko M-6 grease (or
-r
I equivalent) on the sealing surface df the seal and around
I O the crankshaft at the sealing surface.
_L
_1 -I V 1 8- 75. Slipthe sealaround the crankshaftwith the seal-
ing Zip toward the crankcase recess.
8-76. Clean the outsidediameterof the crankshaft seal
4 3 2 with solvent to remove any grease film. Apply Goodyear
PIiobond No. 20 or Dow Coming Silastic No. 140 to
the outside diameter and the split.
COUNTERWEIGHT BUSHING PULLER
1. Puller bolt 3. Puller removal bushing

2. Puller plate 4. Puller nut
WASHER
Figure 8-18. Removal of Counterweight
Bushing from Crankshaft
main bearings of both crankcase halves, making cer-

tain that the tang of each insert is fitted into the recess
provided in the crankcase. Place the front main bearing
temporarily in position in the right crankcase half. Be ASSEMBLE
sure that insert is properly located. Using a sharp pen-
cil, trace on the bearing both lines of intersection be-
tween the crankcase parting flanges and the bearing.
Also make a verticalreference markon both the bear-
ing and the crankcase at any convenient point along the
line of intersection, thus locating the bearing both
radially and axially. These marks are necessary to
ensure proper seating of the bearing halves when
positioning crankshaft in the crankcase.
8-73. CrankshaftOilSeal (TIO´• 541) Clean thoroughly Figure 8-20. Assembly of Circlip
oilseal recess in crankcase and crankshaft sealing Counterweight
8-14
Crankcasc. Crankshatt.
.901 MINIMUM DISTANCE FROM
gear (10) over the shaft, secure with circlip (9). As-
TO OPPOSITE
semble the fuelpump drive gear (11), thrust washer
.222 MINIMUM GAP7 (12) intothe opening in the case and secure on the out-
side of the case with the circlip (9). Assemble the
breather slinger gear (21), thrust washer (12) breather
shield(19), second thrust washer on the breather gear
shaft(6). Installthe assembly through the opening in
the case, assemble slotted shear nut (18) tighten and
secure with cotter pin (17). Install the hydraulic and
vacuum pump drive shaft (8), accessory idler gear (16

and intermediate accessory drive gear (7).
8-81. Coat the main bearingjournals of the crankshaft

and the main bearing inserts with the mixture described
in paragraph 3-39 and assemble the inserts. Pick up
the crankshaft by numbers one and five connecting rods
ASSEMBLE CIRCUPS WITH cAP

POSITIONED AS SHOWN TIMING GEAR
Figure 8-21. Location of Gap When Installing

Retaining Rings
8-77. Place the right crankcase half on a suitable sup- 1111 B?Y\
port on the benchwith the cylinder mounting pads down.
8-78. See figure 8-5. (TIO-541). Place the governor

driven gear (3) inits recess in the housing. Insertthe ALIGN TIFXj MARKS
idler gear shaft (4) throughthe opening in the case and AS SH~NN WHEN IN-
STALLING CAMYIWT
assemble the idler gear (2) and thrustwasher (1). Note
OOGEAR
that the thrust washeris a selectivefit. Assemble the
gasket (5), plug(6) and secure with lockwire.’
8-79. Place the crankshaft in the right crankcase half

with the sealin its recess so the split will be in the
1 o’clock position. Now install the left crankcase half
in place. Work the seal for final seating by using both
hands, starting opposite the gap and working toward o~o
the gap.
8-80. See figure 8-6. Assemble the fuel pump idler

gear shaft (14), lockplate (3) and secure with hex head
bolts (15). Assemble the thrust washer (12) and idler
CAMSHAFT GEAR
L’
oCS~ Figure 8-23. Alignment of Timing Marks
and lower the shaft into the right crankcase half, per-
mitting rods 2, 4 and 6 to pass through their respec-
tive cylinder mounting pads. Using the reference marks
previously made, adjust the main bearings.
8-82. See figure 8-22. If either the crankcase or

crankshaft has been replaced, the end clearance of the
crankshaftin the crankcase mustbe checked. Pushthe
crankshaft as far front as possible and check the clear-
ance at the rear of the front main bearihg surface be-
t~aeen the crankcase and crankshaIt shoulder. If clear-
/n\ ance is evident between the crankcase and crankshaft
shoulder (see point "A"), regrind the front face of the
Figure 8-22. Crankshaft End Clearance Check crankshaft slinger (point "B") to remove the clear-
8-15
section e OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Crankc´•K. Crankshaft.
ance. Grind only that amount from the face of the a suitable press, press the sealinto the thrust bear-
slinger to remove clearance, ing cap(5). The seal should be locatedwith the twin
lip side down.
8-83. (TIGO-541). See figure 8-8. Reassemble the
accessory drive gears in the reverse order of dis- e.Apply Anolith No. 2, Shell Alvania No. 2, or
equivalent to the inside surface ofthe propeller

assembly. Consult figure 8-7.
shaft seal (4) and the outside surface of propeller
8-84. Assemble the two halves of the cranltcase to- shaft (2). Stand the shaft on the flange, and place
gether with three, 1/2-20 thru studs. One at top and the thrust bearing cap and seal on shaft and slide
two atbottom of bearingbore. Tighten 300 inchpounds toward the propeller nange. In this position the two
torque. Also, secure the rear of the crankcase with
lips of the seal are facing up.
several 1/4-20 bolts; tighten these to 40 inch pounds
torque. previously prepared
f. install the shim (6), on the
propeller shaft.
a. Place thrust bearing (8) in thrust bearing bore
with the filling slot toward the rear of the crank- g. Install slinger (7) with chamfered side of hole
case; be sure it is tight against the seat. toward propeller shaft Range.
b. Place the thrust bearing cap(5) on the mounting h. Liberally pre-oil the bearing (8) with 600W or
studs and hold in place with two or three 3/8-16 SAE No. 50 engine oil around the inside surface of
nuts, finger tight so cap is against the bearing. the races and then install on propeller shaft with the
filling slot facing upward.
c. The amount of pinch, orpressure erected on the
bearing is controlled by the thickness of the shim.
i. Installbrass cone (9) with slot in line with keyway
This is accom plished as follows: Measure the clear-
of the propeller shaft.
ance between the crankcase and the thrust bearing
cap with a thickness gage. The clearance minus j. Install gear (10) with lockwire hole pointing up-
.003/. 005 is the thickness for the new shim (6) when ward and in line with keyway of the propeller shaft.
installed. The thickness of the shim is reduced by
k Lubricate propeller shaft threads with Parker
peeling off laminations; each lamination is .002 inch
thick. Threadlube or equivalent.
d. Apply a liberal amount of engine oil to the outside i. Lubricate the split cone (11) on outside surface
diameter of the double lip front oilseal (4) and with and install on propeller shaft.
TH TIGHTEN ON LEFT SIDE ONLY
4TH TIGHTEN ON BOTH SIDES

2ND TIGHTEN ON BOTH SIDES
IST TIGHTEN ON BOTH SIDES
ill--fco ~-3RD TK;HTEN ON RIGHT

SIDE ONLY
IO>--h. I
or o~ 16/ O
or 1~ ol lo o
o O/ \O 0/
O O _o
7TH TIGHTfN 3/8 IN.

NUT ~3) Q
6TH TIGHTEN THRU-STUDS ~THRU O BTH TIGHTEN THESE FASTENINGS IN THE

ON BOTH SIDES IN SEQUENCE AS INDICATED SEQUENCE INDICATED.- SEQUENCE IS
OPTIONAL FOR ALL OTHERS
Figure 8-24. Crankcase Tightening Sequence (TIGO-541)
8-18
Crankcase. Crankrh´•tt.
TH
2ND
TIGHTEN ON NUTS ON
BOTH SIDES BOTH SIDES AT SAME TIME
TIGHTEN ON
BOTH SIDES 1ST
TIGHTEN NUTS ON TIGHTEN OH
SIDES AT SAME TIME
RIGHT SIDE ONLY
10 t
7TH
TIGHTEN THESE FASTENINGS
QTn
IN ME SEQUENCE INDICATED-
TIGHTEN ON
LEFT SIDE ONLY SEQUENCE OPTIONAL FOR ALL
OTHER CRANI<CASE-
FASTENINGS.
Figure 8-25. Crankcase Tightening Sequence (TIO-541)
m. Install propeller shaft nut (12) on shaft, tighten timing markbetween the two markedteeth on the cam-
with finger keepingthe spacing of cone equal on both shaft gear. See figure 8-23. Check the end clearance
sides of shaft. of the camshaft. (See Table of Limits).
n. Install propeller shaft on ST-329 fixture (pro- 8-86. Coat the outer mating surface of each crank-
poller shaftlocknut assembly) and tighten propeller case half with a thin film of non-hardening gasket
shaft nut to 1000 foot pounds torque. compound. T~e compound, which is used only to pre-
vent leakage of oil to the outside of the engine, must
o. Set propeller shaft assembly inv-blocks located not be to any of the interior mating surfaces
applied
at the thrust bearing and at other end of propeller such the bearing support webs. Next, imbed a length
as
shaft. Place 1/4 inch diameter length of drill rod of "00" silk thread in the gasket compound along the
between the gear teeth; check run-out of the gear outside edge of crankcase half. Run thread so that it
at about 6 places. Allowable run-out of the gear is is on both sides of bolt hole without touching each other.
~t.001 inch (.002 total indicated reading). If the
run-out of the gear is notwithin the limits of .001, 8-87. Install the "0" rings (21, figure 8-1 or 15, fig-
loosen propeller shaft nut and rotate split cone ure 8-2). Lower the left half of the crankcase care-
AN-5007-20, 900. Retorque propeller shaft nut and fully so that the studs align properly with the right
recheck run-out. Repeat untilthe run-out is within half. If necessary, tap the left half gently with a soft
the limits, hammer to facilitate assembly. However, no difficulty
will be encountered if the two halves are kept parallel
p. Safety wire propeller shaft nut (12) to gear (10).
while the left is being lowered onto the right. After
NOTE the cases are together, tap the right half with a soft
hammer to seat it securely all around.
Lubricate propeller shaft thrust bearing 8- 88. Assemble the crankshaft oil seal retaining plates
with a liberal amount of 600W type lubri- (where applicable) (17, figure 8-1) and secure with
cant or engine oil before installing in the
capscrews.
crankcase.
8-85. (All Models). Coatcamshaftas directedinpara- 8-89. There is a definite sequence that must be fol-
graph 3-37 through 3-39. Install the camshaft in the lowed when tightening the fastenings of the crankcase
right crankcase half positioning the crankshaft gear halves.
8-17
s~ctlon s OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
Cr´•nkc´•´•~, Cr´•nk´•h´•tt,
´•nd Acce´•rory Drlv~´•
8-90. In the integral accessory drive models, one pair 8-101. See figure 8-1. Assemble the oil relief valve
of half-inch thru-studs on each cylinder pad las well assembly (1 or 26), the oil filler extension (7 or 8) and
as additional thru-studs at both front and rear of the the dip stick (5 or 6). Assemble engine mounts, lifting
crankcase) are not securedby screw-threads; instead, eyes (9 or 10) andlifting strap (19).
the center of each stud serves as a dowel to insure
crankcase alignment at the bearing webs, while the
threaded ends of the studs protrude through the cyl-
8-102. (TIGO-541). See figure 8-2. Assemble the oil
bypass valve housing assembly (10), oil pressure re-
fnder mounting pads of the crankcase for attaching the
lief valve assembly (11) and install. Install the oil
cylinders. Consequently, each of these studs as in- filler tube (5) and the dip stick(8). Assemble the lifting
dlcated in figures 8-24 and 8-25 must be tightened at
strap (4) and engine mounts.
both ends, simultaneously,
8-103. See figure 8-10. Reassemblethe starter drive
NOTE
assembly in the reverse order of disassembly as
directed in paragraph 18. ConsultService Instruction
Before the tighteningprocedure is started,
No. 1242.
make sure allhalf-inch thru- studs are as-
sembled with equal lengths extending from
both sides of the crankcase. Also be sure 8-104. See figure 8-13. Reassembly of the starter
the threaded end of the half-inch thru-bolts drive adapter assembly. Fill 15~ of starter motor
extend through the side of the crankcase housingassembly with Molytex "O" Grease. Assemble
as indicated in figure 8-24 and 8-25. in the reverse of the disassembly.
8-91. Proceed to tighten fastenings in the following

8-105. Reassemble the thrust bearingpropeller shaft.
sequence.
Figure 8-11. Fill 50~6 of cavity near end of gear with
8-92. (TIGO-541). See figure 8-24. Installspacers or Loctite GradeA sealingcompound. Positionthe thrust
flat washers and nuts over the 1/2 inch thru-studs bearing rear race (7) squarely in gear cavity and drive
and tighten to 300 inch pounds torque in the sequence it in place untilseated. Lubricate the thrust bearing
indicated in figure 8-24. (6) with Molytex O Grease or 600W oil and place on
bearing seat (5). Install both thrust bearing and seat
8-93. In the same sequence tighten all 1/2 inch thru- into recess of crankcase. Temporarily install cover
studs to 600 inch pounds torque. (1) gently pressing against the cover to move the en-
tire assembly to the rear. Secure the cover with four
8-94. Tighten the balance of the crankcase fastenings nuts. Determine the shim by measuring
thickness
as directed in figure 8-24. clearance between cover and mounting pad with feeler
gage. Distance measured plug .007 inch will equal
8-95. (TIO-541). See figure 8-25. Install spacers or the shim thickness requiredto maintain.005/. 010 inch
fiat washers and nuts over the 1/2 inchthru-studs and ,,d clearance for gear and housing.
tighten to 300 inch pounds torque in the sequence in-
dfcated in figure 8-25.
Installoilringseal (2) in groove of cover. Coatboth
8-96. In the same sequence tighten all 1/2 inch thru- sides of shim and mating surfaces of cover and crank-
studs to 600 inch pounds torque. case with General Electric Corp. RTV-1O6 sealant.
Installoil sea! ring (3) in recess around dowel on cover.
8-97. Tighten the balance of the crankcase fastenings Place shim over dowel and second oil seal ring (3) on
as directed in figure 8-25. dowel. Install cover and shim on crankcase.
8-98. Note that the bolts securing the inside of the 8-106. See figure 8-14. Reassemble the alternator
halves are lockwired. drive assembly in the reverse order of disassembly
as shown in figure 8-14.
8-99. (TlGO-541).
The thrust bearing cap, both sides
of thebearing cap shim, and the mating surface of the NOTE
crankcase should be coated with POB (or equivalent)
before assembly. Apply Molytex Type "O" Grease to alterna-
tor drive coupling and the alternator drive
8-100. Assemble the ring gear and support assembly coupling adapter assembly before assem-
(1, figure 8-3) on the crankshaft flange. bly. Figure 8-14.
8-18
SECTION
TEST PROCEDU RE
Test Procedure
SECTION 9.
TEST PROCEDURE
of the engine after

assembly of 9-7. Engines equipped witha fuel pump shall be tested
g,l. At the completion
with a test stand fuel system terminating in a float
overhaul, it is recommendedthat the engine be mount-
ed upon a test stand for its initialer run-in operation. chamber vented to the atmosphere. The fuel level in
The run-in serves a twofold purpose; first, to seat this chamber shall be below the entrances to the fuel
piston rings and burnish any new parts that may have pump by at least one foot. The fuel pressure to the
been installed and second, to give the operator control chamber shall be maintained at 2 to 5 psi.
over the first critical hours of operation, during which

time he can observe the functioning of the engine by 9-8. Engines not equipped with a fuel pump shall be
means of the test cell instruments and observe and re-
tested with either a remote or installed representative
pair any oil leaks that may occur. fuelpump. The test stand fuel system for this type of
engine shallterminate in a float chamber vented to the
NOTE
atmosphere. Fuel pressure to the chamber shallbe
maintained at 2 to 5 psi.
Avco Lycoming recommends that a test cell
be used for run-in of engines after over-
haul. In the event that a test cell is not 9-9. Any engine accessory drive, such as propeller
available, it is permissible to mount the governor drive, which transmits oil pressure through
oil passages in the engine andwhich is not pressurized
engine in the airframe for the run-in pro-
viding the following requirements are by normal operation of the engine on the test stand
observed, shall be checked for leakage at normal oil pressure by
means ofspecial drive cover with oil transfer pas-
a
1. The proper test club, not a flight pro-
required. The oil passages involved shall
as
sages
peller, is used. be inspected for external leaks at the completion of
the run.
2. A cooling shroud equivalentto a test cell
cooling shroud is installed.
9-10. It is desirable to have some method of main-
3. The airframe gages maynotbeused. All taining the oil temperature within the specified Limits
necessary calibrated gages shall be instal- during the run-in.
led independent of the airframe.
9-11. The engine should be operatedduring the run-in
9-2. The following instruments should be used, plus with ashless dispersant lubricating oil conforming to
any additional instruments that may be deemed nec- specification MIL-L-22851. The oil should be heated
essary bythe operator. Cylinder headthermocouples, to 1400 F. minimum before starting the run-in schedule.
counter tachometer, fuel flow meter, fuel pressure
gage, manifold pressure gage, oil temperature gage,
9- 12. If the engine is not to be installed in the airframe
oilpressure gage and an oil flow measuring device.
immediately, the engine should be pre served as directed
i" Section 10.
9-3. The test stand should be installed in a test cell
that is clean and free of any articles that could be
moved by the test club air blast.
9-13. Fuel shall conform to specifications. The speci-
fled fuel for this series engine is 100/130 minimum
9-4. Test stand oil supply pressure to engines which octane aviation grade gasoline.
can be run simulatedwet sump shall be held to 1. 5-2. 0
psi throughoutthe test. Test stand oilsupply pressure 9-14. Attach the instrument connections and install
to engines tested simulateddry sump shallbe held be-
,il and fuel lines. Connect throttle and mixture con-
tween 0. 5-3. 0 psi at rated conditions, trol levers to the stand controls. Be sure the cables
are free and not binding and that the travel is suffi-
9-5. Engines equipped with an integral, fullflow, oil
ciently long enough to completely open and close the
filter, should be tested with a slave filter assembly throttle andto move the mixture controlfrom full rich
and the regular filter installed at the end of the run. to idle cut-off.
9- 6. Also, a slave filter should be installedbetween the

oil supply hose and the turbocharger oil inlet. This 9-15. Install cooling shroud (ST-164), test club(64803)
slave filter shall have a particle filtering capability of and adapter (64981) on TIO-541series. Install cooling
100 microns or less and have a pressure relief valve shroud (ST-164), test club (ST-241) and adapter (ST-
set to 15-18 psi differential. This will insure that no 242) on TIGO-541series. Be certain the test club will
metal particles are carried from the engine to the turn up rated RPM 50 at limiting manifoldpressure.
turbocharger lubrication system. See Table 9-1.
9-1
s.ctlon 9 OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES
T´•´•t Proc´•dura
TABLE 9-1
ENGINE RUN-IN TEST SPECIFICATIONS
Max. Cyl.
Fuel Pressure Fuel Minimum Head Temp.
psi at inlet Octane Rating Bayonet Rated Engine Limiting Manifold
to injector Aviation Grade Location "F. Speed RPM Pressure
541-A 33- 37 100/130 475 2575 37 in, hg.

541-E 33-37 100/130 475 2900 41 in. hg.
541-C 33-37 100/130 475 3200 42. 5 in. hg.
541-D 33-37 100/130 415 1 3200 46. 5 in. hg.
GO-541-E 33-31 100/130 415 3200 45 in, hg.
ENGINE RUN-IN SPECIFICATIONS (CONT.
Maximum Oil Oil Pressure

Consumption Operating- psi Oil Inlet Oil Outlet*
Temp. Temp.
Lbs. /Hr. &t. /Hr. Normal Idle OF. OF.
541-A 2. 0 1. 1 70- 79 1 25 190- 245 210-230

O-541-E 2. 0 i. 1 70-79 25 190- 245 210-230
GO- 541-C 2. 0 1. 1 70-79 25 190-245 210-230
GO-541-D 2. 0 1. 1 70- 79 25 190-245 210-230
GO- 541-E 2. 0 1. 1 70- 79 1 25 190-245 210-230
Desired during oil consumption run.
9-16. It is desirable to keep a log sheet and record the d, Turn magneto switchto "left" and engage starter.
instrument readings during each speed of the run-in Turn combination magneto- starter switches to "start".
schedule. See Table 9-2. e. When engine fires, move mixture to full rich.
9- 17. Before starting be certain that the magneto switch
f. Move magneto switch to "both", combination
is in the "off" position. Turn the engine over a few
spring loaded switches will return to "both".
revolutions to ascertain that no interference elrists
within the are of the test club or within the engine itself. CAUTION
If it does not turn freely, do not try to force it or at-
If oil pressure is not indicated within ten
tempt to start untilthe cause has been determined and
the fault corrected.
seconds, stop engine and determine cause.
9-19. Operate engine at approximately 1000 RPM until
9-18. TEST RUN. Start the enginein accordance with
oil temperature of 145"F. is obtained. Check magneto
the following procedures, drop off and general operation of the engine. Check the
a. Place mixture control in idle cut-off. engine for obvious oil leaks. Any malfunction or oil
leak should fw! remedied before continuing the run.
b. Turn fuel valve to "on" position. 9-20. Complete the run in accordancewith the sched-
c. Set throttle at 1/10 open position, ule listed in Table 9-2.
TABLE 9-2
RECOMMENDED RUN-Ri SCHEDUI~E
RPM LOAD TIME
1000 Prop. Load 10 Check for oil leaks.

1800 Prop. Load 10
1800 Prop. Load 10
2000 Prop. Load 10 Check magneto drop-off. Do n
2200 Prop. Load 10 exceed 125 RPM on either mag
2400 Prop. Load 10 or 35 RPM between mags.
Rated ~t50 Limiting Manifold 15

ee Remarks Prop. Load 15 Stabilization run.
See Remarks Prop. Load 30- 60 Oil consumption run.

Rated 2575 Operate 2575
Rated 2900 Operate 2700
Rated 3200 rate 2850
9-2
ENGINES
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT
Section 9
Test Procedure
9-21. OIL CONSUMPTION RUN. An oil consumption ing the succeeding steps, readjust the idle speed ad-
schedule, justment to restore the desired RPM.
run should be made at the end of the run-in
This can be accomplished by the use of a scale tank
9-24. When the idle speed has been stabilized, move
through which the oil lines pass and the scale reading
the mixture control lever with a smooth, steady pull
taken at the beginning and end of the oil consumption
into the "Idle Cut-Off" position and observe the tach-
run. Or itcan be accomplishedby drainingand weigh-
ometer for any change during the leaning process.
ing the oil in the supply tank before the oil consumption
the oil in thesupply tank Caution must be exercised to return the mixture con-
run and draining andweighing
at the end of the oil consumption run. Oil temperatures trol to the "FULL RICH" position before the RPM can
should be the same at the beginning and end of the oil drop to a pointwhere the engine cuts out. An increase
of more than 50 RPM while "leaning out" indicates an
consumption run. Oil consumption should not exceed
the maximum as listed in Table 9-1. excessively rich idle mixture. An immediate decrease
in RPM (if not preceded by a momentary increase) in-
dicates the idle mixture is too lean.
9-22. OIL PRESSURE RELIEFVALVE. Theoil pres-
sure relief valve, located in the crankcase just
for-
9-25. If it is indicated that the mixture is either too
ward of the fuelpump drive, is adjustable. This allows rich or too lean, turn the idle mixture adjustment one
the operator to maintain oilpressure within the speci- two notches in the direction required for correction.
fiedlimits. Tables-I. Ifthepressureis lessorgreat- Check this setting by repeating the above procedure.
er than specified, adjust the valve as follows. Stop Each time the adjustment is changed, the engine should
the engine, remove the oil pressure relief cap and b,,,.p to 2000 RPM to clear the engine before pro-
adjustthe adjustingscrew. Tighten to increase, loosen
ceeding with the RPM check Make final adjustment
to decrease pressure. Select spring to give a minimum of the idlespeed adjustment to obtain the desired idling
of three threads exposed on adjusting screw to allow RPM with closed throttle. The above method aims at a
field adjustment. setting that will obtain maximum RPM with minimum
manifoldpressure. In case the setting does not remain
9-23. IDLE SPEED ANI~ MMT~RE ADJ~STMENT. stable, check the idle linkage; any looseness in this
linkage would cause erratic idling.
With engine thoroughly warmed up, check magnetos
in the usualmanner. If the drop-off is excessive, check
for fouled spark plugs. If drop-off is normal, proceed 9-26. In the eventthat the engine is not to be installed
in the airframe at the end of the run-in, it should he
with idle adjustment. Close the throttle to idle at ap-
prepared for storage shipment as described in
proximately 600 RPM. If the RPMincreases appreci-
or
the idle mixture adjustment dur- Section 10.

ably after a change in
9-3
SECTION
PRESE RVATION AN D
STORAGE
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES section to
Preservlltlon end Stor´•go
SECTION 10.
PRESERVATION AND STORAGE
10-1. Overhauled engines, not destined to be imme- 10-9. Reinstall the spark plugs in the lower spark
diately installed in an airframe, should undergo the plug holes and dehydrator plugs (Avco Lycoming P/N
run-in period using the recommended oil as directed 40238 or equivalent) in the upper spark plug holes.
in Section 9. Attach the ignition harness at the bottom locations and
have ignition cable protectors, AN-4060, on the top
10-2. Before removalfrom the stand, the engine should location.
be further protectedagainst corrosionin the following
manner. NOTE
Dehydrator plugs do not remove moisture

10-3. Upon completion of the test run, drain the oil from theengine. The changing colorof the
from the engine. Remove bottom spark plug from
dehydrator plug indicates only that mois-
each cylinder. Fill engine completely with a 1 to 1 ture is present and remedial steps must be
mixture of MIL-C-6529 Type 1 and ISOPAR "M" or taken.
equivalent until oilnows from breather fitting. With
engine full of oil, slowly turn propeller through two
complete revolutions. Let engine stand with oil ten 10- 10. MTERIORSURFACES AND ACCESSORIES. All
minutes, after which the propeller shall be recited exposedcadmium platedand machined surfaces should
back and forth through 90" for 12 cycles. Drain pre- be coated with soft film corrosion- preventive com-
servation oil from the engine, pound MIL-C-16173 Grade 2. Any other accessories
or parts not attached to the engine must be protected
NOTE by dippingthe part in preservative oil. It mustthen be

drainedand wrappedin grease-proof paper. This pro-
Preservative oil drained from the engine cedure applies to spark plugs and electrical com-
may be saved and returned to the tank for ponents, except they are not to be dipped in the pre-
reuse. servative oil.
10-11. The above procedures do not preserve the en-

10-4. Without turning the engine, spray each cylinder
gine for extended periods. The engine should be ex-
with an airless spray gun, Spraying System Company amined periodically for evidence of corrosion. The
"Gunjet" model 24A-8395 or equivalent through the time between examinations will vary depending. on
spark plug holes with MIL-C-6529 oil Type 1. weather, locality and storage conditions. If corrosion
is in evidence, the engine should be cleaned free of
NOTE corrosion and represerved.
Do not turn engine crankshaft after treat-

ment as stated in paragraph 10-3. 10-12. Also, if the internal parts of the engine should
be accidentally turned, represervation is required at
once.
10-5. For all spraying the spray nozzle temperature
shall be maintained between 2000F. and 220"F.
10-13. FUEL INJECTORS. (Removed from engine).
Any unit taken out of service, or those units being re-
10- 6. Spray each cylinder through the spark plug holes
turned foroverhaul, must be flushed with a preserva-
with MIL-C-6529 Type 1 oil. Seal all openings with
grade oil (Mii-O-6081Grade 1010). This is ac-
tive
suitable covers.
complished by the following procedure:
10-7. All accessory drives for which oil seals are a. Remove all plugs and drain all fuel from the
provided shall be liberally coated with MIL-C-6529 injector.
Type 1 oil before installing the drive covers.
b. Replace allplugs and pour approximately one
10-8. The fuel injectors shouldbe emptied of fuel and ounce of flushing oil into the fuel inlet fitting and
flushed with oil, MILO-6081, grade 1010. During rock to cover all the interior surfaces.
flushing, the oilpressure applied to the fuel passage
shall not exceed eight pounds’per square inch. Under c. Installsuitable shippingplug onallfittings. Lock
no circumstances shall the regulator air chambers, the throttle in the closed position.
air passages or automatic mixture control be flushed
with oil; these must be kept dry at all times. Drain d. The injector should be protected from dust and
excess oil and replace the plugs. Lock the throttle in dirt and given such protection against moisture as
the closed position, the climate conditions require.
10-1
ENGINES
section to OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT
Preservation and Storage
10-14. SALT WATER PRESERVATION OF FUEL IN- b. Pack in a sealed, dust-proof container, and wrap
JECTORS. If any of the units are to be shipped over container with moisture and vapor-proof material
or stored near salt water, the following precautions
and seal. Pack a one-half pound bag of silica-gel
should be observed. crystals in the dust-proof container along with the
injector. The bag must NOT touch the injector. Pack
a. Spray the exterior of the injector with an approved the wrapped unit in a suitable shipping case.
preservative oil, Socony MobilOil, Avrex 901or
equivalent.
10-2
SECTION
TABLE OF LINIITS
SECTION 11
TABLE OF LIMITS
This section of the manual has been reserved for the

Special Service Publication No. SSP-1776 Part II, Table of
Limits and Tightening Torque Recommendations.
Upon receipt of the owner’s registration card, attached

in the front of this manual, at Avco Lycoming, a copy of
the Special Service Publication SSP-1776 Part II ~iill be
forwarded to the registered owner.
The SSP-1776 Part II should then be inserted in the

manual at this location.
Also, the return of the registration card will assure the

owner that for period of three (3) years all future revi-
a
sions to this publication and the Table of Limits will

automatically be forwarded.
Revised May, 1980

INTRODUCTION
SERVICE TABLE OF LIMITS
This Table of Ilmits Is provided to serve as a guide to 9 service and maintenance personnel engaged in the repair and
overhaul of Avco Lycoming Aircraft Engines. Much of the material herein contained is subject to revision; therefore, if my
doubt exists regarding a specific limit or the incorporation of limits shown, an inquiry should be addressed to the Avco
Lycoming factory for clarification.
DEFINITICNS:
Ref. (Ist column) The nunbers 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.
Ref. (2nd column) Indicates the old reference number. There are no diagrams in this manual for
these numbers. Tbese numbers are only to be found in previous publications.
~hart(lrdedumn) The letter letter and number in this column are used as symbols to designate
or
engine models to which the specific limits is applicable. A list of the letter or
letter and number and the engine to which they refer is shown below.
Nomenclature (461 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.
Mmensions (561 661 columns) The dimensions shown in cdumn 5 are the minimum and maximum dimensions
for the part as manufactured. The dimensions shown in column 6 indicate the
limit that must not be exceeded. Unless it can be restored to serviceable size, any
part that exceeds this dimension must not be rebuilt into an engine.
Clearance (7dr 8th columns) Iike the dimensions shown in the 5th and 661 columns, the clearance represents
the 6t 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 dimenional data has
been deleted from the list; proirided compliance with the change is not mandatory.
]Letters of the alphabet and numbers are used as symbols throughout the Table of Limits to represent specific
interpretationsand to designate engine models. lattersin parenthesis refer to dimensional characteristics; letters (or
combinations of letters and numbes) without parenthesis indicate engine models. They are listed below with their separate
definitions
(A) These fits either shrink 6ts controlled by machining, 6ts that may readily be
are
adjusted, fits
or where wear does not normally occur. In each case, the fit must
be held to manufacturhrg tolerance.
(6) 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.
(6) Permissible wear of the crankshaft (rod and main bearing journals) to be minus
0.0015 on the diameter.
(L) ~Loose fit; wherein II definite dearance is mentioned between the mating
surfaces.
(T) Tight fit; shrink or interference fit.
(WD) Wide Deck Crankcase.

Introduction
The Illustrations shown aretypical of the referenced limit or fit described in the Table and in no instance are these
lustra#ons intended to represent a specific part or e~ne model unless specified. Also, the terms used to designate cylinder,
piston and ring materials such as ’hitride, chrome, halt-wedge" are more fully explained in the latest edition of Service
Instnrction No. 1081.
LDERVICE TABLE OF LIMITS
PART II INTEGRAL ACCESSORY DRIVE ENGINES
CHART MODELS
AQ TIO0541
AZ ’iIGO-541
SECTION r 500 SERIES CRANKCASE, CRANKSHAFT 6 CAMSHAFT
SECTION II 600 SERIES CYLINDERS
SECTION liI 700 SERIES GEAR TRAIN
SECTION IV 800 SERIES BACKLASH (GEAR TRAIN)
SECTION V 900 SERIES TORQUE AND SPRINGS
(A) These fits are either shrink fits controlled by machining, 6ts that may readily be
adjusted, or fits where wear does not normally occur. In each case, the 6t must
be held to manufacturing tolerance.
Side clearance piston rings must be measured with face of ring flush with
(6) on
piston
(D) The dimensions shown are measured at the bottom of the piston skirt It right
angles to the piston pin.
Permissible of the crankshaft (rod and main bearing journals) to be minus

(E) wear
0.0015 on the diameter.
(L) Loose fit; wherein a definite clearance is mentioned between the mating
surfaces.
(7) TTght fit; shrink or interference fit.
~WD) Wide Deck Crankclrre.
SSP1776 July31,1979*
Indicates cut´•off date for data retrieved prior to publication.

BERVIOE TABLE OF LIMITB
SECTION I CRANKCASE, CRANKSHAFT, CAMSHAFT
Re!. Ikl. Chut Dfm´•ndona Ciaarancoa

Mh´•. Lbtr.
Nea Old ~din. 8av. Min. amv.
i Man. Lbu.
Mu. Man.
soo AQ Main Bearin~j and ~ankshatt

ii3i~ (Except Front) .0011L .0050L
iI1’ i
jiiiX AZ Main Bearings and Crankshaft .0011L
.0041L .0050L
~bi
AQ Front Main Bearings and .0021L~VYIIU
Crankshaft .0046L .0050L
:388 AQ-AZ Diameter of Main Bea~ing

idiil Journal on Crankshait 2.6245
(2-5/8 Main) ’2~626 (8)
AQ Diameter of Front Main
Bearing Journalon Cranhshaft 2.6240
(25/8 Main) 2.6250 (E)
500
´•.´•:.´•.´•~;I np.Az Crankcase
Diameter
Bearing Bore 2.9365
279375 2.9390
AQ-AZ Connecting Rod Bearing Ilnd 10008L

iiiiiii~ii Crankshaff .0038L .0050L
501
.;s. ;.i AZ
A8
AZ
Diameter of Connecting Rod
Journal on Crankshaft 72-1/8)
Diameter ot Connecting Rod

Journal on Cranlrshaft (’2-1/4)
2.1235
2.125
2.2485
2.250
(E)
(E)
Connecting Rod Bearing Bore
I~
Diameter ~2-1/8) (Measure at
Axis3000neachside)
Connecting Rod Bearing Bore
Diameter (2-114) (Me~sure at 2.4205
Axis 300 on each side) 2.;1210
502 II:~i: AQ-AZ Connecting Rod -Side Clearance

.010L .016L
503 AQ-AZ Connecting Rod Alignment .010 in 10 Inches
sea AQ-AZ Connecting Rod Twist .012 in 10 Inches
505 Crankshaft Run-Out At Center

Main Bearings
AZ 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

r


8821776
21
SERVIOE TABLE OF LIMITS
CRANKCASE, CRANKSHAFT, CAMSHAFT
Chut DtmePdona Cbnrnncaa

nai. aar.
Mfr. LLtr.
N´•W old Ldin. BQY. Llln. BcTv.
Yu. Yu.
sdu. LIu.
506 AQ (Cont.) Mounted on No. 3 and 5 Journals

Crankshaft and Crankcase .005L

AQ-AZ
506’’’ ’i s.,t~
Front End Clearance ~m6i; .026L
607 AQ Clearance Front Face of

´•;´•;´•.´•;i´• Crankshaft Oil Binger to
Front Face of Recess in
´•.´•.´•t.S´• Crankcase (Crankshaft .002
iS~ii5iii T67~ (A)
Against Thrust Face)
Cranbshaft Propeller Flange
Run-Out .005
Gear and .014T

Ring
Starter
i...... Support (A)
.002L
sie fjt~iigijl AP-AZ Crankshaft Timing Gear
(A)
and Crankshaft
.001
sil IliBs~SI’ ’ ZA-PA Tappet Body and Crankc~se
.004L
O.D. o~ Ta~pet .9990

A&´•AZ
iiiiI~iSi: ~IF5 .9987
AQ-AZ ID. Tappet Bore in

Crankc~se 1.0018
514
i:•´. :’ ZA•´Q Camsha[tandCrankc~se
.006L
.002G
gig 1:3~´•3 AQ-AZ Camsbaft -End Clearance
.009L .015L
´•;´•.´•;´•.´•I´•.´•
Camshaft Run-Out At Center .000

516 i61~ AQ-AZ .006
Bearing Journal
.0019T
517 AQ´•AZ Counterweight Bushing and
Cranksha& ~662mC (A)
.003L
5181/:619’ ~LP´•AZ CaunterweigbtRoller-End
Clearance ~625L- .038L
AQ-AZ Counterweight and Crankshaft-

Side Clearance (Me~sure Below .003L
Roller Next To Fiat) ~13f; .017L
i"-"’
Bore sad 0002L

Calmte.aeight
5201:~] AQdZ Washer O.D. (A)
~´•i´•I´•:´•
LI). Counterweight Bushing .7485
AQ´•AZ
.7505 .7512
iiiiiI~
.liiiiWt 1.030
AZ LD. Counterweight Bushing ~a52
(2nd Older)
""El~"" ´•.r.r.´•.´•.´•
(8ee latest edition of Service
Instruction No. 1012)
AZ ’Ihlust Bearing and Repeller .ooolL

shlt~t .oo12L .002L
88P1776
2-2
IERVICE TABLE OF LIMIT8
SECI~ION I CRANKCASE, CRANKSHAFT, CAMSHAFT
RI1. I 61sl. Chrrt Nnmanelatnre I Dimandona

MfI. ]Str.
Old Min. I 8av. I Min. &cnv.

Nea
Mu. Mu.
Wu. I I Mu.
and Rear .0015L

~ijii Propeller Shaft
5M
li: AZ
Bearing ~U030L .0040L
Propeller Shaft Bearing Bore 2.1865

Diameter 2.1815 2.1885
and Crank- 0006L

525 liiiii.iii~:ti51 AZ Thrust Bearing
case (A)
526 Az ?hlust Bearing and Thrust Bear-

ing Cap Clamp Fit (Shim to .003T
i~iliijiiri this Fit) .005T (A)
Thrust Bearing Tilt At 4 Foot .027 Tilt

527 AZ
528 AZ Thrust Bearing End may ,Ol)q~

.008 .010
Crankshaft and Crankshaft .0002T

529 I.~Sfj.24i.l Az
Front Bearing .0015T (A)
OIF-
1. a
o 1
Section Thru Prop. Shaft, Crankshaft and Front Bearings
SSP1776
2-3
IERVICE TAB~E OF LINIITS
PART I) INTEGRAL ACCESSORY DRIVE ENGINES
SECI~ION I CRANKCASE, CRANKSHAFT, CAMSHAFT
Connecting Rod, Coonterweigt~ts and Related Parts
8SP1776
24
SERVICE TABIE OF LIMITS
PART ii INTEGRAL ACCESSORY DRIVE ENGINES
SECITON I CRANKCASE, CRANKSHAFI~, CAMSHAFT
iii’
8 a 8
j~ij
I(c)i (:o
L~--?
i41,~
Longitudinal Section Thru Engine

SSP1776
25
QERVIOE TASLS OF LIMITS
SE~TION I CRANKCASE, CRANKSHAFT, CAMSHAET
501~
I’ f~ B ~ir O
aagllid:116~6
Connecting Rod Bearing, Tappet Body and Crankcase
SSP1776
26
L~ERVICE TABI.E OF IIMITS
SECTION II CYLINDERS
Chart Nomcncl´•t~m Dfmandola Claaranaa

Roi. Rei.
Mt~.
iLin. 8av. Lbln. BQv.
Norr OLd
i Llu. i arna.
Hu. Lbu.
600 Connecting Rod and Connecting Bushing To Be

Rod Bushing Burnished In Place
AQ-AZ Finished LD. of Connecting ~.1254

Rod Bushing 1.1262
Ii~ngth Between Connecting 6.7485

601
~i"" Rod Bearing Centers 6.7515
Connecting Rod Bushing and .0008L

soz AQ-Az
Piston Pin .0021L .0025L
Piston Pm and Piston .0003L

603 AQ´•AZ
.0014L .0018L
´•. ;´• .´• .: :. f13 AQ-AZ Diameter of Hston Pin

Hole in Piston
1.1249
1.1254
2~1:´•; .´• .´• ´• AQ-AZ Diameter of Hston Pin 1.1241

1.1246
Piston and Piston Pin Plug .0002L

AQ´•AZ
.0010L .002L
~It’ ’ "’ ’ AQ´•Az *Diameter of Piston Pin Rug 1.1242

1.1247
605 AQ-AZ Piston Pin and Piston Pin
.0005L
Plug Nitrided and Chrome
~ir .; . . ´•. Cylinders .0025L .005L
:1AP-AZ *Diameter of Piston Pin .5655

Plug.5665
´•;´•.´•.´•.´•1´•.´•
See latest edition of Se~ice Instruction No. 1267.
.0025L
i:’:"’’’’’’’~,.AZ
Piston Ring and Piston Side
606
1"’ ’ ’ ’ aearance (Top Ring Comp.) .0055L .008L(B)
.000L
Clearance (2nd Ring Comp.) .004L .O~L(B)
Piston Ring and Piston Side .002L

sos
’ ’~i .ji Ii : AQ-AZ Clearance (Oil Regulating .OaQL .006L(B)
607 AQ-AZ Piston Ring Gap (Compression)

~hrameCylinderr .020
~dSi (Straight Barrels) .030 .047
AG-AZ Piston Ring Gap (Com_pression)

Nitrided and Chrome Cylinders .045
(Choke Barrels) .055 .067
Piston Ring Gap (Oil RegulaBng) .015

AQ-AZ
(All Bawls) .030 .017
is measured within 4 inches from bottom. Ring gap at top of travel must not be
For Choke Barrels Ring gap
less than .0075.
"’:L’:"jq For all Other Bawls _Ring gap is measured at top limit of ring travel.
6SP1776
27
BERVIOE TABLE OF LIMITS
net. net. Chut Nomcnc~tun I Dfmendon~ I

Mfr. Mtr.
Min. Serv. I Min. am.
New Old
Mu. Lbu.
Mu. Mu.
ine and Piston Application I Min. Piston Diameter I Cylinder Barrel

ax.
Clearance
Type of Maximum Piston Skirt
Engine
Code Letter Piston Number Top Bottom Type of Piston Surface Diameter Cyl.
5.0790 5.1090 Forged-Cam N-C 5.1305 .018L

608 519~:I: A(1, AZ 76966, LW-10515
608 522:i:
sos
slo
N OTES:
To find the average diameter of cylinder in an area 4" above service is.oW5 inch.
iiii:iiiiS~iil bottomof barrel: Fint, measure diameter at right angles
from plane in which valves are located. Second, measure See Service Instruction No. 1243 for identification of forged
diameter through the plane in which valves are located. Add pistons. The suffix ’5" that will be found with the part
both diameters; this sum, divided by 2, represents the average number on 76966 and LW-1o545 pistons indicates the piston
diameter of the cylinder. weight is within the limits specified for any group of pistons
I~iiiiiii and may be substituted for any like piston on a particular
tjriiiiiijilrl Cylinder Barrel: N=ninide hardened, C=Chrome plated, engine. Other pistons are manufactured within weight limits
that do not require any weight controlled piston for
To find the average out-of-round, measure diameter of replacement.
cylinder in an area 4" above bottom of barrel: Pint, measure
diameter at right angles from plane in which valves are Piston diameter at top is measured at top n’ng land (between
anles to
located. Second, measure diameter through the plane in top and second compression ring grooves) at right
hole; diameter at bottom of piston is measured at
which valves are located. Difference between diameters must piston pin
not exceed .0045 inch. the bottom of the piston skirt at right angles of the piston
pin. See Service instruction No. 1243 for illustration.
Maximum taper and out´•of-round permitted for cylinder in
CLutncc~
Nomenc~tw
Chut
Mfr. I I Mtr.
Min. Suv. Min. Serv.
E~´•. Mu.
Mu. Mu.
Exhaust Valve Seat and .0075T

Cylinder Head .OllT (A)
O.D. Exhaust Seat 1.9355

i~ig AQAz 1.937
LD. Exhaust Seat Hole 11.926

in Cylinder Head 1.928
Intake Valve Seat and .0065T

612 Ei52~ AQ-AZ
Cylinder Head -,010T (A)
O.D. Intake Seat 2.2885

AC-AZ -2~6
AQ´•AZ LD. Intake Seat Hole 12.280

in Cylinder Head 2.282
Exhaust Valve Guide and 0011T

Cylinder Head .0030T (A)
AQ-AZ C.D. Exhaust Valve Guide 1.6954

.6963
I.D. Exhaust Valve Guide 1 .6933

ii$iii~iiiil AQ-AZ
Hole in Cylinder Head
SSP1776 2-8
8ERVICE TABIE OF LIMIT8
SECTION Ii CYLINDERS
Rci. Rel. Chut Nomcnd´•tun Mmcnrion~ QLurncs~

M~. Mtr.
Nea old
Min. Sav. Min. gcn.
i Max. a Max.
Max. Max.
614 AQ-AZ Intake Valve Guide and .0010T

Cylinder Head .0025T
ir AQ-AZ O.D. Intake Valve Guide .5933

.5938
AQ-AZ I.D. Intake Valve Guide Hole .5913

in Cylinder Head .5923
:•´ :•´.; •´;.ZA-Q

t.´•.´•.´•.´•.
Exhaust Valve Stem and
Valve Guide
.00371,
L (A)
O.D. Exhaust Valve Stem .4955
.4965 .4937
615iW AQ-AZ Finished I.D. Exhaust Valve

Guide .5005.4995
:I:l:li::::’:l 1/2 inch diameter exhaust valves may have exhaust valve guides that are .003 in. over the maximum
inside
3::i:::i:i:i:l diameter limit, anytime up to 300 hours of service. After 300 hours of
qervice, inside diameter of exhaust valve
guide may Increase .001 m. durine each 100 hours of oPeration up to therecommended overhaul time for the
engine or not to exceed .015 inJ1 over the basic LD. see latestedition d Service Instruciion No. 1009 ior
jiij:~i: overhaul time.
616 AQ-AZ Intake Valve Stem and .OD1OL

Valve Guide .00281, .006L
i:li.iitiitli AQ-AZ O.D. Intake Valve Stem 24022

.4030 .4010
616 AQ-AZ Finished LD. Intake Valve .4040

iiiii~iiXi Guide.4050
1""" Intake and Exhaust Valve and

Valve Cap -(=learance (Rotator .000
Type With Small Diameter Head) .0051,
618 I:85j~. AQ-AZ Dry Tappet aearance .040

.105
61e AQ-Az Valve Rocker Sha~tand Valve .0001L
Rocker Bushing .00131, .00251,
AQ-AZ Finished I,D. of Valve Rocker
Shaft (Burhing) in Cylinder .6246
Head .6261 .6270
620 AQ-nz Mw Reeker Shalt and valve .Oa07L
Valve Rocker Bushing .00171, .0041.
AQ-AZ Finished IJ). of Rocker Arm .6252
Bushing .6263 .6270
i AQ-AZ O.D. Valve Rocker Shaft .6241
.6245 .6231
621 .632 AQ-AZ Valve Rocker Bushing and Bushing Must Be
Valve Rocker Burnished In Place
szzt:~ A4´•nz valve Rocker Shalt Bushing .M)22T

and Cylinder Head .0038T (A)
.7380
Hole inCylind~rHead .7388
623 AQ´•AZ Valve Reeker and Cylinder Head .002L
Side Clearance .0201, .024L
SSP1776
2-9
BERVICE TABLE OF LINIITEI
INTAKE VALVE CAP CLEARANCE-

ROTATOR TYPE
623
CHOKE
-607
OPTIONAL
601
609
TAPER
Cylinder, Piston and Valve Components
85P1776 2-10
BERVICE TABLE OF LINIITB
SECTION m GEAR TRAIN
Rai. Rlt. CM Nnmanclahne Dim~ndon, Cfcurncu

Lbfr. ~dfr.
Near Old Idin. 8arv. Illn. 8srv.
a Idu. a LLu.
Mu. Hu.
700 AQ´•AZ Oil Pump Drive Shaft and .0010L

Ii f~bI’ "’ or Pump Pody T6b5m; .D04L
i"""
701 tiiitSi:ji~ AQ-AZ Oil Pump Drive Shift and 0035L

Oil Pump Cover ;0050L .0065L
Oil Pump Impellers- Diameter .002L

703 AQ-AZ
Clearance .oosL
?M AQ" Oil Pump Impellers- Side

Clearance .005L
Width of Oil Pump Impellers 1.372

1.374 1.371
AQ-AZ Oil Pump Driven Impelles and

Idler Shaft .004L
722~’’’’’ AQ-AZ Fuel Pump Idler Gear and .001L

Shaft r~03L .005L
AQ´•AZ Fuel Pump Idler Gear End .W2L

3Si~liiil Clearance .028L .038L
.´•.´•.´•.´•~if:
Drive Shaft Gear .0010L
726
lij AQ-AZ Fuel Pump
and Crankcase ~0025L .004L
727 AQ´•AZ Fuel Pump Drive Shaft Gear .0015L

-End~learance r0385L .0485L
iilijii!iii
728’ Front Governor Drive Idler Shaft .0010L
(Both Ends) and Crankcase ~6625I; .004L
7311i~jifj AQ-AZ Governor Driven Gear and .oOlOL

Crankcase .0025L .004L
´•S
782
11~: i As´•az Propeller Governor Drive Gear
End Clearance
.008L
.016L .021L
739 Az Tachometer Drive Shaft and .0015L

Adapter ~5Ln; .006L
Vacuum and Hydraulic

159
t’j: ´•:i:i AQ-AZ
Ddve Shalt Gea~ ~d PumpCrankcase .0025 .006L
’i´•~´•
Vacuum and Hydraulic Pump

760
Pssoiil AP-AZ Drive Shaft Gear End ,P
Clearance .035L
0010L
´•´•´•´•´•´•:I ~ij nQ-nz Magneto Coupling and Crankcase
.004L
.0010L
762
’ ~’ : ´•: ´• i AQ-AZ Magneto Drive Shaft Gear and
Crankcase ~mf; .004L
763 t~1.58Riil A~-AZ Accessory Drive Gear

Intermediate and Crank- .0010L
case (2 Places) .0030L .005L
764 AQ-AZ Accessory Drive Gear End .016L

Clearance .018L .020L
765 [ii~jSit AQ-AZ Accessory Drive Gear and .0010L

.wsaL .OOSL
IT´•~
~´•´•-´•1
SSP1176
211
sERVIOE TABLE OF LINIITB
SECI~ION III GEAR TRAIN
Rli. I aei. caut Nomenck~ne I Dfmendolu Cleurnc+~

Mfr. Mt~.
NII Old I I I Min. 8av. I L6Ln. Ism.
a I M~x. I a IMu.
H´•x. I 1 Mu.
766 A&-AZ Compressor Drive Shaft I I .0010L

and Compressor Drive Adapter .0030L .005L
767 AQ´•AZ Compressor Drive Shaft End .0005

Play .0295 .0;10
768 Breather Slinger Gear and .0021L

Shaft .0035L- .005L
769 AQ-AZ Breather Slinger Gear End .008

iiii~jriijiil I Play .017 .025
710
IliiE1S~1" Propeller Shaft Drive Gear
and Bearings
.0025L
.0050L .0060L
771 ii’
i~ AZ Propeller Shaft Drive Gear
E~d Play
.005
;015 .022
772 AZ Propeller Shaft and Rear .0015L

Bearing .0030L .004 OL
773 AZ Alternator Driven Gear and .0025L

ijiiiiiiijil I Adapter Bushing .0045L .0065L
774 Az Starter Drive and Alternator .004

iiiiiiiiiiiil I Drive Gear ~d Play .011
775 AZ Starter Driven Gear and .0015L

iiiI~iiri Adapter Bushing .0030L .005L
776 AZ Starter Drive Shaft (Slip .0015L

Coupling) and Crankc~se .004 OL .007L
777 :gg~i Az Starter Idler Gear and Idler .0005L

.xiiliif Gear Bearing .0020L .005L
SSP17j6
2-12
sERVICE TABIE OF IIMITs
SE~TION IIi GEAR TRAIN
r;
~j?"
O
-[i ´•V_h;’ ri´•
rs
O
771
770
Prop. Shaft Drive Gear
SSP1776
2-13
OERVICE TABL~E OF IINIITS
SECTION III GEAR TRAIN
;1 I;! ALTERNATOR
S1´• 1~
i
:i’ri
1 I’A
II
´•i.´•C
774
;’1
~zTi i
‘I.i´•´•i~
~41 L775
STARTER 1 I ~Y
-1 ir~l ~772
Alternator, Starter and Propeller Shaft
SSP1776
214
IERVICE TABCIE OF l6MIT8
SECTION III GEAR TRAIN
761 nz
751
_r766 764
I ~-f´•; 21’7"9
i_i
I I
727
Fuel Pump, Magneto, Vacuum and Hydraulic Pump

f3SP1776
2´•15
Q6ERV1OE TABI~E OF LIMIT8
PART ii INTEGRAL ACCESSORY DRIVE ENGINES
731
TIGO-541 TIGO-541
PRO~ GOVERNOR PRO~ GOVERNOR
768
FUEL PUMP IDLER GEAR

BREATHER GEAR
TIG-541 ONW
Gov., Fuel Pump and Breather Gear
88P1776
216
BERVICE TABLE OF LIMITE
767
766
-COMPRESSOR
DRIVE
703
739
701
Oil Pump, Tachometer and Compressor
66P1776
217
8ERVICE TABIE OF LIMITS
PART (I INTEGRAL ACCESSORY DRIVE ENGINES
SECTION IV BACgLASH
~aut Non#ncktlm I Dimendo~ I Ch´•zmcel

IL~I. I ac~.
Mfr. I I Wr.
NII O~d Min. Brrv. I Bav.

Mu. I I LLu.
Hu. I I Hu.
AZ Oil Pump Impellers- Backlash .008

808
.013 .020
Propeller Governor Idler and .005

822
~I Camshaft- Backlash .015 .020
AZ Propeller Governor Drive and .004

823
Idler- Backlash .008 .015
Crankshaft Timing Gear and .005

825
~Ag´•nz Camshaft- Backlash .015 .020
AZ Accessory Drive and Accessory .004L

Drive Intermediate .006L .010L
827 AQ-AZ Accessory Drive Gear Inter-

mediate and idler -Spline .002
Backlash .005 .007
828 AZ Accessory Idler and Vacuum
i and Hydraulic
Backlash
PumpGear- .004
.011 .016
829 ::;IIAZ Propeller Shaft Reduction

Gear Total Backlash At 4 Foot .38
Radius .75 .90
i;~cii:´•:
AZ Starter (Bendix Slip Coupling)
830T and Starter Drive Gear

Backlash
.016
.a3~ .045
Accessory Idler and Magneto .005

AQ´•AZ
Drive Shaftgear -Backlash .015 .020
832 Starter Drive Gear and Starter

and Alternator Drive Shaft Gear .004
-Backlrrsh .008 .015
833z~liP AZ Alternator Drive Gear and

Starter and Alternator Drive .003
Shaft Gear Backlash .008 .012
834flfrsiitl AQ´•AZ Fuel Pump Idler Gear and

Vacuum and Hydraulic Pump SP2
Drive Gear- Backlash .015 .020
835 AB-AZ ~el Pump Idler Gear and

iiiii~: Fuel Pump Drive Backlash .0160 .021
836 Marmeto Drive Shaft Gear

ancrPnaaneto Coupling .0010
Spline Backlash ~b;i5 .0075
837 F ij AQ´•AZ Accessory Drive Gear and

Compressor Drive Shaft .0040
.0076 .014
Spline Backlash
838 f#~8. AQ-AZ Crankshaft Gear and Accessory

Drive Shaft Gear Spline .0040
Backlash .0076 .014
iiri::::::i
839 AQ Breather Slinger Gear and
.015 .020
Accessory Idler- Backlash
8SP1776
218
BERVICE TABLE OF LINIITs
SECTION IV BACKLASH
Rci. I 8si. Chut I I Mmcndon, I Ck´•rmee~

Mtt. I I abh´•.
N~rr Old I I I HLn. 8en. I Ldln. I 8sn.
i I Mu. I i I Ilu.
idu. I I Llu.
&10 Front Crankshaft Spline Bushing

and Alternator and Starter Shaft gal
Gear Spline Backlash .005 .006
&11 PropellerShaft Drive Gear and
~I Alternator and Starter Shaft

Gear Spline Backlash
.001
.004 .006
::’:IAZ Propeller ShaftDrive Gear and ~PS

B~ Driven Geru -Backlash .014 .016
&13 Starter Slip Coupling Gear and .0002

Starter Idler- Backlash .0045 .0015
’:IAZ Bendix Starter Motor Shaft Gear 9002

1 and Idler- Backlash .0045 .0015
&15 Propeller Shaft Spline and
~Ii Ii : : r Propeller Shaft I)riven Gear

Spline Backlash
(When Measured
Propeller Gear)
At O.D. Of
.011
.020
.028
.015
.036
ACC. DRIVE IMTERMELATE
DRIVE
DRIVE
ICOMPRESSOR DRIVE SHAFT
CRANKSHAFT
Msg
IDLER
CI~MSHPlrT
HM) 8 VAC.
Nn
OIL PUMP
LIOENRD
PUMP
5i~
i GOV IDLER
PROP GOV DRIVE
TIG-54 I
(Accessory Drivts)
SSP1776
219
LIERVICE TABLE OF LIMITEI
SECTION IV BACKLASH
1121
DRIVEN rc,/ rACC,\DLER
SHAFTGEAR I -L--ACC. DRIVE GEAR INTER

h
MAG COUPLING
---+-H~Y ’-126
SECTION D’D
GOV. DRIVE~
ACC. DRIVE
TOTAL BACKLASH ~29
SECTION B-B SECTION C-C
SHAFT DRIVEN
DRIVE
DRIVEN
COMPRESSOR SHAFT
ACC IDLER
s VACUUM
STARTER DRIVE
STARTER
,il
FUEL PUMP
ALTERNATOR DR. IDLER
PROP SHAFT DRIVE GEAR

PUMP
CRANKSHAFT
ALTERNATOR Ef ;YL,1 r~
STARTER DRIVE SHAFT GEAR-s II I
STARTER
STARTER DRIVE
´•t-
OIL PUMP DRIVE
(Accessory Drives)
SSP1776
220
8ERVIOE TABL~E OF LIMIT8
SECTION V SPECIAL TORQUE REQUIREMENTS
Rli. RII.
Thread
Chart Size Nomenekttm TorgueLimUI
N´•w Old
a/8-24 Connecting Rod Nuts Tighten

To 2.255- 2.256
.´•.´•.´•.´•.´•.5
3/8-24 Magneto Nut (To attach drive

eoa
II member to magneto) 300 in. Ibs.
1032 Magneto -Plate Screws 15 in. Ibs.

904 AQ-Az
114-20 Rocker Box Screws 50 in.lbs.

905 AQ-AZ
18MM Spark Plugs 420 in.lbs.
907 AQ-AZ
Alternator Pulley Nut 450 in. Ibs.
909 AQ
’ ’ ’ i it~lji Alternator Quill Shaft Nut 414 in. Ibs.
910
.´•.´•I´• ´• ´•:Ii 1/4-28
tuNlanOutput
Alternator
imreT 85 in. Ibs.
10-a2 Altemator Auxiliary Nut 90 ia. Ib~.
5/16-24 Starter Terminal Nut 2 in.lbs.

912 AP-AZ
Piston Cooling Nozzle in Crankcase 100 in.lbs.
918 AQ-AZ llla´•27 NPT
915 111889’Iil AQ-AZ 3/4-16 Oil Filter Bolt (AC Can

Element Type) 300 in. Ibs.
´•.´•.´•I´•.´•.´•
13/16-16 on Filter (Throw Away Type) 240 in.lbs.

AQ-AZ
iiiiii8~ AQ´•AZ 314-16 Converter Stud 720 in. Ibs.
1.00-14 oil Cooler Bypass Val~e 300 in. IbJ.

917 Aq-AZ
918 Ij’ iiiii~iii:i AQ-AZ 1 114-12 Oil Pressure Relief Valve 300 in. Ibs.
Hose Clamps 45 in. Ibs.

919 AQ-AZ
921 AQ-AZ Exhaust V-Band Coupling Torque Data
T-Bolt Split 114 In. Drilled Hex Nut

!Ilijii4iil~ Coupling Size Avco Lycoming Vendor Loc~ut
Type With Safety Wire
Tube aD Part No. Tart No. Torque In. Lbs. Torque In. Lbs.
2.00 in. LW-12093-5 85

~W;12093-6 MVT691 225 85 75
2.25 in. LW-12125-3 MV’1‘69197-225
922 AZ Turbocharger V-Band Torque Data
Turbocharger Model No. V-Clamp Part No. V-Clamp Diameter Torque In. Lbs
n8A21* 400500-925 9.25 in. 40-60
AiResearch turtoohaager.
See latest edition of Service Instruction No. 1238 for assembly procedure.
1000FT.IgS~i
’1´•-´•´•:´•´•
923 AZ 21/16-12 Propeller Shaft Inch Nut
924 AQ-AZ 7/16-20 ~el Injector Nmzles (In

i’"
Induction Housing) 210 in. IbJ.
825 814-16 Comprerror Driw RIIlFy Nul 2401n.lba.

AP-AZ
SSP1776
221
8ERVICEE TABLE OF LIMITS
I IL´•I. T~ue´•d
Chut I size Nomend´•tun Tomue Limtta
NI1 I Old
926 AZ 5/8-18 Starter Dli~e Shdt Gear Nut 900 in. Ibs.
927 AQ´•AZ 1/4 Bolts Crankshaft Gear 46 120 in. Ibs.
928 AQ-AZ 3/8-16 Cylinder Hold Down Studs

(Crankcase Driving Torque) 100 in. Ibs.
1/2-13 Cylinder Hold Down Studs

(Crankcase Driving Torque) 250 in.lbs.
929 ii AQ-AZ 3/8 Cylinder Hold Dow Nuts 300 in. Ibs.
I 1/2 Cylinder Hold Down Nuts
Cylinder Hold Down Nut Tightening Procedure See latest edition of Service Instruction No. 1029.
600 in. Ibs.
932 AQ-AZ 5/16-18 Exhaust Transitions Studs

(Driving Torque) 100 in. Ibs.
S::i´•:´•:´•:´•
3/8-16 Exhaust Transitions Studs
jj$iiiW) I I (DrivingTorque)_ 1 200 in. Ibs.
SECTION V SPRINGS
LenCth I I COMP. LOAD

AvcoL~c. IWire I AtComp. I Mh´•. Mh~ I Serv.
Chut I Nomenckftuc I PutNo. IDk. I LellOth I Min. I Mu I Mu.
950 ri:Ejijlijii AQ´•AZ Outer Valve Spring LW-117981.192 1.610 in. 136 Ib. 144 Ib. 133 Ib. min.
76351 .177 1.610 in. 136 Ib. 144 Ib. 133 Ib. min.
951 j A~´•AZ Auxiliary Valve Spring LW-11 .148 1.48 in. 86 ib. 94 Ib. 83 Ib. min.
76352 .142 1.48 in. 86 Ib. 94 Ib. 83 Ib. min.
i t
952 ~8eTt AQ-AZ OiI Pressure Relief

Valve
Avco Lycoming
Part Numbers Dye Free Length
::::::::8 68668 2~04 7.11b. 7.8 Ib. 7.11b. min.
Purple .054 1.30 in.
LW-11713 White 2.12 .059 1.44 in. 10.19 Ib. 11.92 Ib. 10.5 Ib. min.
LW-11138 None 2.64 .051 1.44 in. 8.55 Ib. 9.45 Ib. 8.3 Ib. min.
AQ-AZ Fuel Drain Check

i Valve Spring .047 .75in. I 5.501b. 6.50 Ib. 5.35 Ib. min.
956 AQ-AZ Oil Filter Relief

a~l Valve Spring .054 1.93 in. 3.05 Ib. 3.55 Ib. 3.00 Ib. min.
957 Cili:i:.l.:~ill AZ Shroud Tube Spring .105 2.09 in. 14 Ib. 16 Ib. 13 Ib. min.
958 AQ´•AZ Pressurizing Valve Spring .032 .455-2485 .65 Ib. .75 Ib. .63 Ib. min.
959 B~.il AZ Spring Between Crankshaft

and Starter and Alternator
Drive Gear .13 lz40 in. 48 Ib. 52 Ib. 46 Ib. min.
´•:´•´•t~5:´•
860 I AttematorDrive
Coupling Spring .047 .83 In. 10 Ib. Illb. 9 Ib. min.
:8:iM:S
8SP1776
2-22
8ERVIOE TABL~E OF IIMITs
STANDARD TORQUE
UNLESS OTHERWISE LISTED
Torque limits for propeller attaching bolts to be supplied by propeller or airframe manufacturer.
TABLE II
TABLEI
PIPE PLUGS
BOLTS, SCREWS AND NUTS
T Torque
ue Torque Thread In. Lbs.
Thread In.Lb. Ft.Lb. Thread In. Lb. Ft. Lb.
1116-27 NPT 40
1 49 1 900 75
1/8-27 NPT 40
114 96 9/16 1320 110
1 18 NPT 85
5116 204 17 5 1800 150
3/8-7 8 NPT 110
318 360 30 3 3240 270
1 -14 NPT 160
7/16 600 50
14 NPT
1-111 NPT 315
THIN NUTS (1/2 DIA OF BOLT)- i/2 LISTED TORQUE
TABLE IV
TABLE I1I
FLEXIBLE HOSE
OR TUBE FITTINGS
CRUSH TYPE ASBESTOS GASKETS
Thd. Pitch On Part ANGLE OF TU RN Torque

Tube Size Th read In. Lbs.
To Be tened Aluminum
rea er Asbestos Asbestos
(-3) 3/16 3/8-24 30
8 1350 670 (-4) 1/4 7/1 6-20 30
10 1350 670 (-5) 5/16 1/2-20 35
12 180" (-6) 3/8 9/16-18 35
14 1 -8 1 3/4-16 60
16 2700 1350
18 2700 1350
-10) sis 7/8-14 70
20 27 135
3 1
28 3 1
NOTE TABLE V
Install all crushtype gaskets except the self centering STUDS

type, with the unbroken surface against the flange of MIN. DRIVING TORQUE
the plug or part being ti~tened against the seal. Turn Torque
the part until the sealing surfaces are in contact and Threads In. Cb s.
then tighten to the angle of turn listed for the
appropriate thread size. 1 20 15
5/16-18 25
NOTE: Lubricate Threads Unless Otherwise Specified. 3/8-16 50
SSP1776 2-23
bERVIOE TABLE OF LIMITS
sEcnoN v SPECIAL TORQUE REQUIREMENTS
:´•~´•I´•
3‘j O
/I
1, *r
957
Engine Accessories and Hardware
224
SERVICE TABIE OF LIMITS
903
04
225
BERVICE TABLE OF LlMIT8
SECTION v SPECIAL TORQUE REQUIREMENTS
921
’I’’
i,,,
MPRESSOR DR.
PISTON COOLING NOZZLE
I
I ii
911
226
SERVIOE TABLE OF LIMITS
i:
ALTERNATER
909
´•i’
c;~
STARTER
912
2-27
BERVIOE TABLE OF LIMITB
I I a
I~
x
a
228
SERVICE TABLE OF LIMITS
SE~TION V SPECIAL TORQUE REQUIREMENTS
FUEL INJECTION NOZZLE ASSEMBLY
229
BERVIOE TABLE OF LIMIT8
951
950
VALVE SPRINGS
955
OIL RELIEF VALVE
FUEL DRAIN CHECK VALVE
958
952
OIL PRESSURE RELIEF VALVE
Engine Springs and Hardware
230
SECTION
OVERHAUL TOOLS
Overhaul Tool~
SECTION 12.
OVERHAUL TOOLS
12-1. The tools listed and illustrated in this section haul of the engines covered in this manual. Unless
comprise the special tools which, in conjunction with specifically called out to the contrary, the tools listed
the standard hand tools and gages to be found in all are applicable for use on all engines.
competent repair shops, are necessary for the over-
Ref. Tool No. Nomenclature and Description
1 218-B Socket, Spark Plug Wrench .88 Hex

2 1121-B Wrench, Cylinder Stud Nut 3/8"
3 64505 Drift, Valve Guide Installation (Intake)
4 64507 Gage, Valve Guide OD .005" o/s (Intake)
7 64514 Gage, Valve Guide ID (Intake)
8 64526-2 Block, Cylinder Holding
g 64530 Gage, Connecting Rod Parallelism and Squareness
10 64535 Drift, Connecting Rod Bushing Removal
11 64536 Drift, Connecting Rod Bushing Replacement
12 64537 Gage, Flat Plug Connecting Rod Bushing Rejection
13 64540 Fixture, Rebushing Operation Valve Rocker
14 64541 Burnisher, Valve Rocker Bushing
15 6´•4542 Gage, Plug, Valve Rocker Bushing ID (Finish)
16 64545 Block, Vee Check Crankshaft Run-Out
17 64553 Basket, Valve Parts, Cleaning
t
~L
4-5-6-7-15
10
8 9 11
12
14
13 B~
16 17
12-1
Overhaul Tools
Rcf. Tool No. Nomenclature and Description
1 64571 Gage, Plug Valve Guide Hole in Cylinder Head (Std. (Intake)
2 64572 Wrench, Cylinder Stud Nut 1/2"
3 64580 Burnisher, Connecting Rod Bushing
4 64593 Expanding and Staking Tool, 18 MM Spark Plug Hell-Coil Insert
5 64594 Inserting Tool, 18 MM Spark Plug Hell-Coil Insert
6 64595 Removing Tool, 18 MM Spark Plug Hell-Coil Insert
7 64596-1 Tap, 18 MM Hell-Coil Spark Plug Bottoming Tap
8 64597 Fixture, Remove, Replace, Burnish Connecting Rod Bushings
9 64613 Gage, Rocker Shaft Bushing Rejection
10 64639 Gage, Plug, Valve Guide OD .030" o/s (Intake)
11 64644 Fixture, Valve Guide Replacement
12 64678-2 Reamer, Valve Guide OD .005" o/s (Intake)
16 64681 Drive, Crankshaft Welch Plug
17 64684 Reamer, Valve Guide ID (Intake)
;I
10
9
-9
12-13-14-15
16
17 11
12-2
Overhaul Tools
1 64712 Compressor, Piston Ring

2 64713 Expander, Piston Ring
3 64721 Wrench, Propeller Flange Spanner
4 64766 Puller Magneto Drive Shaft Sleeve
5 64767 Gage, Connecting Rod Bushing ID Finish
6 64782 Puller, Slide Hammer Medium
7 64803 Club, Test

8 64810 Gage, Plug, Rocker Shaft Bushing Hole in Cylinder Head
Head
9 64811 Gage, Plug.005" o/s, Rocker Shaft Bushing Hole in Cylinder
10 64812 Reamer, .005" o/s Outer Rocker Shaft Bushing Hole ill Cylinder Head
11 64813 Reamer, .010" o/s Outer Rocker Shaft Bushing Hole in Cylinder Head
12 64814 Drift, Rocker Shaft Bushing Removal
13 64815 Drift, Outer Rocker Shaft Bushing Installation
14 64816 Drift, Inner Rocker Shaft Bushing Installation
15 64819 Reamer, Semi-Finish, Outer Rocker Shaft Bushing ID
18 64820 Reamer, Semi-Finish Inner Rocker Shaft Bushing ID
17 64821 Reamer, Finish Outer Rocker Shaft Bushing ID
18 64822 Reamer, Finish Inner Rocker Shaft Bushing ID
19 64823 Gage, Plug Rocker Shaft Bushing ID
o´•.
8-9-19
10 -1 I
12 13
%2~
14 15 17 16 -18
12-3
Overhaul Tool´•
Rcf. Tool No. Nomenclature and Description
1 6´•4838 Reamer, .005" o/s Rocker Shaft Hole in Cylinder Head

2 64839 Reamer, .010" o/s Rocker Shaft Hole in Cylinder Head
3 64843 Puller, Piston Pin
4 64861 Crimping Tool and Wire Stripper
5 64872 Puller, Remove and Install Crankshaft Counterweight Bushings
B 64873 Fixture, Ream Crankshaft Counterweight Holes
7 64874 Reamer, .005" o/s Counterweight Bushing Holes
10 64878 Fixture, Grind Bushings in Dynamic Counterweight Not illustrated
11 64885 Tool, BaffleInstallation
12 64886 Jaw, Slide Hammer Puller (Small Diameter)
13 64892 Gage, Check Circlip in Counterweight
14 64923 Drift, Exhaust Valve Guide Installation
15 64924-1 Reamer, Valve Guide OD (Exhaust) .005" o/s All cylinder heads with.6613/. 6623
valve guide hole
16 64924-2 Reamer, Valve Guide OD (Exhaust) .010" o/s All cylinder heads with .6613/’. 6623
valve guide hole
17 64923-3 Reamer, Valve Guide OD (Exhaust) .020" o/s All cylinder heads with .6613/. 6623
valve guide hole
18 64923-4 Reamer, Valve Guide 01) (Exhaust) .030" o/s All cylinder heads with.6613/. 6623
valve guide hole
19 64928 Gage, Plug, Valve Guide OD (Exhaust) .005" o/s All valve guides with .6613/’. 6623
valve guide hole in cylinder head
20 64929 Gage, Plug, Valve Guide OD (Exhaust) .010" o/s All valve guides with .6613/. 6623
21 64930 Gage, Plug, Valve Guide OD (Exhaust) .020" o/s All valve guides with.6613/. 6623
22 64931 Gage, Plug, Valve Guide OD (Exhaust) .030" o/s All valve guides with .6613/. 6623
23 64940 Gage, Plug, Exhaust Valve Guide Hole in Cylinder Head (Std. Ail cylinder heads
with.6613/. 6623 valve guide hole in cylinder head
24 64969 Gage, Dry Tappet Clearance Not illustrated
25 64974 Tool, Rework Shroud Tube Holes in Cylinder Head
1-2
7-8-9 12
13 19-20-21-22-23
i----~--
14 15-16-17-18 25
12-4
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT ENGINES Sactlon 12
Overhaul Tool~
1 64981 Adapter, Test Club

2 64984 Bolt, Propeller 1/2-20 Drilled Hex Head
3 65521 Handle, Offset, Spark Plug Wrench
4 ST-25 Compressor, Valve Spring and Bar
5 ST-51-1 Cutter, Valve Seat (Intake) 010" o/s)
8 ST- 54-1 Cutter, Valve Seat (Exhaust) 010" o/s)
11 ST-66 Pilot, Valve Seat Cutter (Standard)(Intake)
12 ST- 66-1 Pilot, Valve Seat Cutter 010" o/s)(Intake)
13 ST-66-2 Pilot, Valve Seat Cutter 020" o/s)(Intake)
hole
16 ST-67 Pilot, Valve Seat Cutter (Standard) Cylinder head with 6613 valve guide
17 ST- 67-1 Pilot, Valve Seat Cutter 010" o/s) Cylinder head with .6613 valve guide hole
18 ST-67-2 Pilot, Valve Seat Cutter 020" o/s) Cylinder head with. 6613 valve guide hole
19 ST- 67-3 Pilot, Valve Seat Cutter 030" o/s) Cylinder head with. 6613 valve guide hole
20 ST- 67-5 Pilot, Valve Seat Cutter 005" o/s) Cylinder head with. 6613 valve guide hole
21 ST-73 Gage, Counterweight Dial Bore 7485/7505 ID of bushings) Replace Bushings in
Counterweights
22 ST- 78 Tool, Crimping Connecting Rod nut
23 ST-81 Gage, Flat Plug Rejection (Intake Valve Guide ID)
24 ST-91 Gage, Counterweight Squareness (Check Parallel and Squareness of Finished Inside
Diameter Bushing Hole)
BS..~ g(T~
i~r‘´• 3
3 i 31 2
´•C
ci,
r
I -,1 i)
g´• ~RUIO II THRU 20
22
,rLW
24
2! 23
12-5
Overhaul 7001e
1 ST-92 Driver, Counterweight Bushing (Remove and Install Bushings)

2 ST-93 Fixture Assembly, Counterweight (Install Bushings in Counterweights)
3 ST-94 Gage, Counterweight Bushing Location (Check Hole Location After Grinding)
after
4 ST-95 Weight, Counterweight Balancing 004 pound Check Balance of Counterweight
Rebushing)
5 ST-96 Arbor, Counterweight Balancing (Check balance of Counterweight after Rebushing)
6 ST- 107 Wrench, Remove Front Oil Plug
7 ST-115 Tool, Install and Remove Propeller Flange Bushings
8 ST- 129 Sleeve This tool is used to install AiResearch Piston (475515) into cylinder
g ST-131 Gage Belt, Tension Dial
10 ST-133 Fixture- Holding, Turbocharger
Wrench is used to remove back plate nut after it has been
11 ST- 134 Wrench, Turbocharger
drilled and cracked.
Drill plate is used to drill back plate nut in order that it
12 ST- 135 Drill, Plate, Turbocharger
chisel. Use this drill plate with holding fixture ST- 133
may be cracked with a
’.’Y-d
2
~nlb
i, 3
~r´•
~1-------
j1--
Lj~
7 8
;"’7~5:
~cur
10
I-III~
12
9 11
12-6
Overhaul Tool~
1 ST-136 Gage, Special Turbocharger (This gage is used for checking radial bearing play)
2 ST- 138 Gage Block, Turbocharger (This block is used to set up vernier height gage and oval
indicator to measure impeller tip height)
3 ST- 139 Jig, Welding Single Butterfly Exhaust By-Pass Valve
4 ST- 140 Gage, Plug Exhaust By-Pass Valve (Wire type for sizes up to. 125 dia. This is
the clearance between the butterfly and the housing in the closed position
5 ST- 142 Wrench, Shroud Tube
6 ST- 143-1 Reamer, Valve Guide ID (Ni-Resist)
7 ST- 143-2 Reamer, Valve Guide ID (Ni-Resist) Oversize
8 ST- 155 Gage, Plug, Valve Guide ID (Exhaust) All cylinder heads with .4995/. 5005 ID valve
guide hole
9 ST- 158 Puller ("V" Pulley) Generator and Alternator
10 ST- 160 Pilot Bar, Assembling Rocker Arms to Cylinder Head
11 ST- 161 Ring, Engine Mounting
12 ST- 162 Stand(Engine), A-Frame, Overhaul
13 ST- 163 Wrench, Remove Exhaust Pipe Flange (7/16")
14 ST- 164 Shroud, Cooling Not illustrated
5 6-7
~e
8
3tril. 1
10
II n
12
13
12-7
Overhaul Toole
1 ST- 165 Adapter, Engine Overhaul Assembly

2 ST- 177 Wrench, Turbocharger Impeller
3 ST- 184 Kit, Hell-Coil Repair Not illustrated
4 ST- 190 Wrench, Injector Nozzle
5 ST- 191 Gage, Plug, .010" o/s, Rocker Shaft bushing hole in cylinder head
6 ST-210 Reamer, .0075" o/s Counterweight Bushing Holes
7 ST-211 Reamer, .0125" o/s Counterweight Bushing Holes
8 ST-212 Gage Blocks, Crankshaft Counterweight Bushing To check parallelism of counter-
weight bushing to crankshaft Not illustrated
9 ST-213 Wrench, Remove Exhaust Pipe Flange (1/2")
19 ST-218 Bearingizer, Internal Thru 2. 4210/2. 2870 Diameter
11 ST- 220 Cable, Engine Lifting
12 ST-221 Staking Tool, Thermocouple Cylinder Barrel
13 ST- 223 Swaging Tool, Turbocharger Exhaust Pipes
14 ST-232 Fixture, Valve Seat Replacement and Refacing
15 ST-233 Fixture, Disassemble and assemble hydraulic lifters (automotive type) Not
illustrated
16 ST-238 Skid (Engine A- Frame Overhaul) (Use with ST- 161)
6-7
,------7-~4
i~ii"-=----------
10 9
12
-´•t--
14
IS 16
12-8
ENGINES
OVERHAUL MANUAL -AVCO LYCOMING INTEGRAL ACCESSORY DRIVE AIRCRAFT sec
Overhaul Tools
I ST- 239 Kit, Engine Overhaul Ring Mounting (Use with ring ST- 161)
2 ST-251 Socket, Connecting Rod Nut
3 ST-257 Pilot, Valve Seat Cutter (Std. All cylinder heads with .6933 valve guide hole
4 ST-257-1 Pilot, Valve Seat Cutter 010 o/s) All cylinder heads with.6933 valve guide hole
5 ST-257-2 Pilot, Valve Seat Cutter 020 o/s) All cylinder heads with.6933 valve guide hole
6 ST-257-3 Pilot, Valve Seat Cutter 030 o/s) Ail cylinder heads with .6933 valve guide hole
7 ST- 25 7- 5 Pilot, Valve Seat Cutter 005 o/s) All cylinder heads with 6933 valve guide hole
8 ST-258-1 Reamer, Valve Guide Hole OD 010 o/s) All cylinder heads with.6933/. 6943 valve
guide hole
9 ST-258-2 Reamer, Valve Guide Hole OD 020 o/s) All cylinder heads with .6933 .e943 valve
guide hole
10 ST-258-3 Reamer, Valve Guide Hole OD 030 o/s) All cylinder heads with .6933. 6943 vahe
guide hole
11 ST-258-5 Reamer, Valve Guide Hole OD 005 o/s) All cylinder heads with .6933/. 6943 valve
guide hole
12 ST-259 Gage, Plug, Valve Guide OD (Std. All cylinder heads with.6933;’. 6943 valve guide
hole
13 ST-259-1 Gage, Plug, Valve Guide OD 010 o/s) All cylinder heads with .6933,’. 6913 valve
guide hole
14 ST-259-2 Gage, Plug, Valve Guide OD 020 o/s) All cylinder heads with .6933’. 6943 valve
guide hole
15 ST-259-3 Gage, Plug, Valve Guide OD 030 o/s) All cylinder heads with.6933i.69´•13 valve
guide hole
16 ST-259-5 Gage, Plug, Valve Guide OD 005 o/s) All cylinder heads with.6933/’. 6943 valve
guide hole
17 11-7073 Needle, Installation of grommet over lead assemblies
18 11-7074 Tool, Seating, Seat Ferrules in cover assembly
19 11-7803 Tool, Flaring, Work braid up so ferrule can be installed
mr
´•0‘ 2
J-
3 THRU 7
iDGO
8-9- 10-II
12 -13 -14 -15 -16
r"-1~---4
17 18 19
12-9

Integral Acc Drive

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OVERHAUL MANUAL

LYC O N1 I N G VVI LLI ANI S rO RT D I VI s ION

2nd Edifion Part No, 60294 1 6

Oerober, 7915 PRIHTED IH US.~.

REVISION NO. PUBLICATION PUBLICATION NO. PUBLICATION DATE

60294-6-3 Integral Accessory 60294-6 October 1975

Previous revisions to this publication This revision consists of:

April, 1976 6-3, 6-4 June 1996

TO THE OWNER OF THIS MANUAL

IN ADDITION TO THIS MANUAL AND SUBSEQUENT REVISIONS, ADDITIONAL

equipment or part thereof.

Revised June 1996

SECTION PACE SECTION PAGE

1 INTRODUCTION 1-1 5 INDUCTION AND EXHAUST

TABLE OF CONTENTS (CONT.

SECTION PAGE SECTION PAGE

7 CYLINDERS, PISTONS AND VALVE 8 CRANKCASE, CRANKSHAFT AND

Inspection (Cont. Inspection (Cont.

Spark Plug Thread Insert 7-8 Crankshaft Flange

Valve Guides 7- 10 Crankshaft Counterweight

Valve Rocker Bushings 7-11 Reassembly

Cylinder 7- 12 Crankcase Tightening

Disassembly 8-1 Idle Speed and Mixture

Additional sections provided for general descrip-

bered cylinders on the left side.

Figure 1-1. Typical TIGO-541 Series Engine

Descr~tion of Eng~ne Model Code

Example: TIO 541 EIB4D

L Leftbond Engine Rototion 000* E Fbwer Sectiw, B Rot~iiji

V -Vertical Hdicopter B -Acces~ory Section

H -Horizontal Helicopter 4 -counterweism Application

A Aerobatic D --Duol Magneto

G -Ge~xed Nose Sectlbn

2- 2. CYLINDERS. The cylinders are of air- cooled con-

Rah~ I I I ~-a’l Faer Bypass volue

Brain Oil ~Suchon Scnen

Dmin 01 to Sump Thru

stallation. valve clearance at zero eliminating the need of any

BREATHER SLINGER GEAR

I I INTERMEDIATE ACCY. DRIVE GEAR

Figure 2-3. Gear Train Diagram TIG-541

Hydmhe Rnlp BDrm

Acceaay Cme Gear

gogeam Ikmd (hl s~mp

beanls al Pccessa~ Malne)o

left bank I ~kwn pump

Dmn oil lo sump

Figure 2-4. Lubrication Diagram TIO-541-E

2-8. CRANKCASE. The crankcaseor integralhousing

Mogneto drive gear

No.ofteeth 30 Ir?o.2.500/ t- I CcCmnkshaftgwr

Camshoft gorr dr~Le gear

Prop go~ ~dlergwr

Figure 2-5. Gear Train Diagram TIO-541-E

Accessory Drive Gear C