Lycoming TG ST Ste

01
~n"\cO LYCON1ING VVILLIANISPORT DIV1510N

652 Oliver Street,
Williamsport, Pennsylvania
17707
L~AVCO LYCOMING ENGINE GROUP
SPECIAL SERVICE TOOLS FOR AVCO LYCOMING PISTON ENGINES
J
SSP384
JAN.1985
EBs.ao
REALIZING THE WEALTH OF

WE
INFORMATION
SERVICE
IN THE
FIELD,
GUIDE.
WELCOME ANY AND ALL COMMENTS AM) ADDITIONS

IS MADE THE MORE
WE
TO THIS
THIS BOOKLET
TO HELP ALL
PERSONNEL AND THE MORE HELPFUL HOPE
MECHANICS.
IT WILL BE. TO MAKE THE
COMPLETE WE MAKE
IT,
LOOK FORWARD TO HEARING FROM YOU AND
1976 EDITION BIGGER AND BETTER.

TO:
PLEASE ADDRESS
YOUR COMMENTS
AVCO LYCOMING WILLIAMSPORT DIVISION AVCO CORPORATION
WILLIAMSPORT, PA.
E.
17701
L.
TYLER, MANAGER
PROMOTION Sr TRAINING
AVCO LYCOMING SERVICE TOOLS
INTRODUCTION
This
catalog replaces
Tool
Catalog
SSP578 dated November, 1978.
This catalog contains information relative to tools used for modification and maintenance of Avco Lycoming opposed aircraft engines. It consists of four sections: The first is an alphabetical index and the second a numerical pictorial listing with brief descriptions. The third is a Service Publication Cross Reference Index and the fourth is a listing of obsolete tools. The illustrations used in this size. In
some
catalog show
the
general
appearance of the tools but

cover a
are
not related
according
to
cases,
single
illustration has been used to
ferent tool numbers; therefore it is necessary, when ordering numbers in the text. Any tool described as being applicable to
number of tools similar in appearance, with diftools, to note carefully the descriptions and tool
engines
with "crosswise accessories"
or
"crosswise accessory housings" do not include VO-435-B1A and TVO-435-F1A helicopter engines and TIG-541 and TIGO-541 integral accessory drive engines; tools applicable to these engines are specifically designated by
engine model.
PRICES
This catalog does not list prices. A separate numerically arranged parts supplied to distributors of Avco Lycoming engines. and tool
price list
is available and is
HOW TO ORDER
by or through authorized Avco Lycoming distributors. A tool must be designated by a together with a name sufficiently descriptive to identify the tool. It is not necessary to write the full catalog description of the tool. Do not enter price of the tool on the order. Be sure to give definite shipping intool number structions.
Tools must be ordered

ALPHABETICAL INDEX
C (Cont.)
Adapterdynafocal mounts -64898, ST-88 engine overhaul assembly ST-165,

hand drive
ST-63 64899
64836 64866 64917
Club -test- 64773, 64783, 64801, 64802, 64803,
64807, 64988, 64990, ST-241, ST-297, ST-298, ST-351,

ST-240 ST-456
hydraulic tappets
overhaul stand
Compressor piston ring 64529, 64559, 64712 valve spring ST-25, ST-266, ST-419
Counterbore
crankcase "o"
propeller shaft flange sludge tube removal

test club
ring
recess
64904, ST-323
64840, 64979, 64980, 64981, 64989, 64991,

NC-2 thread to 16 MM
x
cylinder heads
Counterbore intake
ST-199
ST-242, ST-455
Adapter 5/8-18
thread
ST-333
64752
pipe bore salvage spark plug pad ST-370

pipe bore salvage
tool and wire
ST-228, ST-274
Adapter, Puller
check valve retainer
Countersink-
intake
ST-273
64861
crankshaft front oil crankshaft crankshaft

starter
rear
plug
64735
oil relief valve
ST-248, ST-439
oil tube
64737, 64831
64784
Crimping
Cutter
stripper
sludge tube
64748
jaw
salvage fretted crankcases

shroud tube relief ST-363
ST-145, ST-269
Arbor
connecting rod slave bolts ST-236, ST-237 counterweight balancing ST-96 finish pilot bushing 64590
B
oil pump housing 64868 valve seat ST-50, ST-51, ST-52, ST-53, ST-54, ST-55, ST-56, ST-57, ST-58
D
Ba11s- sizing- ST-147-1, ST-147-2, ST-300-1, ST-300-2, ST-300-3
Drift-
Bar, boring
accessory
cross
housing
cover
bushing
64884
shaft in accessory housing
64877
generator drive bushing 64870 valve parts, cleaning 64553 Blade, Counterweight- 64603-7 Blade, Valve Adjusting ST-418-3
Basket
bushing installation ST-276, ST-230 connecting rod bushing removal 64535 connecting rod bushing replacement 64536 crankshaft,~ front plug ST-234 crankshaft, oil plug 64647, 64754, ST-46, ST-295,
64770
crankshaft, oil tubes -64548, 64648, ST-44
Block
cylinder holding 64526, 64526-1,

thrust nut
vee
64526-2
64607
64545
Bolt Bracket
propeller 64982, 64983, 64984 engine lifting 64758
Burnisher-
connecting rod bushing 64580 magneto drive idler gear 64887 valve rocker bushing 64541 Bushing
oil relief valve
pilot bushing 64588 spline bushing ST-170 exhaust valve guide 64923 intake pipe bore salvage ST-230 magneto coupling sleeve 64741 magneto drive idler bushing 64743 main bearing oil tubes 64649 oil pump drive shaft bushing 64747 oil seal plug- 64770 outer rocker shaft bushing 64815, 64824 rocker shaft bushing 64814, 64825, 64816 starter drive adapter bushing 64745 valve guide 64505, 64796, ST-302, ST-303,
crankshaft valve seat
crankshaft
ST-304
ST-243, ST-245
C
ST-64, ST-65
ST-124 conversion
64939
Drillcrankcase thru-stud dowel dowel hole in crankcase Cable ST-379
Cap
engine lifting 1240, 64834, ST-220 protector, propeller shaft thread 72762
piloted, exhaust valve guide plate, turbocharger ST-135
ALPHABETICAL INDEX
(Cont.)
ST-10 ST-19
(Cont.)
ST-387
reduction gear
housing
tapper body magnaflux
Drill
Jig-
housing assembly ST-17, mounting bushing 64771 crankcase bearing oil drain ST-372 Drive Assembly test 64894
accessory
turbocharger, holding ST-133 valve guides, replace 64501, 64644,

valve
64714
crankcase
guide
hole
ST-179
valve rocker valve seat

Former
64540
ST-250, ST-232
ST-340
Driver
oil relief valve seat
bearing dowel
ST-378
ST-291, ST-305, ST-306, ST-307,

G
counterbore, intake pipe
ST-275
ST-92
counterweight bushing
crankcase thru stud crankshaft crankshaft intake
ST-316, ST-317
ST-168
Gage
belt tension
ST-131
plug
rear
64681
spline bushing
ST-332
dowel crankcase
oil relief valve
pipe bore salvage

ST-62
E
ST-253
ST-215, ST-249
valve seat cutters
connecting rod bolt stretch 64945 connecting rod bushing 64767 connecting rod parallelism and squareness 64530 counterweight bushing ST-94 counterweight, circlip -64892 counterweight, clearance in crankcase ST-37 countenireight- dial bore ST-73
counterweight, Expander piston ring 64528, 64560,

Expander and staking tool Eye engine lifting -64769,
64593
squareness
ST-91
64713
feeler- 64992
ST-48
F
Fixture
pin, depth ST-9 injector and controller ST-318 hydraulic tappet body 64909 intake pipe bore salvage ST-226 turbocharger ST-136 spring positions 64971
flush
fuel
housing bushing 64859 accessory housing cover bushing 64863 connecting rod bushing 64597 convert carburetor cylinder ST-28 counterweight bushing ST-93 crankcase fretting salvage ST-144, ST-252 crankshaft counterweight holes ST-280 crankshaft flange ST-256
accessory
valve clearance valve
62700, ST-23, ST-279
crankshaft gear drill ST-390 crankshaft oil seal retainer ST-40, ST-105 crankshaft rear spline bushing ST-169
cylinder shroud
drill
tube
ST-364 ST-377
bearing dowel hole fuel injector ST-319 grind bushing 64878
guides, bell mouthing ST-71, ST-310 valve guides ID 64514 Gage, flat plug connecting rod bushing 64537 rocker shaft bushing 64613 valve guide ID ST-81 Gage, plug by-pass valve ST-140, ST-141 rocker arm bushing 64542 rocker shaft bushing 64810, 64811, 64823, ST-191 valve guide ID 64901, 64927, ST-26, ST-155 Gage valve guide ID ST-314 valve guide OD ST-89, ST-89-1, ST-89-2, ST-89-3,
ST-89-4, ST-89-5, ST-259, ST-259-1, ST-259-2, ST-259-3, ST-259-4, ST-259-5, ST-429, ST-429-1, ST-429-2, ST-429-3, ST-429-4, ST-429-5, ST-431, ST-431-1, ST-431-2, ST-431-3, ST-431-4, ST-431-5
hydraulic
intake
lifters
ST-233
ST-277
pipe bore salvage ST-227, locating and reaming ST-149

oil seal cap ST-39
plug type, drill generator housing ST-20, propeller, shaft locknut assembly ST-329 reduction gear housing ST-8 reduction gear housing, drive plate dowel shroud tube adapter ST-357
ST-21
64827
Gage, plug and depth ST-126, ST-331 Gage block crankcase counterveight bushing ST-212 turbocharger ST-138
III
ALPHABETICAL INDEX
H Handle
(Cont.)
cylinder offset spark plug wrench ST-345 Holder, accessory drive shaft ST-173, ST-174 Holder, shroud tube barrel springs ST-37~ Hub Assembly 64774 Hub and Cone Assembly ST-415
I
base nut wrench
64711
engine mounting ST-47 impeller nut 64715

torque hold-down
ST-222
Plug bearing
Pointer
Protector
64906
crankshaft counterweight
ST-280-10, ST-280-ii
ignition timing
64697
thread -475-B, 72762, ST-86, ST-87
Puller
compressor pulley ST-321 crankcase thru stud ST-271
Indicator
Expander
ST-24
Inserting Tool 64594 Installer, seal ST-443

J
crankshaft crankshaft
spline bushing 64772 counterweight bushing

insert
64872
cylinder head
ST-356
Jaws, slide hammer puller
64886
64780
Jig
generator and alternator ST-158 generator drive countershaft 64728 magneto drive shaft sleeve 64766 magneto gear 64976
oil seal
supercharger
shaft gear
ST-172
64698
64843
welding, by-pass valve Jig, drill 64599
ST-139
pinion cage piston pin

valve
slide hammer
K
64782
guide
ST-49
R
Kit
engine overhaul ring mounting helicoil repair ST-184

valve train removal
ST-368
M
ST-239
Reameraccessory
housing
oil transfer tube
counterweight bushing
ST-210, ST-211
hole
ST-435, ST-436 64874, 64875, 64876,
Mount
crankcase, body fit thru studs 64902, 64903 crankcase, thru stud dowel ST-125, ST-328-2,
maintenance ST-460, ST-461 P
engine
crankshaft
ST-366-5, ST-366-1 flange ST-254, ST-255

64589
crankshaft, pilot bushing
Pilot
cylinder intake pipe

arm
head shroud tube

bore
ST-362 ST-231
seat
salvage
bar, rocker
crankcase
ST-160 ST-229
oil relief valve oil temperature
ST-244, ST-246
ST-324
ST-369
by-pass valve
ST-388
counterbore, intake bore salvage
pinion
cage
ST-150-1, ST-150-2, ST-299-1, ST-299-2,
spark plug pad

valve seat
ST-299-3
ST-66, ST-66-1, ST-66-2, ST-66-3, ST-66-4, ST-66-5, ST-67, ST-67-1, ST-67-2, ST-67-3, ST-67-4, ST-67-5, ST-68, ST-68-1, ST-68-2, ST-68-3, ST-68-4, ST-68-5, ST-257, ST-257-1, ST-257-2, ST-257-3, ST-257-4, ST-257-5
ream
propeller
shaft
bearing dowel
ST-380
reduction gear bolt
64891, 64891-1, 64891-2, 64893,
64893-1, 64893-2
Pin, locating Pin, locating

ST-179-3
valve
pinion cage ST-149-9 guide hole in cylinder head fixture
Plate
housing, dowel hole 64828, 64829, ST-12, ST-13, ST-14, ST-15 rocker shaft bushing ID 64819, 64820, 64821, 64822, 64826 rocker shaft bushing hole 64812, 64813, 64838, 64839, ST-427
reduction gear
bushing
crankcase
64856, ST-123, ST-270, ST-327

ST-122
shroud tube valve
adapter
ID
ST-354
guide
64684, 64900, 64925, ST-27,
IV
AVCO LYCOMING SERVICE TOOLS ALPHABETICAL INDEX
R (Cont.)
(Cont.)
64907
ST-113-1, ST-113-2, ST-143-1, ST-143-2, ST-181-1, ST-181-2, ST-267, ST-309-1, ST-309-2, ST-315,
91-338 valve
crankcase, thru stud high compression
spark plug, hell-coil insert 18MM 64596-1 Thermocouple Probe, Deck Temperature ST-264-B
ST-264-C
guide OD ST-90-1, ST-90-2, ST-90-3, ST-90-4, ST-90-5, ST-180, ST-258-1, ST-258-2, ST-258-3, ST-258-4, ST-258-5, ST-430-1, ST-430-2, ST-430-3, ST-430-4, ST-430-5, ST-432-1, ST-432-2, ST-432-3,
ST-432-4, ST-432-5
Thermocouple
Tool-
Extension
ST-265
baffle installation
64885
Removing Tool hell-coil insert 64595 Ring engine mounting 64759, ST-161, ST-272,
ST-285, ST-286, ST-287 Mount, Rubber test stand
S
64975
crankcase separator ST-389 crankshaft countenveight plug crankshaft oil seal

ST-383
64603
cooling -64612, 64857, 64867, 64888, 64944, ST-45, ST-114, ST-128, ST-164, ST-352 Skid overhaul ST-278
Shroud
Sleeve
crimping ST-22, ST-78, ST-198, ST-301 density controller adjusting ST-260 flare cylinder head shroud tube adapter ST-365 hydraulic tappet assembly 64941, ST-440, ST-474 fuel injector oil filter 64914 peening, crankshaft spline bushing ST-171
pressure controller lock
ST-284 ST-115
connecting rod and

64530-11
gage
64530-9, 64530-10,
propeller flange bushing roll pin spreader 64864

shroud tube holes shroud tube
64974
tubocharger piston
Socket-
ST-129
connecting rod nut ST-251 injector nozzle ST-190-2

oil pressure
screen
assembly and disassembly spinner, cylinder base nut 64987 valve adjusting ST-418
ST-361
ST-80
spark plug wrench ST-288 Spacerpinion cage ST-148 supercharger impeller 64704 Spinner cylinder base nuts 64987 Spinning Tool crankshaft oil tubes 64910 Spring Holder shroud tube ST-376 Spotfacer pilot and driver reduction gear modification rocker shaft bushing 64862
Stand
Universal
Drill, high compression crankcase

W
64908
Weight
Wrench Wrench
ST-112
counterweight balancing
accessory drive shaft nut
ST-95
64709
cankshaft
crankshaft
flange ST-313 spline 1225-B,
ST-38 ST-84
cylinder -64700, 64701, 64942, 64943, ST-83,

ST-322, ST-374, ST-375
overhaul- ST-162, 64916 test, engine

work
64947
reamer
64765, ST-43
ST-156
engine timing
exhaust
ST-235 64933
exhaust head manifold
Stop, Stop Collar
drill and
crankcase- 64905, ST-325

reduction gear housing seal holder crankcase ST-146 ST-11
pipe flange ST-163, fuel flow adjustment ST-29, impeller -64778 injector 64932, 64970
magneto- 64977, ST-79
oil pump drive ST-416 oil plug ST-107
oil
screen
ST-213
ST-30
Stud, crankcase plate
ST-122-2
Swaging
intake
Tool
pipe 64781, 64948, ST-289 turbocharger exhaust pipes ST-223

T
64946
pressure
controller, differential
ST-283
Tap
propeller ST-320 propeller flange spanner 64721 propeller shaft sleeve nut 64719 reduction gear housing ST-108
AVCO LYCOMING SERVICE TOOLS ALPHABETICAL INDEX
W (Cont.)
shroud tube
tee bar
ST-142
ST-345
bearing lock nut 40714 timing -64729, 64764 turbocharger ST-134 turbocharger impeller ST-177
thrust
vacuum
pump
64934
weatherhead fittings
ST-104
VI
Ref.
1
2
Tool No. 475-B

1225-B 1240
40714
Nomenclature and
Description
3
4
Protector, Crankshaft Propeller Nut Thread-All propeller shafts with No. 20 spline Wrench, Crankshaft No. 20 Spline All propeller shafts with no. 20 spline (See ST-38 for No. 30) Cable, Engine Lifting All engines employing two lifting straps Wrench, Thrust Bearing Lock Nut All reduction gear housing employing a thrust bearing lock
nut
5 6
7
62700 64501
64505 64514 64526
8 9 10
11 12
64526-1
64526-2 64528 64529 64530 64530-9
13
14
15
16
64530-10 64530-11
64535 64536
17
18
19
Gage, Valve Clearance 0-235, 0-290-D Series solid tappets only Fixture, Valve Guide Replacement All 4-3/8" and 4-7/8" bore cylinder assemblies Drift, Valve Guide Installation All (flange) intake valve guides and all (flange) exhaust valve guides incorporating the .404/.405 guide hole I.D. Gage, Valve Guide ID All intake valve guides and all exhaust valve guides incorporating the .404/.405 valve guide hole (See 64684 for Reamer) Block, Cylinder Holding All cylinder assemblies with 4-3/8" bore Block, Cgrlinder Holding All cylinder assemblies with 4-7/8" bore Block, Cylinder Holding All cylinder assemblies with 5-1/8" bore Expander, Piston Ring All cylinder assemblies with 4-7/8" bore Compressor, Piston Ring All cylinder assemblies with 4-7/8" bore Gage, Connecting Rod Parallelism and Squareness All engines Sleeve, Tapered, Connecting Rod Parallelism and squareness gage. Detail of 64530. Used on 2.4205/2.4210 bearing bores Sleeve, Tapered, Connecting Rod Parallelism and squareness gage. Detail of 64530. Used on 2.2970/2.2975 bearing bores Sleeve, Tapered, Connecting Rod Parallelism and squareness gage. Detail of 64530. Used on 2.4305/2.4310 bearing bores Drift, Connecting Rod Bushing Removal All engines Drift, Connecting Rod Bushing Replacement All engines
PS_3~FZ
9-10-11
806 o~
15
16 -17
ce~pas,
Ref.
20 21
22
Tool No.
64537 64540 64541 64542 64545
Nomenclature and Description
23 24 25 26 27 28 29 30 31 32 33
64548
64553 64559 64560 64580
64588
64589 64590
64593
64594
Bushing Rejection All engines All engines except 76 Series Fixture, Rebushing Burnisher, Valve Rocker Bushing All engines except 76 Series (Use with 64826) Gage, Plug, Valve Rocker Bushing ID (Finish)- All engines except 76 Series Block, Vee Check Crankshaft Run All engines Drift, Replace Crankshaft Oil Tubes (Sludge Tubes) All four cylinder direct drive engines employing sludge tubes Basket, Valve Parts, Cleaning All engines Compressor, Piston Ring All cylinder assemblies with 4-3/8" bore Expander, Piston Ring All cylinder assemblies with 4-3/8" bore Burnisher, Connecting Rod Bushing All engines Drift, Crankshaft Pilot Bushing All geared engines Reamer, Crankshaft Pilot Bushing Finish All geared engines Arbor, Crankshaft Pilot Bushing Reamer All geared engines Expanding and Staking Tool, 18 MM Spark Plug Hell-Coil Insert All engines (Includes long
Gage, Flat Plug Connecting
Rod
Valve Rocker
34
reach plugs) Inserting Tool, 18 plugs)
MM
Spark Plug Hell-Coil
Insert
All engines (Including long reach
spark
20
22
25
~I
24
26
28
a
30
umnuin~
29
27
cr~
32
33 34
Ref.
35
36
Tool No.
64595
Nomenclature and
Description
64596-1
64597 64597-10
37
38
Removing Tool, 18 MM Spark Plug Heei-Coil Insert All engines (Includes long reach plugs) Tap, 18 MM Heli-Coil Spark Plug Bottoming Tap .010 o/s All engines (Includes long reach plugs) Fixture, Remove, Replace, Burnish Connecting Rod Bushing All engines Spacer, Use under detail 1 or detail 9 to hold connecting rod level with fixture. Use with connec1.271 bearing cap width (detail of 64597) ting rods with
1.273
39
64597-11
Spacer, Use under detail 1 or detail 9 to hold connecting rod level with 1.331 ting rods with 1.333 bearing cap width (detail of 64597) Jig,
Generator
fixture. Use with
connec-
40
64599
Mounting Bushing
Drill for Dowel Pin
GO-435-C2 Series, GO-480-B1C, -C1D6,
-G1D6, -G1F6, -G2D6, -G2F6, -C2 Series, -F Series

41
64603
64603-7
Tool, Crankshaft Counterweight Plugs, Removal and Replacement
All
Counterweights
employing
42
threaded
plugs
43
44
64607 64612
Blade, Counterweight Removal and Replacement Plug Detail of 64603 Block, Thrust Nut in Thrust Plate Assembly Installation All reduction gear housings employ-
ing
thrust
bearing
locknut
Shroud, Cooling All four cylinder engines employing parallel valve cylinder except VO-360 and
IVO-360
45 46 47 48 49
64613 64644 64647 64648 64649
Gage, Rocker Shaft Bushing Rejection All engines except 76 Series Fixture, Valve Guide Replacement All angle head cylinder assemblies Drift, Crankshaft Front Oil Plug All geared engines except IGO-540, IGSO-540 and TIGO-541 Drift, Crankshaft Oil Tubes Replacement (Sludge Tubes) All six cylinder vertical engines and all geared engines employing sludge tubes Drift, Rear Main Bearing Oil Tubes GO-435-C2 Series, GO-480-B Series, -G1A6, -G1C6, -C1D6,
-G1D6, -G1F6, -G2D6, -G2F6, -C2 Series, -F Series
36
35
37
38
39 40
42
41
43
i~,g
I
J
49
47
46
48
Ref.
50 51 52 53 54 55 56 57
ToolNo.
64681
64684 64697
Nomenclature and
Description
64698
64700
64701
64704 64709
Driver, Crankshaft Welch Plug All direct drive except VO-435 and VO-540 Reamer, Valve Guide ID All intake valve guides and all exhaust valve guides incorporating the .404/.405 ID valve guide hole (See 64514 for Plug Gage) Pointer, Ignition Timing All direct drive except TIG-541 Puller, Pinion Cage All geared engines except TIGO-541 Wrench, (9/16" Spline) Cylinder base nut All engines employing 68515 nut (See 64701 for 3/4"
58
59
64711
64712
60 61 62 63
64
64713 64714 64715 64719

64721
Wrench) Wrench, (3/4" Spline) Cylinder base nut All engines employing 68514 nut (See 64700 for 9116" wrench) Spacer, Supercharger Impeller (This spacer is used as a tool in setting up impeller in supercharger housing assembly to obtain tool box clearance) All supercharger engines Wrench, Accessory Drive Shaft Nut All crosswise accessory housing Handle, Cylinder Base Nut Wrench Use with 64700 and 64701 Compressor, Piston Ring All 5-1/8" bore cylinder assemblies Expander, Piston Ring All 5-1/8" bore cylinder assemblies Fixture, Valve Guide Replacement All 5-1/8" bore parallel valve cylinder assemblies Plate, Impeller Nut All supercharged engines Wrench, Propeller Shaft Sleeve Nut All reduction gears employing nut PIN 67729 Wrench, Propeller Flange Spanner All engines with flanged propeller shaft less bushings except TIGO-541 (See ST-313)
50
52
54
55 56
57
60
53
59
r,::b
4~62
63
Ref.
65
Tool No.
64728 64729 64735 64737
Nomenclature and
Description
66 67
68
69 70 71
72
64741 64743 64745 64747
73
74
64748
64752 64754 64758 64759
75
76 77
Puller, Generator Drive Countershaft GO-480-B Wrench, Timing All engines equipped for hand starters Adapter, Puller, Crankshaft Front Oil Plug P/N 70432 VO-435, TVO-435, VO-540, TIVO-540 Adapter, Puller, Crankshaft Rear Oil Tube P/N 69844 VO-435, TVO-435, GO-480-D Series, -C1B6, -G1B6, -G1E6, GSO-480 Series, IGSO-480 Series, IGO-540 Series, IGSO-540 Series, VO-540 Series, TIVO-540 Series Drift, Magneto Coupling Sleeve Removal All engines with crosswise accessory housings Drift, Magneto Drive Idler Gear Hub Bushing All engines with crosswise accessory housings Drift, Starter Drive Adapter Bushing Ah engines with crosswise accessory housings Drift, Oil Pump Drive Shaft Bushing Removal All engines with crosswise accessory housings Adapter, Puller, Starter Jaw All engines with crosswise accessory housings Adapter, Puller, Check Valve Retainer All engines with crosswise accessory housings Drift, Crankshaft Oil Plug Installation VO-435, TVO-435, VO-540, TIVO-540 Bracket, Engine Lifting GO-435-C2A, -C2B, VO-435-A Series Ring, Engine Mounting All engines except turbochargq equipped and 10-720 series. (Use adapters 64898 or ST-88 with 4 cylinder engines. Use engine mounts ST-460 and ST-461 on applicable 6 cylinder direct drive engines). Use with ST-278, ST-162, and ST-165 as re-
quired.
78
64764
64765 64766
79
80
Wrench, Timing All engines with crosswise accessory housing not employing hand starters except VO-435-B1A and TVO-435-F1A Stand, Test-Helicopter Engines All six cylinder vertical engines Puller Magneto Drive Shaft Sleeve All engines employing crosswise accessory housing with rear mounted magnetos
81 82 83
64767
64769 64770
Gage, Connecting Rod Bushing ID Finish All engines Eye, Engine Lifting VO-435, TVO-435, VO-540, IVO-540 and TIVO-540 Drift, Oil Seal Plug Installation 0-235, 0-290, 0-320, 10-920, 0-340, 0-360, 10-960 and HIO-360 (Plug Size 1.753/1.755) PIN 61510
~iBPs,
86 -65
s7
68
69
70
71
72
76
73
74
75
82
77
80
83
Ref.
84 85 86 87
ToolNo.
Nomenclature and
Description
64771
64772 64772-1
64772-5 64773 64774
88
89 90 91 92
Drill, Jig, Mounting Bushing Crankcase 0-320 Puller, Crankshaft Spline Bushing Rear All engines with crosswise accessory housings Nut, Splined 13 Teeth Detail of 64772 Nut, Splined 14 Teeth Detail of 64772 Club, Test, GO-435-C2, VO-435, TVO-435, VO-540, IVO-540 and TIVO-540 (Use with 64774) All No. 20 spline propeller shafts with Hub and Cone Assembly, Test Club (4 Blade)
2.365/2.367 OD
64778
64780
64781 64782
64783
Wrench, Impeller GSO-480 Series, IGSO-480 Series and IGSO-540 Series Jig, Holding Supercharger Shaft Gear GSO-480, IGSO-480, IGSO-540 Series Swaging Tool, Intake pipe Engines employing intake pipe connections PIN 69602, 71699,
78914 with 1.672/1.696 ID
93
94
Puller, Slide
Hammer
Medium
Used with the
following tools: 64735, 64737, 64748, 64752,
95 96
97
64784 64796
64801
64784, 64831, 64866, ST-172 and ST-333 Club, Test (4 Blade)- GO-480-B, -C1, -D, -F2, -F4A6, -G1 Series; GSO-480-A1, -B1 Series; IGSO-480; IGO-540 and IGSO-540 Adapter, Puller, Crankshaft Sludge Tube VO-435; TVO-435; VO-540; TIVO-540; 10-720 and
all geared engines Drift, Valve Guide Installations All (Flange) valve guides with .4371.438, .43751.4385
ID valve
guide
hole
98 99 100
64802 64803 64807
*Club, Test 0-235 with AS-127 type 2 prop flange 0-290-D, 0-320-A, -C, -E series and IO-320A, -D, -E series, AIO-320-A, -B, -C. Use with 64979 or 64980 Club, Test 0-320-B, -D series, IO-320-B, -C series, 0-340-A, -B. Use with 64980 Club, Test 0-360; VO-360; 10-360; AIO-360; TIG-360; MO-360; HIO-360; IMO-360; 0-540; 10-540; TIG-540 and TIG-541 (Use with 64981) Club, Test GO-480-C2, -F6, -F1A6, -F3A6, -F3B6, -G2D6, -G2F6 series; GSO-480-A2A6, -B2
series (Use with 64840)
AS-127
Type
propeller flange
can
be identified
bushing
across
the center of the crankshaft to the
by measuring from one prop attaching opposite bushing. The center to center
measurement is 4-3/4 inches.
85-86-87
84
88-94-97 THRU 199

90
89
93 95
92
se
Ref.
101 102
Tool No.
64810 64811
Nomenclature and
Description
Gage, Plug, Rocker Shaft Bushing Hole in Cylinder Head All engines except 76 Series Gage, Plug,.005 ols, Rocker Shaft Bushing Hole in Cylinder Head All engines except Series (See ST-191 for .010 ols)
Reamer, .005 ols
Outer Rocker Shaft Outer Rocker Shaft
76
103
104 105
106
64812
64813 64814 64815 64816
64819
Bushing Hole in Cylinder Head All engines employing

Bushing Hole
in
angle angle
valves
Reamer, .010 o/s

valves
Cylinder Head All engines employing
107
108
109 110
111 112
64820 64821 64822 64823 64824
Drift, Rocker Shaft Bushing Removal All engines except 76 Series Drift, Outer Rocker Shaft Bushing Installation All engines employing angle valves Drift, Inner Rocker Shaft Bushing Installation All engines employing angle valves Reamer, Semi-Finish, Outer Rocker Shaft Bushing ID All engines employing angle valves Reamer, Semi-Finish, Inner Rocker Shaft Bushing ID All engines employing angle valves
Reamer, Finish Outer Rocker Shaft Bushing ID All engines employing angle valves Reamer, Finish Inner Rocker Shaft Bushing ID All engines employing angle valves Gage, Plug Rocker Shaft Bushing ID All engines except 76 Series
113
Drift, Outer Rocker Shaft Bushing Installation All engines employing parallel valves except
76 Series
114
64825 64826 64827

64828
Drift, Inner Rocker Shaft Bushing Installation

76 Series
All
engines employing parallel
valves
except
115 116
117
118
64829
Reamer, Finish Inner and Outer Rocker Shaft Bushings All engines employing parallel valves except 76 Series (Use with 64541) Fixture, Drill Drive Plate Dowel in Reduction Gear Housing GO-480-F Series, -C2 Series, -G2D6, -G2F6 and GSO-480-B2D6 Reamer, Drive Plate Dowel Hole in Reduction Gear Housing GO-480-C2 Series, -F Series, -G2D6, -G2F6 and GSO-480-B2D6 Reamer, Reduction Gear Housing Dowel Hole GO-480-C2 Series, -F Series, -G2D6, -G2F6 and
GSO-480-B2D6
101-102-112
103-104
105
107- 114
106-113
108
110
109
111
115
117
118
116
Ref.
119 120
121
Tool No. 64831 64834

64836
Nomenclature and
Description
122 123
124
64838 64839
64840
125 126 127 128
64843
64856
Rear Oil Tube 0-435-A, GO-435-C2 Series, GO-480-B, -C2, -F Series, -C1D6, -G1A6, -G2D6, -G1F6, -G2F6, -G1G6 Cable, Engine Lifting All engines not employing lifting eyes Adapter, Propeller Shaft Flange GO-480-C2 Series, -F6, -F1A6, -F3A6, -F3B6, -G2D6, -G2F6 Reamer,.005 ols Inner Rocker Shaft Hole in Cylinder Head (Used with 64812 reamer for angle head cylinder. Used for both shaft holes in parallel valve cylinders except 76 Series) Reamer, .010 ols Inner Rocker Shaft Hole in Cylinder Head (Used with 64813 reamer for angle head cylinder. Used for both shaft holes in parallel valve cylinders except 76 Series) Adapter, Test Club GO-480-C2 Series, -F6, -F1A6, -F3A6, -F3B6 Series, -G2 Series, GSO-480A2A6, -B2 Series Puller, Piston Pin All engines Bushing Plate, Crankcase and Accessory Housing Drill All engines with crosswise accessory
Adapter, Puller, Crankshaft
housings
64857 64859 64861 64862
Shroud, Cooling
All six
cylinder angle
valve
cylinders employing down draft exhaust except
TIO and TIGO-541
129
130
All engines with crosswise accessory housings Crimping Tool and Wire Stripper All 7MM ignition harnesses (See ST-198 for 5MM) Spotfacer, Inner Rocker Shaft Bushing All engines employing angle head valves
Fixture, Bore Accessory Housing Bushing
"~4
119 122
123
121
124
125
~gra
z9-~
~1
126
127
I;
kI~ ~T
129
129
130 128
Ref.
131
Tool No.
64863
Nomenclature and
Description
Fixture, Bore Bushing in Accessory Housing Cover All engines with crosswise accessory hous-
ings
132 133
64864 64866
Tool, Roll Pin Spreader (Connecting Rod)
All engines
employing
roll
pins
134
135 136 137 138 139 140 141
142
64867
64868
Adapter, Sludge Tube Removal 0-540, 10-540 (P/N 60449) Shroud Cooling All six cylinder parallel valve cylinders employing down draft exhaust Cutter, Oil Pump Housing (Convert to Large Capacity Filter) All crosswise accessory housings
64870
64872 64874
equipped with large filter Bar, Boring, Generator Drive Bushing

not
and Annulus in
Accessory Housing
All
engines with
crosswise accessory housings Puller, Remove and Install Crankshaft
Counterweight Bushings
All All
All
engines with
ST-210 ST-211
counterweight bushings
Reamer,.005 ols Counterweight Bushing Holes for.0075 ols) Reamer,.010 ols Counterweight Bushing Holes
for.0125 o/s)
64876 64877
engines with counterweights (See
64875
engines with counterweights (See
Reamer,.015 ols Counterweight Bushing Holes All engines with counterveights Bar, Boring, Cross Shaft in Accessory Housing All engines with crosswise accessory housings
64878
64884
64885 64886 64887
143
144 145 146
Fixture, Grind Bushings in Dynamic Counterweight All engines with counterweight bushings Bar, Boring Accessory Housing Cover Bushings All engines with crosswise accessory hous-
ings
Tool, Baffle Installation
All
engines
with
cooling baffles
Jaw, Slide Hammer Puller (Small Diameter) All engines (Use with 64782) Burnisher, Magneto Drive Idler Gear (Hub Assembly)- All engines with crosswise accessory
housings
133
132
135
137
136
,,_
134
:*p-i~
I;--
"i~
141
142
138
139
140 146
143
145
144
Ref.
147
Tool No.
64888
148
149
64891
64891-1
Shroud Cooling (Permanent Installation) All six cylinder down draft exhaust engines except IGO and IGSO-540, TIO and TIGO-541) Reamer, Body Fit Bolts Reduction Gear "Service" (STD) All geared engines in which PIN 71184 body fit bolts are to be installed in reduction gear housing Reamer, BodyFit Bolts Reduction Gear "Service" (.010 o/s) All geared engines in which PIN
71184
body
fit bolts
are
to be installed in reduction gear
housing
150 151 152

153
64891-2
64892
64893 64893-1
64893-2
154
155 156
157 158
64894 64894-1 64894-3

64894-4
All geared engines in which P/N housing body Gages, Check Circlips in Counterweights All engines with counterweights that employ circlips Reamer, Body Fit Bolts Reduction Gear (STD) All geared engines in which P/N 68364 body fit bolts are to be installed in reduction gear housing All geared engines employing P/N Reamer, Body Fit Bolts Reduction Gear (.010 ols) 68364-P10 body fit bolts in reduction gear housing Reamer, Body Fit Bolts Reduction Gear (.020 ols) All geared engines in which P/N 68364-P20 body fit bolts are to be installed in reduction gear housing Drive Assembly, Test All six cylinder, vertical engines (Use 74822 gasket)
Reamer, Body Fit Bolts Reduction Gear "Service" (.020 ols)

71184 fit bolts
are
to be installed in reduction gear
159 160
64894-5 64894-6
161
162 163
64894-7
64894-13
64894-16
3/8-16 thread (detail of 64894) Bearing, 2.001 OD x 1.377 ID x 1.19 long (detail of 64894) Spacer, Tapered 1.0 diameter x .150 thick (detail of 64894) Shim, Lamina~ed 7.13 OD x 4.63 ID x .060 thick (detail of 64894) Screw, Sholder -.500 diameter x 1.42 long 3/8-16 thread (detail of64894) Nut, 3/8-24 x 2.25 long 9116 hex (detail of 64894) Pad, Access hole cover (detail of 64894) Screw, Sholder .500 diameter x 1.72 long 3/8-16 thread (detail of 64894)
Nut, Slotted
148
149
150
152
153
154
158
157
156 160
161
163
155
9~
n<sI
162 159 10
Ref.
164
Tool No.
64898 64899
64900 64901 64902 64903
Adapter, Dynafocal
mounts
Mounts (Test Stand and of
Mounting Ring)- All engines employing

All
300
165
Adapter, Magnetic Particle Inspection
Hydraulic Tappets
engines except 0-235,
166
0-290-D, 76 Series, TIG-541 and TIGO-541 (Use with ST-387) Reamer, Valve Guide ID (Exhaust) All valve guides with.43751.4385 ID valve guide hole (See
64901 for Plug Gage) Gage, Plug Valve Guide ID (Exhaust)
167
All valve
guides
with .4375/.4385 ID valve
guide
hole
168 169 170 171 172 173

174
64904
64905 64906
(See 64900 for Reamer) Reamer, Rework High Compression Crankcase (Rough) 0-320, 0-340, 0-360, VO-360 and 0-540 Series To incorporate Body Fit Thru Studs (PIN 72698) and 0-540 Reamer, Rework High Compression Crankcase (Final)- 0-320, 0-340, 0-360, VO-360 Series To incorporate Body Fit Thru Studs (PIN 72698) Counterbore, Rework High Compression Crankcase "O" Ring Recess 0-320, 0-340, 0-360, VO-360 and 0-540 Series To incorporate Body Fit Thru Studs (P/N 72698) Stop Collar, Use with 64902 and 64903 Reamers High Compression Crankcase 0-320, 0-340,
0-360, VO-360 and 0-540 Series
To
incorporate Body
Fit Thru Studs
(PIN 72698)
64907
64908 64909 64910
175 176
Plug, Bearing, High Compression Crankcase 0-320, 0-340, 0-360, VO-360 and 0-540 Series To incorporate Body Fit Thru Studs (P/N 72698) Tap,.007 ols for 1/2" Thru-Stud, High Compression Crankcase, 0-320, 0-340, 0-360, VO-360 and 0-540 Series To incorporate Body Fit Thru Studs (PIN 72698) Universal, Drill 1/2" Rework High Compression Crankcase 0-320, 0-340, 0-360, VO-360 and 0-540 Series To incorporate Body Fit Thru Studs (PIN 72698) Gage, Reject Hydraulic Tappet Bodies All engines except 0-235, 0-290-D, 76 Series, TIG-541
and TIGO-541
Spinning Tool, Crankshaft Oil Tube Replacement (Sludge Tubes) sludge tubes
All
engines employing
o.
167 165 166
164
170 168
169 171
174 173
172
176
175
11
Ref.
177 178
179 180
ToolNo.
64914 64916 64917 64923 64925 64927 64932 64933 64934 64939
Nomenclature
andDescription
Tool, Remove Fuel Injector Oil Filter 1GSO-480 Series Stand, Overhaul All engines available from (B.K. Sweeney Mfg. Co., 6300 East 44th Ave., Denver 16, Colorado) Adapter, Overhaul All engines available from (B.K. Sweeney Mfg. Co., 6300 East 44th Ave., Denver 16, Colorado) Drift, Exhaust Valve Guide Installation All engines employing 1/2" (Flange) exhaust valve
guides
181
182
183
184 185 186 187
Reamer, Valve Guide ID (Brass) (Exhaust)- Pilot dia..48881.4893, Finished ID .49851.4995 (Not used on Ni-Resist guides) (See 64927 for Plug Gage) Gage, Plug, Valve Guide ID (Exhaust)- All valve guides with .49851.4995 ID valve guide hole (See 64925 for Reamer) Wrench, Offset Alien, Simmonds Injector Pump Installation 1GSO-540-B Wrench, 1/2" Top Exhaust Head Manifold Removal Tool 10-540 Series, IGO-540-B Series, IGSO-540-B Series, IO-720-B Series Wrench, 7116" Dry Vacuum Pump Installation All engines employing 3P-194 Pesco Vacuum
Pump
Piloted Drill, Install 1/2" Diameter Exhaust Valve Guide verted from 7/16" to 1/2" exhaust valves All
angle head engines
to be
con-
64941
64942
Tool, Remove Hydraulic Tappet Assemblies

TIG-541 and TIGO-541
All
engines except 0-235, 0-290-D,

71133 Nut
76
Series,
188
Wrench, (1/2" Alien) Cylinder Base Nut All engines employing PIN 3/8" wrench)
(See 64943 for
189
190
64943
64944
Wrench, (3/8" Alien) Cylinder Base Nut All engines employing P/N 71134 Nut (See 64942 for 1/2" wrench) Shroud, Cooling (Updraft Exhaust)- IO-540-B Series, IGO-540-B, IGSO-540-B Series, TIO540-A Series
181
177 180
184
183
178 179
182
188
189
186
C--"
;i
P
190
12
Ref.
191
Tool No.
64945 64945-7 64945-9 64945-10 64945-11 64946
64947 64948
Nomenclature and
Description
Rod Bolt Stretch All
Gage, Connecting
Dial Indicator Set Master 2.1255 Set Master 2.2555
engines employing stretch bolts
in
connecting rods
192 193 194 195 196

197
Detail of 64945
Length Length
Detail of 64945
Detail of 64945
indicator in Aero Commander
Gage Assembly and Set Masters Less dial Wrench, Offset, (1-5116") Change Oil Screen
198
IGO-540, IGSO-540 Stand, Work- IGO-540, IGSO-540 Swaging Tool, Intake Pipe, 0-235, 0-290, 0, IO, AEIO-320, 0-340, 0-360, 10-360, MO-360 engines employing intake pipe connections P/N 61376, 61377, 62115, 70482 with
1.422/1.446 ID
on
199 200 201 202 203 204
64970 64971
Wrench, Adjust Bendix Injector (Idle Speed)
Aero Commander
IGO-540 Series
Gage,
Check Switch and Retard Terminal Contact
Springs
Positions (200 Series
Magnetos)
All
64974 64975 64976
64977
engines employing
200 series
magnetos
Tool, Rework Shroud Tube Holes in Cylinder Head All engines employing angle head valves Rubber Mount, Test Stand (64765)- All six cylinder, vertical engines Puller, Gear, Magneto Assembly (PIN 60971) All engines employing low tension magnetos Wrench, Special, Gears on Low Tension Magnetos (PIN 60971)- All engines employing low tension magnetos
196
200
191 THRU 195
197
199
198
203
204
202
13
Ref.
205
206
ToolNo.
64979 64980 64981
Nomenclature and
Description
207 208 209 210

211
64982
64983
64984 64987 64988 64989

64992 72762
*Adapter, Test Club All engines with AS-127 Type 2 propeller flange with bushings for 3/8 inch propeller attaching bolts (See ST-455 for AS-127 Type 1 propeller flange) *Adapter, Test Club All engines with AS-127 Type 2 propeller flange with bushings for 7116 inch propeller attaching bolts *Adapter, Test Club All engines with AS-127 Type 2 propeller flange with bushings for 1/2 inch propeller attaching bolts Bolt, Propeller 3/8-24 Drilled Hex Head Use with Adapter 64979 Bolt, Propeller 7116-20 Drilled Hex Head Use with Adapter 64980 Bolt, Propeller 1/2-30 Drilled Hex Head Use with Adapter 64981 Spinner, Cylinder Base Nut All engines employing hex head cylinder base nuts
Club, Test- 10-720
212 213 214 215 216

217
ST-8
ST-9
218 219
ST-10 ST-11
Adapter, Test Club 10-720 Gage, Feeler to Set Simmonds 580 Injector IGSO-540-B Series Protector, Crankshaft Propeller Nut Thread All propeller shafts with No. 30 spline Fixture, Counterboring PIN 72572 Reduction Gear Housing Seal IGO and 1GSO-540 Depth Gage, Flush Pin, Counterbore Oil Passage Holes for "0" Rings on Reduction Gear Housing P/N 72572 IGO and IGSO-540 Drill, 4 Flute Flat Bottom, Drill Reduction Gear Housing P/N 72572 for Seal IGO and
IGSO-540
Stop Collar, 19/32" Diameter Drill Reduction

IGSO-540 AS-127
Gear
Housing P/N
72572 for Seal
IGO and
Type
propeller flange
can
be identified
bushing
across
the center of the crankshaft to the
by measuring from one prop attaching opposite bushing. The center to center
measurement is 4-3/4 inches.
211
208
209
210
205- 206-207
~8n,he
214
213
~p
216 215
219
~iZ218
217
14
Ref.
220
Tool No. ST-12 ST-13 ST-14 ST-15

ST-17
Nomenclature and
Description
All GO and GSO-480
Reamer, Hollow Dowel Holes in Reduction Gear
engines with flange

engines with engines with engines with
propeller
221
shaft
All GO and GSO-480 All GO and GSO-480 All GO and GSO-480
in P/N 68967
Reamer, Hollow Dowel Holes in Reduction Gear .005 ols
flange propeller shaft

222
flange propeller
223
224
shaft
flange propeller shaft Drill, Jig, Drill Hole to Pin
Generator Drive Shaft
Bushing
Accessory Housing
GO-480-B, -B1A6 and -B1E6

225 226 227 228 229 230
231
ST-19 ST-20 ST-21

ST-22 ST-23 ST-24 ST-25
ST-26
232
233 234 235 236
ST-27
ST-28 ST-29 ST-30
Drill, Jig, Remove and Install Generator Drive Gear Thrust and Drive Gear Bushings PIN 69525 Accessory Housing GO-480-B1C Fixture, Plug Type Drill, Generator Housing Assembly GO-435 and GO-480 Series Fixture, Plug Type Drill, Generator Housing Assembly GO-435 and GO-480 Series Tool, Crimping, Crimp Burndy Hy-Rings on Low Tension Harness Gage, Valve Clearance .028 .080 All engines requiring a valve clearance between .028 -.080 Indicator, Expander, Check alignment between crankshaft bore in accessory housing and the accessory drive GSO-480, IGSO-480 and IGSO-540 Series Compressor, Valve Spring and Bar All engines except 76 Series and TIG-541 Series (See St-266 and St-419) Gage, Plug, Valve Guide ID (Exhaust) All valve guides with.437/.438 ID valve guide hole (See ST-27 for Reamer) Reamer, Valve Guide ID (Exhaust) All valve guides with .4371.438 ID valve guide hole (See
ST-26 for
0-540
Plug Gage)
to convert carburetor
are
Fixture, Drill Jig used
cylinders
to fuel
injection cylinders
All 0-360,
10-360, 10-540 Wrench, Injector Fuel Flow Adjustment (Simmonds No. 580 Injector)- IGSO-540-B1A Wrench, Injector Fuel Flow Adjustment (Simmonds No. 580 Injector)- IGSO-540-B1A
cylinders
which
to be converted to
220
THRU
223 224
1~
227
228
225
226
229
232
231
235
236 233
234
15
Ref.
237 238
239 240
ToolNo. ST-37 ST-38 ST-39 ST-40
Nomenclature and
Description
Gage, Counterweight Clearance in Crankcase All VO-540 engines employing counterweights Wrench, Crankshaft No. 30 Spline All propeller shafts employing No. 30 spline Fixture, Insert Oil Seal in Thrust Bearing Cap All geared engines Fixture, Drill Four Holes in Crankshaft Oil Seal Retainer All direct drive engines with
241 242
ST-43 ST-44 ST-45 ST-46 ST-47 ST-48 ST-49 ST-49-4 ST-50-1 ST-50-2 ST-50-3
243
244
245 246 247

248
249 250
251
bearing bore 2.566/2.567 diameter This fixture can be used only when engine is disassembled. Stand, Engine Test VO-360 and IVO-360 Drift, Install Rear Crankshaft Oil Tube All engines with crosswise accessory housings employing crankshafts with rear crankshaft oil tube (PIN 69843) Shroud, Cooling VO-360 and IVO-360 Drift, Install Crankshaft Oil Plug 0-540, 10-540 and TIG-540 (Plug size 1.38011.382 PIN 71640) Plate, Engine Mounting VO-435, TVO-435, VO-540, IVO-540 and TIVO540 Series Eye, Lifting All vertical engines Puller, Valve Guide All engines Hex Head Cap Screw, Valve Guide Puller (Detail of ST-49)- All engines Cutter, Valve Seat (Intake) (.010 ols)- All cylinder heads with 2.307 valve seat hole
crankcase front main
Cutter, Valve Seat (Intake) (.020 ols)- All cylinder heads with 2.307 valve seat hole Cutter Valve Seat (Intake) (.030 ols) All cylinder heads with 2.307 valve seat hole
31.
j
23~ 242
iY
~TD
239
240
243
241
249
THRU
251
B
244
B
247
~ib,,
246
245
248
16
Ref.
252 253
254
255
Tool No.
ST-51-1
ST-51-2 ST-51-3
ST-52-1
Cutter, Valve Seat (Intake) (.010 ols) All cylinder heads with 2.281 valve seat hole Cutter, Valve Seat (Intake) (.020 ols)- All cylinder heads with 2.281 valve seat hole Cutter, Valve Seat (Intake) (.030 ols)- All cylinder heads with 2.281 valve seat hole
All cylinder heads with 1.734 valve seat hole Cutter, Valve Seat (Exhaust) (.020 ols)- All cylinder heads with 1.734 valve seat hole Cutter, Valve Seat (Exhaust) (.030 ols)- All cylinder heads with 1.734 valve seat hole
Cutter, Valve Seat (Exhaust) (.010 ols)
256 257
ST-52-2
ST-52-3
258 259 260 261 262
ST-53-1 ST-53-2 ST-53-3
Cutter, Valve Seat (Intake) (.010 ols) Cutter, Valve Seat (Intake) (.020 ols) Cutter, Valve Seat (Intake) (.030 ols)
All All All
cylinder cylinder cylinder
heads
with
2.074 valve seat hole
heads with 2.074 valve seat hole heads with 2.074 valve seat hole
ST-54-1 ST-54-2 ST-54-3

ST-55-1
263
264
265 266 267
hole Cutter, Valve Seat (Exhaust) (.010 ols)- All cylinder heads with 1.927 valve seat Valve Seat (Exhaust) (.020 ols) All cylinder heads with 1.927 valve seat hole Cutter, hole Cutter, Valve Seat (Exhaust) (.030 ols)- All cylinder heads with 1.927 valve seat
ST-55-2
ST-55-3
Cutter, Valve Seat (Intake) (.010 ols) All cylinder heads with 2.160 valve seat hole Cutter, Valve Seat (Intake) (.020 o/s)- All cylinder heads with 2.160 valve seat hole Cutter, Valve Seat (Intake) (.030 o/s)- All cylinder heads with 2.160 valve seat hole
Cutter, Valve Seat (Intake) (.010 o/s) All cylinder heads with 1.919 valve seat hole Cutter, Valve Seat (Intake) (.020 ols) All cylinder heads with 1.919 valve seat hole Cutter, Valve Seat (Intake) (.030 ols)- All cylinder heads with 1.919 valve seat hole
ST-56-1 ST-56-2
ST-56-3
268
269
270
271 272
ST-57-1 ST-57-2 ST-57-3 ST-58-1 ST-58-2 ST-58-3

ST-62 ST-63 ST-64 ST-65
Cutter, Valve Seat (Intake) (.010 ols)- All cylinder heads with 2.0885 valve seat hole Cutter, Valve Seat (Intake) (.020 ols)- All cylinder heads with 2.0885 valve seat hole Cutter, Valve Seat (Intake) (.030 ols) All cylinder heads with 2.0885 valve seat hole Cutter, Valve Seat (Exhaust) (.010 o/s)- All cylinder heads with 1.995 valve Cutter, Valve Seat (Exhaust) (.020 ols)- All cylinder heads with 1.995 valve Cutter, Valve Seat (Exhaust) (.030 o/s) All cylinder heads with 1.995 valve
seat hole seat hole seat hole
273 274 275 276

277
278
279
Driver, Special Length for Use with Valve Seat Cutters All cutters in ST series only Adapter, Hand Drive Use with ST-62 Driver Drift, Valve Seat Replacement All valve seats with dimensions between 1.870 and 2.040 Drift, Valve Seat Replacement All valve seats with dimensions between 1.575 and 1.710
ID
ID
252 THRU
269
270 THRU
275
276
278
279
17
Ref. 280
281
ToolNo.
Nomenclatureand
Description
ST-66 ST-66-1 ST-66-2

ST-66-3
282
283
284
ST-66-4 ST-66-5 ST-67

ST-67-1
285
286
Pilot, Valve Seat Cutter (Standard) All cylinder heads with .5913 valve guide hole Pilot, Valve Seat Cutter (.010 ols) All cylinder heads with.5913 valve guide hole Pilot, Valve Seat Cutter (.020 ols)- All cylinder heads with .5913 valve guide hole Pilot, Valve Seat Cutter (.030 o/s)- All cylinder heads with .5913 valve guide hole Pilot, Valve Seat Cutter (.040 o/s)- All cylinder heads with .5913 valve guide hole Pilot, Valve Seat Cutter (.005 ols)- All cylinder heads with .5913 valve guide hole
287 288 289

290
291
ST-67-2 ST-67-3
ST-67-4 ST-67-5 ST-68 ST-68-1
Pilot, Pilot, Pilot, Pilot,
Valve Seat Cutter (Standard)- All cylinder heads with .6613 valve guide hole Valve Seat Cutter (.010 ols)- All cylinder heads with .6613 valve guide hole Valve Seat Cutter (.020 ols)- All cylinder heads with .6613 valve guide hole
Valve Seat Cutter (.030 ols)- All cylinder heads with .6613 valve guide hole Pilot, Valve Seat Cutter (.040 o/s) All cylinder heads with .6613 valve guide hole Pilot, Valve Seat Cutter (.005 ols) All cylinder heads with .6613 valve guide hole
292
293
294 295 296
ST-68-2 ST-68-3
ST-68-4 ST-68-5
297
Pilot, Pilot, Pilot, Pilot, Pilot, Pilot,
Valve Seat Cutter
(Standard)
All
Valve Seat Cutter (.010 ols)- All Valve Seat Cutter (.020 ols)- All
Valve Seat Cutter (.030 ols)- All Valve Seat Cutter (.040 ols)- All Valve Seat Cutter (.005 ols)- All
cylinder heads with.6247 valve guide hole cylinder heads with .6247 valve guide hole cylinder heads with .6247 valve guide hole cylinder heads with .6247 valve guide hole cylinder heads with .6247 valve guide hole cylinder heads with .6247 valve guide hole
298
ST-71 ST-71-8 ST-73
299
300
301 302
303
ST-78 ST-79
ST-80
304 305 306
ST-81 ST-83 ST-84
Gage, Check Bell-Mouthing of Exhaust Valve Guides All parallel valve engines (See ST-310 for Angle Valves) Adapter (Post), Check Bell-Mouthing of 1/2" Exhaust Valve Guides All parallel valve engine (Detail of ST-71) Gage, Counterweight Dial Bore (.7485/.7505 ID of Bushings) Replace Bushings in Counterweights All engines equipped with counterweights employing bushings except counterweight PIN 77002 Tool, Crimping Connecting Rod Nut and Ring Gear Plate Nut All engines using crimp nuts Wrench, (Spanner) To Hold Magneto Gear All four cylinder engines Socket, (Special) (1-5116") Remove Oil Press~re Screen IGSO-540 Series Gage, Flat Plug Rejection (Intake Valve Guide ID) All engines Wrench, Break Loose Cylinder Base Nuts All engines employing 1/2" Alien head cylinder base
nuts (P/N 71133)
Wrench, Break
nuts
Loose
Cylinder
Base Nuts
All
engines employing 3/8" Alien head cylinder
base
(P/N 71134)
Ja
280 THRU 297
"IWs,
f4
298
299
301
300 302 303
304
305
306
18
AVCO LYCOMINC SERVICE TOOLS
Ref.
307 308
309 310
Tool No. ST-86 ST-87

ST-88
Nomenclature and
Description
Protector, Thread No. 20 Spline Shaft This tool must be used when changing propeller in order
to
keep
from
damaging propeller shaft threads
Protector, Thread No. 30 Spline Shaft This tool must be used when changing propeller in order
to keep from damaging propeller shaft threads Adapter, Dynafocal Mounts All engines employing 180 mounts Gage, Plug Valve Guide OD (Exhaust) (Standard) All valve guides with .62471.6257 valve guide hole in cylinder head Gage, Plug Valve Guide OD (Exhaust) (.010 o/s) All valve guides with .62471.6257 valve guide hole in cylinder head Gage, Plug Valve Guide OD (Exhaust) (.020 ols)- All valve guides with.6247/.6257 valve guide hole in cylinder head Gage, Plug Valve Guide OD (Exhaust) (.030 o/s) All valve guides with .62471.6257 valve guide hole in cylinder head Gage, Plug Valve Guide OD (Exhaust) (.040 ols)- All valve guides with .62471.6257 valve guide hole in cylinder head Gage, Plug Valve Guide OD (Exhaust) (.005 ols) All valve guides with .6247/.6257 valve guide hole in cylinder head
ST-89 ST-89-1 ST-89-2 ST-89-3
311 312
313
314
315
ST-89-4
ST-89-5
316 317 318
ST-90-I
Reamer, Valve Guide OD (Exhaust) (.010 ols)

hole in
All valve
guides with .62471.6257 valve guide guides with .6247/.6257 valve guide guides with .62471.6257 valve guide
cylinder head
All valve
All valve
ST-90-2
ST-90-3
Reamer, Valve Guide OD (Exhaust) (.020 o/s) hole in cylinder head Reamer, Valve Guide OD (Exhaust) (.030 ols)
hole in
cylinder head cylinder head
319 320
321
ST-90-4 ST-90-5
ST-91
Reamer, Valve Guide OD (Exhaust) (.040 o/s)- All valve guides with .6247/.6257 valve guide
hole in
Reamer, Valve Guide OD (Exhaust) (.005 ols)- All valve guides with .62471.6257 valve guide
hole in cylinder head Gage, Counterweight Squareness (Check Parallel and Squareness of Finished Inside Diameter of Bushing Hole) All engines equipped with counterweights employing bushings except Counterweight PIN 77002 Driver, Counterweight Bushing (Remove and Install Bushings) All engines equipped with counterweights employing bushings except Counterweight P/N 77002 Fixture Assembly, Counterweight (Install Bushings in Counterweights) All engines equipped with counterweights employing bushings except Counterweight PIN 77002 Spacer, Control Depth of Bushing .370 thick (detail of ST-93) Spacer, Control Depth of Bushing .440 thick (detail of ST-93)
322
ST-92
ST-93
323
324
325
ST-93-3 ST-93-5
i
309
310
THRU
315
307
308
322
316 THRU
320
321
323
THRU 325
19
Ref.
326
Tool No.
Nomenclature and
Description
ST-94
327
ST-95
328
ST-96
Gage, Counterweight Bushing Location (Check Hole Location After Grinding) All engines equipped with counterweights employing bushings except Counterweight P/N 77002 Check Balance of Counten~eight after Weight, Counterweight Balancing (.004 pound kebushing) All engines equipped with counterveights employing bushings except Counterweight P/N 77002 All Arbor, Counterweight Balancing (Check Balance of Counterweights after Rebushing) with counterweights employing bushings except Counterweight P/N engines equipped
77002
329 330
ST-104
ST-105
Wrench, Install and Remove Weatherhead Fittings All engines with crosswise accessory housings Fixture, Drill Four Holes for Crankshaft Oil Seal Retainer All direct drive engines with a 2.375 Crankshaft seal diameter This fixture can be used only when the engine is assembled.
331
ST-107
ST-108
332 333
Wrench, Front Oil Plug Remove and replace front oil plug (controllable pitch propeller) Wrench, Offset to Torque Nuts on Reduction Gear Housing All geared engines except
TIGO-541 Back
ST-112 ST-113-1
ST-113-2
Spotfacer,
Pilot and Driver
Modify all flanged reduction gear housings for use of body fit
Finished ID .49851.4995 Finished ID .4985/.4995
bolts
334
Reamer, Valve Guide ID Exhaust (Ni-Resist) Pilot Dia..48281.4833

for
large
ID valve
guide replacement (See
64927 for
Plug Gage) Plug Gage)

flanged propeller shafts employing
335 336 337
Reamer, Valve Guide ID Exhaust (Ni-Resist) Pilot Dia..47781.4783

for small ID valve guide replacement (See 64927 for Shroud, Cooling IO-720-B1A Up Draft Exhaust
ST-114
ST-115
Tool, Install and
Remove
Propeller Flange Bushings
All
bushings
ba328
il~ll327 326 332
331 330
329
334 333
335
337
336
20
Ref.
338
339
Tool No.
ST-122 ST-122-2 ST-122-3 ST-122-4
340 341
342
ST-123
engines Plate, Crankcase Separates and draws together doweled crankcase ing crankcase thru stud dowels Stud, Crankcase Plate -(Detail of St-122) Nut, (Detail of ST-122) Washer, (Detail of ST-122) All standard thru stud dowels Plate, Bushing (Crankcase) Drill and ream crankcase for base flange engines to employ crankcase standard thru stud dowels, except large cylinder
halves All
employ-
343 344
ST-124
crankcases (See ST-270) Drill, Crankcase (Standard) Thru Stud Dowel All engines
to
employ
to
crankcase standard thru crankcase standard
St-125 ST-126
stud dowels Reamer, Crankcase (Standard)- Thru Stud Dowel

thru stud dowels
All
engines
employ
345
Gage, Plug and Depth (Standard)- Crankcase

crankcase standard thru stud dowels
Thru Stud Dowel
All engines to
employ
346 347
ST-128
ST-129
Shroud, Cooling 10-720 A1A (Down Draft Exhaust) into bypass cylinder Sleeve, This tool is used to install AiResearch Piston (PIN 475515) T-1108 and T-1112 turbochargers
All
348 349
350
ST-131 ST-133 ST-134 ST-135
351
Tension Dial All direct drive engines Use with St-135 Fixture-Holding Turbocharger All T-1108 and T-1112 turbochargers back plate nut after it has been drilled and Wrench, Turbocharger Wrench is used to remove cracked All T-1108 and T-1112 turbochargers nut in order that is may be Drill, Plate, Turbocharger Drill plate is used to drill back plate All T-1108 and T-1112 cracked with a chisel. Use drill plate with holding fixture ST-133
Gage-Belt,
turbochargers
352
ST-136
Gage, Special Turbocharger (This T-1112 turbochargers
gage is used for
checking radial bearing play.) All T-1108 and
343
342
338 THRU
341 346 344
347
345
348
349
350
351
352
21
Ref.
353 354 355
Tool No.
Nomenclature and
Description
St-138
ST-139
ST-140
356
STL141
357 358
359
ST-142 ST-143-1
ST-143-2 ST-144
360
361
ST-145 ST-146 ST-147-I ST-147-2
362
363
364
ST-148
Gage, Block, Turbocharger This block is used to set up vernier height gage and oval indicator to measure impeller tip height All T-1108 and T-1112 turbochargers Jig, Welding Single Butterfly Exhaust Bypass Valve All turbochargers single butterfly exhaust bypass valve Gage, Plug Exhaust Bypass Valve (Wire Type for size up to .125 dia.) This is the clearance between the butterfly and the housing in the closed position All turbocharger exhaust bypass valves Gage, Plug, Double Exhaust Bypass Valve This is the clearance between the butterfly and the housing in the open position All turbocharger exhaust bypass valves used on TIG-541 engines Wrench, Shroud Tube All engines employing lock type shroud tubes Reamer, Valve Guide ID Exhaust (Ni-Resist) Pilot Dia..48281.4833 Finished ID .49951.5005 for large ID valve guide replacement (See ST-155 for Plug Gage) Reamer, Valve Guide ID Exhaust (Ni-Resist) Pilot Dia..47781.4783 Finished ID .49951.5005 for small ID valve guide replacement (See ST-155 for Plug Gage) Fixture, Salvage Fretted Crankcase Used on four and six cylinder engines with conventional crankcases. Use this tool with ST-145 and ST-146. (See ST-252 for crankcases with large cylinder base flanges) Cutter, Salvage Fretted Crankcase (Conventional)- See ST-144, ST-269 Holder, Stop Collar, Salvage Crankcase See ST-144 and ST-252 Balls, Sizing Pinion Cage, Balls are used to burnish pinion shaft holes to proper size All standard reduction gears (Tools ST-148, ST-149, ST-150 are used in conjunction with this tool) All engines with standard planitary reduction gears Spacer, Adjustable, Pinion Cage -Spacer is used inside of pinion cage to keep it from collapsing when sizing balls are pushed thru pinion cage -All engines with planitary reduction gears
355 353
356
358
359 360
362
O
363
361
364
22
Ref.
365
Tool No.
ST-149 ST-149-9 ST-150-1 ST-150-2 ST-155 ST-156 ST-158

shaft holes in Fixture, Location and Reaming Pinion Cage Gage was designed to keep pinion with planitary reduction gears alignment with fixture All engines Pin, Locating (Detail of ST-149) in alignment with fixture Reamer, Piloted Pinion Cage (.011" ols) To keep pinion shaft holes in conjunction with this tool) ST-149. (ST-147, ST-148, ST-149 and are used in alignment with fixture Reamer, Piloted Pinion Cage (.022" ols) To keep pinion shaft holes ST-149. (ST-147, ST-148, ST-149 and are used in conjunction with this tool)
366
367 368 369 370
Gage, Plug, Valve Guide
371 372
373 374 375
(Exhaust)- All cylinder heads with .49951.5005 ID valve guide hole (See ST-143-I or ST-143-2 for Reamer) thru-stud dowels (Tools ST-124 and Stop, Drill and Reamer All engines to employ crankcase used in conjunction with this tool) ST-125 are and 0-435 Puller ("V" Pulley) Generator and Alternator All direct drive engines except 0-145
ID
series
ST-160
ST-161 ST-162 ST-163 ST-164
ST-165
376 377
Assembling Rocker Arms to Cylinder Head All engines except 76 Series Ring, Engine Mounting TIG-541 and TIGO-541 Stand (Engine), A-Frame, Overhaul- All engines ST-213 for 1/2") Wrench, Remove Exhaust Pipe Flange (7/16") -TIO-541 and TIGO-541 (See Shroud, Cooling TIG-541 with ST-278 overhaul Adapter, Engine Overhaul Assembly All direct drive engines (Use A-frame skid)
Pilot Bar,
O
369
BID Tli
371
370
372
367 365
368
i
376
-e
377
373
23
Ref.
378
379 380
ToolNo. ST-168 ST-169 ST-170 ST-171
Nomenclature and
Description
rear
Driver, (Special Assembly) Crankshaft

cessory
spline bushing
All
engines with crosswise
ac-
housings
381 382
383 384 385 386
Fixture, Drill, Crankshaft Rear Bushing All engines with crosswise accessory housings Drift, Crankshaft Rear Spline Bushing Dowel All engines with crosswise accessory housings Tool, Peening, Crankshaft Rear Spline Bushing Dowel All engines with crosswise accessory
housings
ST-172
ST-172-5
Puller Set
Oil Seal
For Use With STD-547 Seal
ST-172-6
ST-172-7 ST-172-8
For Use With

For Use With
For Use With For Use With
387
388 389
ST-172-9
ST-173 ST-174 ST-177
ST-172-10 For Use With
64782 Slide Hammer) (Detail of ST-172) STD-O11 Seal (Detail of ST-172) STD-2217 and STD-208 Seals (Detail of ST-172) STD-213 Seal (Detail of ST-172) LW-14260 and 61165 Seals (Detail of ST-172) STD-1708 Seal (Detail of ST-172)
All
engines (Use with
390
391 392
accessory housings employing thirteen cessory drive shaft assemblies Holder, Accessory Drive Shaft All crosswise accessory housings employing fourteen cessory drive shaft assemblies Wrench, Turbocharger Impeller All T-1108 and T-1112 turbochargers
Holder, Accessory Drive Shaft All crosswise
spline
ac-
spline ac-
ST-179
Fixture, Reaming Valve Guide Hole

from 7/16" exhaust valves to 1/2" with this tool)
in
Cylinder Head
All
(10019 ST-180, ST-181 and ST-199
parallel valve engines converting are used in conjunction
393 394
395
ST-179-2
ST-179-3
ST-180
Bushing, Reaming valve guide hole in cylinder head fixture (Detail of ST-179) Pin, Locating Reaming valve guide hole in cylinder head fixture (Detail of ST-179) Reamer, Rework Valve Guide Hole in Cylinder Head All parallel valve engines converting 7116" exhaust valves to 1/2" (Tools ST-179, ST-181 and ST-199 are used in conjunction with
this tool)
391
379 378 380 381
~m,
389
393 392 390 382
THRU
388
395 394
24
Ref.
396
Tool No. ST-181-1
Nomenclature and
Description
All
Reamer, Valve Guide ID Exhaust (Ni-Resist)
parallel
valve
engines employing 1/2"
ex-
haust valves Pilot dia..4828/.4833 Finished ID .49851.4995 For large ID valve guide replacement (Tools ST-179, ST-180 and ST-199 are used in conjunction with this tool) (See
64927 for 397
Plug Gage)
Finished ID .49851.4995
are
ST-181-2
Reamer, Valve Guide ID Exhaust (Ni-Resist)- all parallel valve engines empoying 1/2" exhaust
valves
ment
Pilot dia..47781.4783
398 399
400
401
ST-184 ST-190-2
ST-191 ST-198 ST-199
(Toois Plug Gage) Kit, Hell-Coil Repair All engines Socket, Injector Nozzle All TIO541 and TIGO-541 engines Gage, Plug,.010 o/s, Rocker shaft bushing hole in cylinder head All engines except
for -See 64811 for .005 ols
ST-179, ST-180 and ST-199
used in
For small ID valve guide replaceconjunction with this tool) (See 64927
76 Series
402
on (5MM) harness (See 64861 for 7MM) Counterbore, Rework Parallel Valve Cylinder Heads in Exhaust Valve Guide Flange Area All parallel valve engines converting from 7/16" to 1/2" (flange) exhaust valves (Tools ST-179,
Tool, Crimping (Grounded Sheath) Crimp ends
403 404 405
ST-210
ST-211 ST-212 ST-213
ST-180 and ST-181 are used in conjunction with this tool) Reamer,.0075" ols Counterweight Bushing Holes All engines equipped with counterweights Reamer,.0l25" ols Counterweight Bushing Holes All engines equipped with counterweights Gage Blocks, Crankshaft Counterweight Bushing To check parallelism of counterweight
bushing
406 407
408 409
410
to crankshaft
All
engines equipped with counterweights
ST-215
ST-220 ST-222 ST-222-2
Wrench, Remove Exhaust Pipe Flange (112")- TIG-541 and TIGO-541 (See ST-163 for 7116") Driver, Sleeve, Oil Pressure Relief Valve All direct drive engines except 76 Series and adjustable valves. (See St-249 for driver used on adjustable valves) Sling, Engine Lifting TIG-541 and TIGO-541 Plate, Torque Hold-Down All engines except 0-235 series Insert, Torque Hold-Down Plate, (Detail of ST-222)
396
397
400 399
401
398
J
402 403 404
ST-212-E
405 406
407
~q"p
408
410
25
Ref.
411
Tool No. ST-223 ST-226
Nomenclature and
Description
412
Swaging Tool, Turbocharger Exhaust Pipes All turbocharger exhaust pipes used on Avco Lycoming engines Gage, Intake Pipe Bore Salvage (Determine necessity for salvage) IO, HIO, TIO and LTIO-540
tuned induction
413
ST-227
Fixture, Intake Pipe Bore Salvage (Mount housing and fixture

TIO and LTIO-540 tuned induction
to radial drill
press)
IO, HIO,
414
415
ST-228
ST-229
416 417 418
ST-230 ST-231 ST-232 ST-233 ST-234
Counterbore, Intake Pipe Bore Salvage IO, HIO, TIO and LTIO-540 tuned induction Pilot, Counterbore, Intake Pipe Bore Salvage IO, HIO, TIO and LTIO-540 tuned induction Drift, Bushing Installation, Intake Pipe Bore Salvage IO, HIO, TIO and LTIO-540 tuned induction
Reamer,.088
tion
.089
Pin, Intake Pipe Bore Salvage

All
IO, HIO, TIO and LTIO-540 tuned induc-
Fixture, Valve Seat Replacement and Refacing

valves
cylinder assemblies employing angle head
419
420
421
422
ST-235
ST-236 ST-237 ST-239
423
424
Fixture, Disassemble and assemble hydrauliclifters 76 Series, TIG-541 and TIGO-541 Drift, Crankshaft, Front Plug (OD Diameter 2.010/2.011) (PIN 77416) Wrench, Engine Timing (Starter Gear)- VO-435-B1A, TVO-435-F1A Arbor, Connecting Rod Slave Bolts All connecting rods with a bore diameter of 2.4205/2.4210 Arbor, Connecting Rod Slave Bolts All connecting rods with a bore diameter of 2.2870/2.2875 Kit, Engine Overhaul Ring Mounting (Use with ring ST-161) TIG-541 and TIGO-541
411 412
413
415
416
414
420 419
418
-~h
10
424
422
ok
421j
423
~da
26
Ref.
425
Tool No. ST-240
Nomenclature and
Description
426 427
ST-241
ST-242
Adapter, Engine Overhaul Assembly (Use with skid ST-278, overhaul stand ST-162 and ST-161 ring)- TIGO-541 Club, Test (Used with adapter ST-242)- TIGO-541 Adapter, Test Club TIGO-541 NOTE: The following tools, ST-243, ST-244, ST-245, ST-246, ST-248 and ST-249 are used to modify the crankcase for use of adjustable oil pressure relief valve. See latest revision of Service
Instruction No. 1172. Relief Valve (.001 ols) All direct drive engines Reamer, Oil Relief Valve (.001 ols) All direct drive engines Bushing, Pilot, Oil Relief Valve (.004 ols) All direct drive engines Reamer, Oil Relief Valve (.004 o/s) All direct drive engines .004 o/s) All direct drive engines (Use with Pilot ST-245) Countersink, Oil Relief Valve (.001 .004 o/s) All direct drive engines Driver, Oil Relief Valve (.001 Fixture, Valve Seat Replacement and Refacing All cylinder assemblies employing parallel
428
429
ST-243 ST-244 ST-245 ST-246
Bushing, Pilot, Oil
430
431 432
ST-248
ST-249
433 434
435
ST-250 ST-251
ST-252
valves
436
Socket, Connecting Rod Nut All engines Fixture, Salvage Fretted Crankcases Used
flange
437
on four cylinder engines with large cylinder base crankcases. Use this tool with ST-269 and ST-146. (See ST-144 for conventional
ST-253 ST-254 ST-255
438
439
crankcases.) Driver, Intake Pipe Bore Salvage IO, HIO, TIO and LTIO-540 Tuned Induction (Tools ST-226, ST-227, ST-228, ST-229, ST-230 and ST-231 are used in conjunction with this tool.) Reamer, Crankshaft Flange -.010 ols Bolt (Use with ST-256 Fixture)- All geared engines Reamer, Crankshaft Flange .010 ols Bolt (use with Fixture ST-256)- All six cylinder vertical engines
426
427
425
V~?
433
430
434
O
437
435
436 438 439
27
Ref.
440
441 442 443 444 445 446 447 448 449 450 451 452
Tool No.
ST-256
Fixture, Crankshaft Flange (.010 ols Bolt) Use with ST-254 and ST-255 Reamers
All
geared
ST-257 ST-257-1
ST-257-2
cylinder vertical engines Pilot, Valve Seat Cutter (Std.) All cylinder heads with .6933 valve guide hole Pilot, Valve Seat Cutter (.010 o/s) All cylinder heads with .6933 valve guide hole Pilot, Valve Seat Cutter (.020 o/s)- All cylinder heads with .6933 valve guide hole
and six
ST-257-3
ST-257-4
ST-257-5 ST-258-1 ST-258-2 ST-258-3 ST-258-4 ST-258-5 ST-259
Pilot, Valve Seat Cutter (.030 ols) All cylinder Pilot, Valve Seat Cutter (.040 ols) All cylinder Pilot, Valve Seat Cutter (.005 ols) All cylinder Reamer, Valve Guide OD (Exhaust) (.010 ols)hole in hole in hole in
hole in hole in
heads with .6933 valve guide hole heads with .6933 valve guide hole heads with.6933 valve guide hole All valve guides with .69331.6943 valve guide
cylinder
head
Reamer, Valve Guide OD (Exhaust) (.020 o/s)- All valve guides with .69331.6943 valve guide
cylinder head cylinder head cylinder head

All valve
Reamer, Valve Guide OD (Exhaust) (.005 o/s)
guides with .6933/.6943 valve guide
cylinder Gage, Plug, Valve Guide hole in cylinder head
head
OD
(Exhaust) (STD)- All valve guides with .69331.6943 valve guide
453 454
455
ST-259-1 ST-259-2
ST-259-3
Gage, Plug, Valve Guide OD (Exhaust) (.010 ols) All valve guides with .69331.6943 valve guide hole in cylinder head Gage, Plug, Valve Guide OD (Exhaust) (.020 ols) All valve guides with .69331.6943 valve guide
456 457 458
ST-259-4 ST-259-5
ST-260
459
460
461
ST-264-B ST-264-C
ST-265
cylinder head Gage, Plug, Valve Guide OD (Exhaust) (.030 ols)- All valve guides with .69331.6943 valve guide hole in cylinder head Gage, Plug, Valve Guide OD (Exhaust) (.040 ols)- All valve guides with .69331.6943 valve guide hole in cylinder head Gage, Plug, Valve Guide OD (Exhaust) (.005 ols)- All valve guides with .69331.6943 valve guide hole in cylinder head Tool, Density Controller Adjusting All engines employing a slotted head density controller adjustment screw Probe, Thermocouple Deck Temperature 3/8-16 NC-3 thread Probe, Thermocouple Deck Temperature 7116-20 NF-3 thread Extension, Thermocouple Use with ST-264-B, ST-264-C
hole in
g
441
~p
THRU
446
452 447 THRU 451
THRU
457
440
459
460
461
458
28
Ref.
462
Tool No. ST-266
Compressor, Valve Spring and
463
464
ST-267 ST-269
ST-270 ST-271 ST-272
Bar TIO-541-E Series, TIGO-541-E Series (See ST-25 and ST-419) Reamer, Valve Guide ID (Ni-Resist) Pilot dia. .47781.4783 Finished ID .4980. This reamer is us-
ed
Cutter,
only when valve guide is to be honed to size after reaming. Salvage Fretted Crankcase "Conventional and Large Cylinder
See ST-252
Base
Flange
Crankcases"
465 466 467
Plate, Bushing (Crankcase)- Drill and ream crankcase for standard thru-stud dowels All wide cylinder base flange crankcase (See ST-123 for conventional crankcases) Puller, Crankcase Thru-Stud All engines employing drive thru-studs Ring, Engine Mounting TIG-540 except -C1A, -E1A, -G1A, -H1A and -V2AD (Use with ST-278 and ST-162)
NOTE: The intake
468
ST-273
469 470
471
ST-274 ST-275 ST-276 ST-277
472
following tools, ST-273, ST-274, ST-275, ST-276 and ST-277 are used to modify the pipe bore in oil sump. See latest edition of Service Instruction No. 1168. Countersink, Intake Pipe Bore IO, AEIO, HIO, LIO and LHIO-360 engines employing large cylinder base flanges Counterbore, Intake Pipe Bore IO, AEIO, HIO, LIO and LHIO-360 engines employing large cylinder base flanges Driver, Counterbore, Intake Pipe Bore IO, AEIO, HIO, LIO and LHIO-360 engines employing large cylinder base flanges Drift, Bushing Installation, Intake Pipe Bore IO, AEIO, HIO, LIO and LHIO-360 engines employing large cylinder base flanges Fixture, Intake Pipe Bore IO, AEIO, HIO, LIO and LHIO-360 engines employing large cylinder base flanges
463
462 464
466
465
468
469
467
470
29
Ref.
473
474
475
Tool No. ST-278

ST-279 ST-280 ST-280-3 ST-280-7 ST-280-8 ST-280-9 ST-280-10
Nomenclature and
Description
476 477 478
Overhaul) All engines (Use with ST-162) All engines requiring a valve clearance between .040 .105 Gage, Fixture, Ream Crankshaft Counterweight All engines equipped with counterweights Plug, Std. Crankshaft Counterweight For.93691.9377 hole Plug may be used with fixture
Skid
(Engine
A-Frame
Valve Clearance
64873
or
ST-280
Plug,
.005 ols Crankshaft

or
Counterweight
For .94201.9425 hole For .94701.9475 hole
Plug Plug Plug
may be used with fixture may be used with fixture
64873
64873
ST-280
ST-280 For .95201.9525 hole
may be used with fixture
Plug,.010 ols Crankshaft Counterweight

or
479
480 481 482
483
Plug,.0l5 ols Crankshaft Counterweight

64873
or
ST-280
Plug,
.0075 ols Crankshaft

or
Counterweight For.9445/.9450 hole Plug may be used with fixture

Counterweight For.94951.9500 hole Plug may be used with fixture
64873
ST-280
ST-280 Pressure Controller
ST-280-ii ST-283
ST-284
Plug,
.0125 ols Crankshaft

or
64873
Wrench, Differential
Adjusting
All
All
turbochargers employing differential

pressure
pressure controllers Tool, Differential pressure controller lock
turbochargers employing differential
controllers
484
ST-285 ST-286 ST-287 ST-288 ST-289
485 486 487 488
Ring, Engine Mounting TIG-360 (Use with ST-278 and ST-162) Ring, Engine Mounting TIO-540-C1A and 6 cylinder direct drive engines without turbocharging (Use with ST-278, ST-162, ST-165) Ring, Engine Mounting TIG-720-A (Use with ST-278 and ST-162) hex All engines Socket, Spark Plug Wrench 7/8 Swaging Tool, Intake Pipe IO, TIG, HIO, LTIO-540 engines employing intake pipe connections PIN 72167, 72168, 72169 and 10-720 engines employing intake pipe connections P/N
75121, 75123, 75125 with 1.54211.568 ID
489
ST-291
Driver, Main Bearing Straight Dowel
All
engines employing straight
main
bearing
dowels
476
THRU 481
:I
473
475
~;of//
487 474
~L
482
483
488
484
THRU
486
489
30
Ref.
490
Tool No. ST-295 ST-297 ST-298 ST-299-1

ST-299-2 ST-299-3 ST-300-1 ST-300-2 ST-300-3
Nomenclature and
Description
491 492
493 494
495
496
497
ST-301 ST-302 ST-303 ST-304 ST-305 ST-306 ST-307 ST-309-1
498 499
500
501
Drift, Crankshaft, Oil Plug- IO, HIO, AIO, TO, TIG, LIO-360; O, TIG, LTIO-540; TIG-541 and 10-720 (plug size 1.251/1.254) Club, Test (Left hand rotation) LIO-320 Club, Test (Left hand rotation) LIO-360 Reamer, Piloted Pinion Cage (.011 ols) To keep pinion shaft holes in alignment with fixture ST-149 (ST-148, ST-149 and ST-300-1 are used in conjunction with this tool) Reamer, Piloted Pinion Cage (.022 ols) To keep pinion shaft holes in alignment with fixture ST-149 (ST-148, ST-149 and ST-300-2 are used in conjunction with this tool) Reamer, Piloted Pinion Cage (.033 0/9) To keep pinion shaft holes in alignment with fixture ST-149 (ST-148, ST-149 and ST-300-3 are used in conjunction with this tool) Balls, Sizing Pinion Cage, (-1, .011 o/s, -2, .022 o/s, -3, .033 ols) balls are used to burnish pinion shaft holes to proper size all heavy duty reduction gears (Tools ST-148, ST-149, ST-299 are used in conjunction with this tool) All engines with heavy duty planitary reduction gears. Tool, Crimping Crimp spark plug wire terminal on 5MM ignition harness having 5/8-24 nut All angle head engines employing Drift, Valve Guide Installation (Intake and Exhaust) flangeless valve guides Drift, Valve Guide Installation (Exhaust) All parallel head engines employing flangeless exhaust valve guides Drift, Valve Guide Installation (Intake) All parallel head engines employing flangeless intake valve guides All crankcases with 2.9370 bearing bore Driver, Bearing Dowel (Straight and Stepped)
diameter
502
503
Driver, Bearing Dowel (Straight and Stepped)

diameter
All crankcases with 2.5665

All crankcases with 2.8165
bearing bore
bearing
bore
Driver, Bearing Dowel (Straight and Stepped)

diameter
504
505
506
ST-309-2
ST-310
Reamer, Valve Guide ID Exhaust (Ni-Resist) Pilot dia..48281.4833 finished ID .50001.5010 for large ID valve guide replacement. (See ST-314 for Plug Gage) Reamer, Valve Guide ID Exhaust (Ni-Resist) Pilot dia..47771.4783 finished ID .50001.5010 for small ID valve guide replacement. (See ST-314 for Plug Gage)
Gage,
Check
Bell-Mouthing
of Exhaust Valve Guides
All
angle
valve
engines employing 1/2"
exhaust valves with down exhaust
(See ST-71 for parallel valves)
490
493
THRU
495
496
497
491
492
504
505
501
THRU
503
506
498
THRU 500
31
Ref.
507 508 509 510 511 512 513 514
Tool No.
Nomenclature and
Description
TIGO-541
ST-313 ST-314
ST-315
Wrench, Crankshaft Flange
Gage, Plug, Valve
Guide ID
(Exhaust)
All valve
guides with .5000/.5010
ID valve
guide hole
(See ST-315 for Reamer) Reamer, Valve Guide ID (Brass) (Exhaust)- Pilot dia..48881.4893 finished ID .50001.5010, (not
used on No-Resist Guides) See ST-314 for Plug Gage Driver, Crankcase Thru-Stud TIG-541 and TIGO-541 Driver, Crankcase Thru-Stud All engines employing thru-studs (except TIO and TIGO-541) Gage, Fuel Injector and Controller Linkage TIG-541 and TIGO-541 (Use with ST-319) Fixture, Fuel Injector and Controller Linkage TIG-541 and TIGO-541 (Use with ST-318) Wrench, Propeller TIGO-541 Puller, Compressor Pulley All engines employing compressors Wrench, (5/8" hex) Cylinder Base Nut All engines employing PIN STD-2106 nut Counterbore, Crankcase Oil Seal recess Use with ST-324, ST-325 All engines employing
crankcase thru-stud dowels
ST-316
ST-317
ST-318 ST-319 ST-320 ST-321 ST-322 ST-323

ST-324
515
516 517 518
Pilot, Crankcase Oil Seal Recess Counterbore Use with ST-323, ST-325 All engines employing
crankcase thru-stud dowels
519
520 521
522
ST-325 ST-327
ST-328-2 ST-329 ST-329-1 ST-329-2 ST-331
Stop Collar, Crankcase Oil Seal Recess Counterbore Use with ST-323, employing crankcase thru-stud dowels Plate, Bushing (Crankcase)- Use with ST-328-2 Ream crankcase for o/s
Reamer, Crankcase (.6350 diameter for .010 ols dowels)
ST-324
All
engines
thru-stud dowels
All
Use with ST-327
engines
to
employ
523 524
525
.010 ols thru-stud dowels
526
ST-332
Fixture, Propeller Shaft Locknut Assembly TIGO-541 Fixture, Propeller Shaft Locknut (Detail of ST-329) TIGO-541 Stand, Propeller Shaft Locknut (Detail of ST-329)- TIGO-541 Gage, Plug and Depth .010 ols Crankcase Thru-Stud Dowel All engines to employ crankcase .010 0/5 thru-stud dowels (See ST-126 for standard gage) Driver, Dowel Crankcase Drive Press fit dowels in crankcase All engines to employ crankcase
thru-stud dowels
509 507
514
508
510
511 512
519
o_
516
518
515
521 525
524
~U
523 522
520
526
32
Ref. 527
528
Tool No.
ST-333
ST-338
Adapter
5/8-18 NC-2 thread to 16 MM
2 thread
Use with Metric Slide Hammer Puller
529
530 531
ST-340
ST-345
ST-351 ST-352
ST-354
532 533
534
ST-356
Reamer, (Short) Hand-Expansion Valve Guide ID All cylinder head with 1/2" valve guide hole Former, Oil Relief Valve Seat (Use with ST-245) All engines Wrench, "T" Bar Spark Plug (Use with ST-288) All engines Club, Test (Left hand rotation) (Use with 64981)- LTIO-540 Shroud, Cooling All four cylinder angle valve engines Use with ST-356, TIO and TIGO-541-E engines Reamer and Stop, Shroud Tube adapter ST-362, ST-363, ST-364, ST-365. ST-357, ST-376, ST-361, All cylinder heads reworked to install Puller Insert, Shroud Tube Cylinder Head adapter shroud tube adapter (PIN LW-13398)- Use with ST-354, ST-357, ST-361, ST-362, ST-363,
ST-364, ST-365, ST-376, ST-381, ST-382. Fixture, Shroud Tube adapter Rework shroud tube adapter (PIN 77755) on TIO and TIGO-541E engines Use with ST-354, ST-356, ST-376, ST-361, ST-362, ST-363, ST-364, ST-365. Reamer Set, Crankcase Bearing Dowel All crankcases to employ .2545 or .2595 o/s Bearing
Dowel Hole
535 536 537 538
ST-357 ST-360
ST-361 ST-362
539
ST-363
Tool, Shroud Tube Barrel, Spring and Assembly TIO and TIGO-541-E Use with ST-354, ST-356, ST-357, ST-362, ST-363, ST-364, ST-365, ST-376, ST-381, ST-382. Reamer, (Tapered) Cylinder Head Shroud Tube Hole Ream cylinder heads to install (PIN LW-13398) adapter TIO and TIGO-541-E Use with ST-354, ST-356, ST-357, ST-361, ST-363, ST-364, ST-365, ST-376, ST-381, ST-382. Back Relief Cutter, Pilot and Driver Cutter to relieve cylinder heads to install (PIN LW-13398) adapter TIO and TIGO-541-E Use with ST-354, ST-356, ST-357, ST-361, ST-362, ST-364,
ST-365, ST-376, ST-381, ST-382. Fixture, Cylinder Head Shroud Tube Hole
Ream
540
ST-364
cylinder head
to install
(P/N LW-13398)
adapter
541
TIO and TIGO-541-E
Use with ST-354, ST-356, ST-357, ST-361, ST-362, ST-363,
ST-365
ST-365, ST-376. Tool, Flaring Flare cylinder head shroud tube adapter (P/N LW-13398)- TIO and TIGO-541-E -Use with ST-354, ST-356, ST-357, ST-361, ST-362, ST-363, ST-364, ST-376, ST-381,
ST-382.
528 527
529
530
531
533
534
i"
535
536
538
540
541
33
Ref.
542
Tool No.
ST-366-5
Nomenclature and
Description
Ream thru-stud hole in crankcase
Reamer, Piloted Crankcase (.005 ols)

PIN 76220-P05 thru-stud
All
engines employing
543 544 545 546 547 548 549 550 551
ST-366-1
ST-368 ST-369
Reamer, Piloted Crankcase (.010 ols)- Ream thru-stud hole in crankcase All engines employing
P/N 76220-P10 thru-stud
ST-370
ST-372
ST-374
ST-375 ST-376 ST-377
Kit, Valve Train Removal Remove valve train with a pumped up hydraulic Lifter Angle valve cylinders Pilot, Spark Plug Pad Counterbore Use with counterbore ST-370 All engines Counterbore, Spark Plug Pad Use with pilot ST-369 All engines Drill Jig, Crankshaft Front Oil Drain Crankcases with no thrust bearing oil drain converting to oil lubrication stainless steel thrust bearing TIGO-541 Wrench, Cylinder Base Nut (9/16 hex) All engines employing P/N STD-383-B nut Wrench, Cylinder Base Nut (3/4 hex)- All engines employing P/N STD-2090 nut Spring Holder, Shroud tube (Barrel Springs) All engines employing Barrel Springs on Shroud
Tubes Drill Fixture, Relocate front -TIGO-541
propeller
shaft drive gear
bearing dowel hole
in crankcase
552 553
554 555
ST-378 ST-379 ST-380 ST-383 ST-387 ST-388 ST-389 ST-390
556
557
Driver, Bearing Dowel (Straight) Crankcases with 2.923 bearing bore diameter TIGO-541 -Use with ST-377, ST-379, ST-380. Drill, Flat Bottom Propeller shaft drive bearing dowel hole in crankcase TIGO-541 Reamer, Propeller shaft drive gear bearing dowel in crankcase TIGO-541 Tool, Crankshaft oil seal installation All engines employing stretch seals Fixture, Tappet body Magnaflux All engines except 0-235, 0-290-D, 76 Series, TIO and TIGO-541 (Use with 64899) Reamer, Guide and Stop Oil temperature By-Pass Valve Seat All direct drive engines except
TIG-541
558
559
Tool, Crankcase separating All doweled crankcase with drive thru-studs Fixture, Drill, Crankshaft Gear TIO and TIGO-541
542
543 545
547
546
544
548
549
(-D
550 551
B
559
552
555 i-
556
553
557 558
554
34
Ref.
560
ToolNo. ST-415 ST-415-2 ST-416 ST-418 ST-418-3 ST-419 ST-427

ST-429
Nomenclature
andDescription
Assembly, Test Club (4 Blade)
All No. 30
Hub and Cone
Spline propeller shafts with
2.615/2.617 OD
561
562
563 564 565 566
Cone, Detail of ST-415 Wrench, Spline, Oil pump drive 76 Series engines Tool, (Solid tappets) Valve adjusting 0-235, 0-290-D Series Blade, Screwdriver Valve adjusting tool (Detail of ST-418)
Compressor, Valve Spring
76 Series
engines
0-235, 0-290 series cylinder for installation of
Reamer, (STD) Rocker Shaft Bushing Hole
bushings
567 568 569
ST-429-1 ST-429-2
ST-429-3 ST-429-4
570
571
572
ST-429-5
ST-430-1
573
574 575 576

577
ST-430-2 ST-430-3 ST-430-4 ST-430-5
Gage, Plug Valve Guide OD (Intake and Exhaust) (STD) All valve guides with .59131.5923 valve guide hole in cylinder head Gage, Plug Valve Guide OD (Intake and Exhaust) (.010 ols)- All valve guides with .59131.5923 valve guide hole in cylinder head Gage, Plug Valve Guide OD (Intake and Exhaust) (.020 ols) All valve guides with .59131.5923 valve guide hole in cylinder head Gage, Plug Valve Guide OD (Intake and Exhaust) (.030 ols) All valve guides with .59131.5923 valve guide hole in cylinder head Gage, Plug Valve Guide OD (Intake and Exhaust) (.040 ols) All valve guides with .59131.5923 valve guide hole in cylinder head Gage, Plug Valve Guide OD (Intake and Exhaust) (.005 ols) All valve guides with .59131.5923 valve guide hole in cylinder head Reamer, Valve Guide OD (Intake and Exhaust) (.010 ols) All valve guides with .59131.5923 valve guide hole in cylinder head Reamer, Valve Guide OD (Intake and Exhaust) (.020 ols)- All valve guides with .59131.5923 valve guide hole in cylinder head Reamer, Valve Guide OD (Intake and Exhaust) (.030 ols) All valve guides with .5913/.5923 valve guide hole in cylinder head Reamer, Valve Guide OD (Intake and Exhaust) (.040 ols) All valve guides with .59131.5923 valve guide hole in cylinder head Reamer, Valve Guide OD (Intake and Exhaust) (.005 o/s)- All valve guides with.59131.5923 valve guide hole in cylinder head
I
560
561
564
563 573
THRU 577
567 THRU
572
565
566
35
Ref.
578 579 580 581
ToolNo.
Nomenclature and
Description
All valve
ST-431 ST-431-1
ST-431-2
Gage, Plug Valve Guide OD (Exhaust) (STD) hole in cylinder head
guides with .66131.6623 valve guide
ST-431-3 ST-431-4
ST-431-5 ST-432-1 ST-432-2
582
583 584 585
Gage, Plug Valve Guide OD (Exhaust) (.010 0/9) All valve guides with .66131.6623 valve hole in cylinder head Gage, Plug Valve Guide OD (Exhaust) (.020 ols)- All valve guides with .66131.6623 valve hole in cylinder head Gage, Plug Valve Guide OD (Exhaust) (.030 ols) All valve guides with .66131.6623 valve hole in cylinder head Gage, Plug Valve Guide OD (Exhaust) (.040 ols) All valve guides with .66131.6623 valve hole in cylinder head Gage, Plug Valve Guide OD (Exhaust) (.005 ols)- All valve guides with .66131.6623 valve hole in cylinder head Reamer, Valve Guide OD (Exhaust) (.010 ols)- All valve guides with .66131.6623 valve hole in cylinder head Reamer, Valve Guide OD (Exhaust) (.020 ols)- All valve guides with .6613/.6623 valve
hole in
guide
guide guide
guide
guide guide
guide
cylinder
head
586 587 588
ST-432-3 ST-432-4 ST-432-5

ST-435 ST-436
hole in
hole in hole in
cylinder head
cylinder
head
Reamer, Valve Guide OD (Exhaust) (.040 o/s)- All valve guides with.66131.6623 valve guide Reamer, Valve Guide OD (Exhaust) (.005 ols)- All valve guides with .6613/.6623 valve guide
cylinder
head
589 590 591
ST-439
ST-440
592 593 594 595

596
Reamer, Accessory Housing Oil Transfer Dowel 1GSO-540 engines Reamer, Accessory Housing Oil Transfer Dowel IGSO-540 engines Countersink, (800) Oil Relief Valve Seat Repair 76 series engines with 1/2 inch oil supply port (Use with ST-245 bushing) Tool, Hydraulic Plunger Removal TIG, TIGO-541 series
Seal Puller and Installation Tool
Remove and install STD 2217 seal in with AS-127
vacuum
ST-443 ST-455 ST-456 ST-460

ST-461
*Adapter,
Test Club
All 0-235 bolts
engines Type
Type
1 prop
flange
and
pump adapter bushings for 3/8
inch prop
attaching
*Club, Test
prop
0-235 with AS-127 Maintenance
1 prop
flange (See
64801 for 0-235 with AS-127
Type
597 598
ST-474
All 6 cylinder direct drive engines without turbocharging. right top crankcase mounting pad Mount, Engine Maintenance All 6 cylinder direct drive Engines without turbocharging. with 64759 at left top crankcase mounting pad Tool Hydraulic Plunger Removal. 76 Series and TIG-541 Series with 64759 at AS-127
across
flange) Mount, Engine
Use
Use
Type 1 prop flanges can be identified by measuring from one prop attaching bushing the center of the crankshaft to the opposite bushing. The center to center measurement
is 4-3/8 inches.
~5h
578
THRU
583
584 THRU
588
589
590
591
-Q
542
3G3j,-
~h/,rI
593 597
594
595
598
36
SERVICE PUBLICATION CROSS REFERENCE INDEX
See Latest Revision Tool No.

1225-B
40714 64501 64514 64530 64535 64536 64547 64572 64580 64593
64594
Name
of Publication No.
Wrench
S.I. 1144 S.B. 290, S.I. 1144 S.I. 1246, S.I. 1366 S.I. 1425 S.B. 244 S.B. 244 S.B. 244 S.I. 1167 S.I. 1029 S.B. 244 S.I. 1043
S.I. 1043
Wrench
Fixture
Gage Gage
Drift
Drift Drift
Wrench Burnisher
64596-1
64597
Expanding Tool Inserting Tool Tap

Fixture Block Driver Drift
Reamer
S.I. 1043 S.B. 244 S.B. 184, S.I. 1144 S.I. 1167
S.I. 1098 S.I. 1425
64607
64648
64681 64684 64698 64700 64701 64719 64737
64765 64767 64770
Puller Wrench Wrench Wrench
S.B. 290 S.I. 1029 S.I. 1029 S.B. 290

S.B. 292
Adapter
Test Stand
S.I. 1144 S.B. 244 S.I. 1098 S.I. 1044, S.I. 1145 S.I. 1246 S.I. 1366 S.B. 216
S.B. 216
Gage
Drift
64772 64796 64810 64827 64828
Puller
Drift
Gage
Drill
Reamer
64829
64856 64861
64862
Reamer Drill
S.B. 216
S.B. 239 S.I. 1119 S.B.225 S.B. 252 S.I. 1142 S.I. 1142
Jig Crimping Tool Spotfacer

Counterbore
Puller Reamer Reamer Reamer
64868 64872 64874 64875 64876 64878 64891-1-2
S.I. 1142
S.I. 1142
Fixture
Reamer
S.I. 1143 S.B. 257, S.I. 1117

S.I. 1012
64892-1-2-3 64894
64899 64900
64901
Gage
Test Drive
Assembly
S.I. 1144 S.I. 1011 S.I. 1425 S.I. 1425 S.B. 273 S.B. 273
Adapter
Reamer
Gage
Reamer
64902 64903 64904
Reamer
Counterbore
S.B. 273
37
SERVICE PUBLICATION CROSS REFERENCE INDEX (CONT.)
See Latest Revision
Tool No.
64905
64906
Name
of Publication No. S.B. 273 S.B. 273 S.B. 273 S.B. 273
Collar
64907
64908 64910
Plug Tap
Universal
Spinning
Reamer
Tool
S.I. 1167
64923
64925 64927 64939 64942 64943 64915 64974 64975
Installation Drift
S.I. 1136
S.I. 1028 S.I. 1028, S.I. 1136, S.I. 1425 S.I. 1028
Gage
Drill
Wrench Wrench
S.I. 1029
S.I. 1029
Gage
Shroud Tube Tool
Gasket Fixture Drill
S.B. 302, S.B. 303, S.I. 1071, S.I. 1138, S.I. 1323, S.B. 371
S.I. 1347
S.I. 1144
ST-8 ST-10
ST-11 ST-23 ST-25 ST-26 ST-27
S.I. 1064
S.I. 1064
Stop Collar Gage Compressor Plug Gage

Reamer
S.I. 1064
S.B. 314, S.B. 315 S.I. 1425 S.I. 1246 S.I. 1246
ST-29 ST-30
ST-40
Wrench Wrench
Fixture Drift Puller Cutter Cutter Cutter
S.I. 1069
S.I. 1069
S.I. 1073 S.B. 292

S.I. 1092, S.I. 1136, S.I. 1246 S.I. 1092 S.I. 1092
S.I. 1092
ST-44
ST-49 ST-50 ST-51 ST-52 ST-53
ST-54
Cutter
Cutter
S.I. 1092 S.I. 1092
ST-55
Cutter
Cutter
S.I. 1092
S.I. 1092
ST-56 ST-57
ST-58 ST-62 ST-63 ST-64 ST-65
ST-66
Cutter Cutter
Driver
S.I. 1092 S.I. 1092

S.I. 1092 S.I. 1092 S.I. 1092
Adapter
Drift Drift
Pilot
S.I. 1092
S.I. 1092
ST-67
Pilot
S.I. 1092
S.B.
ST-71
ST-71-8
ST-73
ST-78 ST-83
ST-84
Gage Gage Adapter Gage

Plierwrench
~93,
S.I. 1088, S.B. 388
S.B. 388
S.I. 1143
S.B. 302, S.I. 1296
Wrench
Wrench
S.I. 1029
S.I. 1029
ST-91 ST-92
Cage
Driver
S.I. 1143 S.I. 1143
38

See Latest Revision
Tool No.
ST-93
Name Fixture
of Publication No. S.I. 1143 S.I. 1143 S.I. 1143

S.I. 1143
ST-94 ST-95
ST-96
Gage
Weight
Arbor Fixture
ST-105
ST-107
S.I. 1073 S.I. 1098 S.I. 1117
Wrench Pilot
Reamer
Reamer
ST-112
ST-113-1 ST-113-2 ST-115 ST-122 ST-123 ST-124
S.I. 1425
S.I. 1425 S.B. 253, S.I. 1098, S.I. 1111, S.I. 1342 S.I. 1112, S.I. 1123 S.I. 1112, S.I. 1123
Tool
Plate
Plate Drill
Reamer
ST-125
ST-126
S.I. 1112, S.I. 1123 S.I. 1112, S.I. 1123

S.I. 1112, S.I. 1123 S.L. L160, S.I. 1129
ST-131
ST-143-1 ST-143-2 ST-144 ST-145 ST-146 ST-147
ST-148 ST-149
Gage Gage
Reamer Reamer Fixture
S.I. 1342, S.I. 1425 S.I. 1342, S.I. 1425

S.I. 1112 S.I. 1112 S.I. 1112 S.I. 1114 S.I. 1114, S.I. 1236 S.I. 1114, S.I. 1236 S.I. 1114 S.I. 1425 S.I. 1112, S.I. 1123
Cutter
Holder
Ball
Spacer
Fixture Reamer
ST-150 ST-155 ST-156 ST-157 ST-158 ST-168

ST-169
Gage Stop Collar

Drift
S.I. 1112
S.I. 1283
Puller ("V" Pulley) Driver

Fixture Drift Tool
S.I. 1145
S.I. 1145 S.I. 1145 S.I. 1145 S.L. L195 S.I. 1136 S.I. 1136 S.I. 1136 S.I. 1122, S. L. L162 S.B. 387, S.I. 1231 S.I. 1153 S.I. 1136 S.I. 1142 S.I. 1142
ST-170 ST-171
ST-172
Puller Set
Fixture Reamer Reamer
ST-179 ST-180 ST-181 ST-184
Repair
Socket
Kit
ST-190-2
ST-198 ST-199
Crimping Tool
Counterbore
Reamer
ST-210
ST-211 ST-212 ST-222 ST-226
ST-227
Reamer
Blocks
Plate
S.I. 1142
S.I. 1112, S.I. 1029, S.I. ~1123, S.I. 1290 S.I. 1168
S.I. 1168
Gage
Fixture
ST-228
Counterbore
Pilot Drive
S.I. 1168 S.I. 1168
ST-229
ST-230
S.I. 1168
39
See Latest Revision Tool No. ST-231 ST-232 ST-236 ST-237 Name
Reamer
of Publication No. S.I. 1168 S.I. 1092
Fixture Arbor Arbor Drill

Drill
S.I. 1184 S.I. 1184

S.I. 1172
S.I. 1172 S.I. 1172
ST-243
ST-244
Bushing Bushing
Reamer Reamer
ST-245 ST-246 ST-248 ST-249 ST-250 ST-252 ST-253

ST-254
S.I. 1172 S.I. 1172 S.I. 1172 S.I. 1092 S.I. 1112 S.I. 1168
S.I. 1209
Countersink
Drift Fixture
Fixture Driver
Reamer Reamer
ST-255 ST-256
ST-264-B ST-264-C
S.I. 1209
S.I. 1209
Fixture
Probe Probe Extension
S.I, 1187
S.I. 1187
ST-265 ST-266 ST-267 ST-269
S.I. 1187 S.I. 1192, S.I. 1425 S.I. 1200

S.I. 1112
Compressor
Reamer
Cutter Plate Puller

Countersink Counterbore
Driver Drift
ST-270 ST-271
ST-273 ST-274
ST-275
S.I. 1112, S.I. 1123 S.I. 1123, S.I. 1290 S.I. 1168 S.I. 1168 S.I. 1168
S.I. 1168 S.I. 1168 S.I. 1142
ST-276
ST-277
Fixture
Fixture
ST-280 ST-289 ST-291 ST-299-1

ST-299-2 ST-299-3
Swaging
Driver Reamer
Reamer
Tool
S.I. 1355 S.I. 1225, S.B. 326
S.I. 1236 S.I. 1236 S.I. 1236 S.I. 1236 S.I. 1236
S.I. 1236
S.I. 1256, S.I. 1430 S.I. 1256
Reamer
ST-300-1
ST-300-2
ST-300-3
ST-302
Sizing Sizing Sizing

Drift
Ball Ball Ball
ST-303
ST-304 ST-305 ST-309-1
Drift
Drift Driver Reamer
S.I. 1256 S.I. 1225 S.I. 1116, S.I. 1425 S.I. 1116, S.I. 1425 S.B. 388
ST-309-2
ST-310
Reamer
ST-314 ST-315
ST-316
Gage Gage
Reamer
Driver
S.I. 1116, S.I. 1425 S.I. 1116, S.I. 1425 S.I. 1290 S.I. 1290 S.I. 1211
ST-317
ST-318
Driver
Gage
40
See Latest Revision
Tool No.
Name
of Publication No.
ST-319
ST-322
Fixture Wrench
S.I. 1211
S.I. 1029
ST-323 ST-324 ST-325 ST-327 ST-328-2

ST-329 ST-329-1
Counterbore
Pilot
S.I. 1123
S.I. 1123
Stop Collar
Plate
Reamer Fixture Fixture
S.I. 1123 S.I. 1123

S.I. 1123 S.I. 1292
S.I. 1292
S.I. 1292 S.I. 1123 S.I. 1123
ST-329-2 ST-331
ST-332
Stand
Gage
Driver Reamer Former
Reamer and
ST-338
ST-340
ST-354
S.I. 1116, S.I. 1425 S.I. 1172
Stop
S.I. 1297 S.I. 1297

S.I. 1297
ST-356
ST-357 ST-360 ST-361
ST-362
Puller Fixture
Reamers
S.I. 1225, S.B. 326 S.I. 1297

S.I. 1297
Shroud Tube Tool

Reamer
ST-363
ST-364 ST-365
Cutter Fixture
S.I. 1297 S.I. 1297 Tool S.I. 1297 S.I. 1290 S.I. 1290 S.I. 1029 S.I. 1292
S.I. 1297 S.I. 1312
Flaring
Reamer
ST-366-5 ST-366-1
ST-367 ST-372
ST-376
Reamer Wrench
Drill
Jig
Holder Fixture
Driver
Drill
ST-377 ST-378 ST-379

ST-380
S.I. 1312
S.I. 1312
Reamer Oil Seal Tool Fixture
S.I. 1312
S.I. 1303, S.I. 1324 S.I. 1011 S.I. 1316
ST-383
ST-387
ST-388
Reamer, Guide and Stop
ST-389
ST-394 ST-395 ST-418
Separator Tool
Wrench Tester
S.I. 1123
S.I. 1029
S.I. 1308 S.L. L196 S.B. 435 S.I. 1366 S.I. 1394
S.I. 1394 S.I. 1172 S.I. 1352, S.B. 424, S.B. 435 Tool
Tool
ST-419
ST-427 ST-435 ST-436
ST-439
Compressor, Valve Spring

Reamer
Reamer Reamer Countersink
ST-474
Hydraulic
41
OBSOLETE SERVICE TOOLS

Tool No. 218-B
1121-B
Description
Socket, Spark Plug Wrench (Replaced by ST-288) Cylinder Base Nut (Replaced by ST-367) Compressor Valve Spring (Replaced by ST-25) Wrench Thrust Bearing Locknut (Replaced by 40714) Wrench, Cylinder Base Nut (Replaced by ST-367) Wrench, Cylinder Base Nut (Replaced by ST-394, ST-375) Extension Cylinder Base Nut Wrench (No Replacement)
Bar
Wrench
1130-B
1228-B
61550
61551
61552 61678 64507
64509
64511
Wrench (No Replacement) Gage, Plug Valve Guide OD (Repiaced by ST-429-5) Gage, Plug Valve Guide OD (Replaced by ST-429-1)
Valve Guide OD (Replaced by ST-429-2) Valve Seat Removal (See latest revision of S.I. 1092) Holder Remove Valve Seat Counterbore (See latest revision of S.I. 1092) Counterbore Remove Exhaust Valve Seat (See latest revision of S.I. 1092) Counterbore Remove Valve Seat (Exhaust) (See latest revision of S.I. 1092)
Gage, Plug
Pilot
64516-1
64517
64518
64519
64520
64521
64522
64523 64525
64527
64547 64565 64571 64572
64579
64581 64582 64583
64597-1
64598
65600
64609 64635 64639 64642 64645 64670
64678-2
64678-3 64678-4 64678-5
64688
64690 64691 64692 64893 64694
64695 64696
Replace Valve Seat (Replaced by ST-250) (Replaced by ST-65) Drift, Replace Wrench, Cylinder Base Nut (Replaced by ST-394) Wrench, Cylinder Base Nut (Replaced by ST-367) Drift Replace Intake Valve Seat (Replaced by ST-65) Drift Piston Pin (Replaced by 64843) Drift, Crankshaft Oil Tube (Replaced by 64548) Drift, Main Bearing Oil Tubes (No Replacement) Gage, Plug Valve Guide OD (Replaced by ST-429) Wrench, Cylinder Base Nut (Replaced by ST-394) Drift, Main Bearing Oil Tubes (No Replacement) Plate Engine Mounting (No Replacement) Pointer Ignition Timing (No Replacement) Gage, Flat Plug Rejection Valve Guide ID (Replaced by ST-81) Fixture Remove, Replace, Burnish Connecting Rod Bushing ~Replaced by 64597) Drift Replace Generator Mounting Bushing (No Replacement) Gage, Plug Generator Mounting Bushing Finished ID (No Replacement) Shroud No Replacement Compressor Valve Spring (Replaced by ST-25) Gage, Plug Valve Guide OD (Replaced by ST-429-3) Drift Valve Seat Replacement (Exhaust and Intake) (Replaced by ST-64) Puller Valve Guide (Replaced by ST-49) Puller Generator Drive Shaft Gear (No Replacement) Reamer, Valve Guide OD (Replaced by ST-430-5) Reamer, Valve Guide OD (Replaced by ST-430-1) Reamer, Valve Guide OD (Replaced by ST-430-2) Reamer, Valve Guide OD (Replaced by ST-430-3) Wrench, Pinion Cage Locknut (No Replacement) Driver Relief Valve Sleeve (Replaced by ST-215)
Fixture
Remove and
Exhaust Valve Seat
Counterbore Counterbore
Counterbore Counterbore
Drift Fixture
Valve Seat Removal (Intake) (See latest revision of S.I. 1092) Valve Seat Removal (Exhaust) (See latest revision of S.I. 1092) Valve Seat Removal (Intake) (See latest revision of S.I. 1092) Valve Seat Removal (Intake) (See latest revision of S.I. 1092)
64699 64702 64703 64708
Replacement (Replaced by ST-64) Replacement (Angle Heads) (Replaced by ST-232) Drift, Piston Pin Puller (Replaced by 64843) Wrench, Pinion Cage Nut (No Replacement) Wrench, Engine Rotor (Replaced by 64764) Holder Accessory Drive Shaft (Replaced by ST-173, ST-174)
Valve Seat Valve Seat
42
OBSOLETE SERVICE TOOLS (CONT.) Tool No.

64717
Description Cylinder Base Nut (Replaced by 64942) Cylinder Base Nut (Replaced by 64943) Wrench, Pinion Cage Nut (No Replacement) Gage Flat Plug Rejection Valve Guide ID (Replaced by ST-81) Gage, Plug Valve Guide ID (No Replacement) Reamer, Valve Guide ID (No Replacement) Drift, Piston Pin Removal (Replaced by 64843) Tool Vertical Lifting (Replaced by ST-48) Drift, Crankshaft Rear Oil Tube (Replaced by ST-44) Skid, A-Frame Overhaul (Replaced by ST-278) Wrench, Magneto Bushing (No Replacement) Stand (Engine), A-Frame Overhaul (Replaced by ST-162) Handle, Cutter Valve Seat Recess (Replaced by ST-62, ST-63)
Wrench
Cutter Pilot Valve Seat Recess (Exhaust) (See latest revision of S.I. 1092) Valve Seat Recess Cutter (Exhaust and Intake) (See latest revision of S.I. Wrench
64718
64722
64724 64725 64726 64727 64753

64755 64760
64761 64762 64786
64787-1,-2,-3 64788-1,-2,-3
1092) 64789-1,-2,-3 64790-1,-2,-3 64791-1,-2,-3 64792-1,-2,-3 64793-1,-2,-3 64794-1,-2,-3 64795-1,-2,-3

64800 64804
Cutter Cutter Cutter

Cutter
Valve Seat Recess (Intake) (See latest revision of S.I. 1092) Valve Seat Recess (Intake) (See latest revision of S.I. 1092) Valve Seat Recess (Exhaust) (See latest revision of S.I. 1092)
Valve Seat (See latest revision of S.I. 1092) Valve Seat Recess (Intake) (See latest revision of S.I. 1092) Valve Seat Recess (Intake) (See latest revision of S.I. 1092)
Cutter
Cutter
Cutter
Valve Seat Recess
(Exhaust) (See latest revision
of S.I. 1092)
Club
Club
Test (Use 64801 or ST-456) Test (No Replacement)
64805
64806
Club
Club
Test (No
Test
Replacement)
(Four-Blade) (Replaced by 64773)
64808 64809
64817 64818 64832
Drill, Rocker Shaft Bushing Dowel Hole (No Replacement) Dowel, Installing, Rocker Shaft Bushing (No Replacement) Drift, Dowel Installation, Rocker Shaft Bushing (No Replacement) Cutter Rocker Shaft Bushing Dowel (No Replacement)
Jig Jig
Reamer
0.005 ols Inner Rocker Shaft

0.010 o/s Inner Rocker Shaft
Bushing Bushing
Hole in
Cylinder Cylinder
Head Head
(Replaced by (Replaced by
64338)
64833 64837
64842
Reamer
64839
Hole in
64869 64873 64873-10
64873-11
64879
Engine Mounting (No Replacement) Engine Mounting (No Replacement) Tool Install and Remove Propeller Flange Bushing (Replaced by ST-115) Fixture Ream Crankshaft Counterweight Holes (Replaced by ST-280) Plug, Crankshaft Counterweight (Replaced by ST-280-10) Plug, Crankshaft Counterweight (Replaced by ST-280-ii) Spacer Adjustable Install Bushings in Counterweights (Replaced by ST-93)
Plate
Counterbore
Plate
64880 64881
Counterbore Cutter Cutter
Exhaust Valve Seat Removal (See latest revision of S.I. 1092) Intake Valve Seat Removal (See latest revision of S.I. 1092)
64882-1,-2,-3 64883-1,-2,-3
64894-18 64896 64897-1 64897-2
64911
Intake Valve Seat Recess (See latest revision of S.I. 1092)
Valve Seat Recess (Exhaust) (See latest revision of S.I. 1092) Gasket, Test Drive (Use 74822 Gasket)
No No
Drift, Installation, Expansion Plug (Replaced by 64681)

Reamer Reamer
Replacement Replacement
Gage
Cutter
Cutter
64912,-1
64913,-1
64920
Check Cam Lobe Wear (No Replacement) Copperlytic Exhaust Valve Seats (No Replacement)
Copperlytic Intake Valve
Seats (No
Gage, Flat Plug Rejection Exhaust Valve Guide

43
Replacement) I.D. (See Table of Limits)
OBSOLETE SERVICE TOOLS (CONT.) Tool No.

64921
Description
Drift
Valve Seat
Replacement (Intake) (Replaced by ST-64)
64922-1,-2,-3
64924 64924-1 64924-2 64924-3
Cutter Intake Valve Seat (See latest revision of S.I. 1092) Reamer, Valve Guide OD (Replaced by ST-432) Reamer, Valve Guide OD (Replaced by ST-432-5) Reamer, Valve Guide OD (Replaced by ST-432-1) Reamer, Valve Guide OD (Replaced by ST-432-2)
64924-4 64926
64928 64929
Reamer, Valve Guide OD (Replaced by ST-432-3)
64930
64931
64935
64937
64938
64940 64969 64978
64985
64986 65521 65522 65523 65526 65528
ST-41 ST-42
ST-59
ST-60
ST-61
ST-74 ST-85
ST-90 ST-97
ST-98
ST-106 ST-110
ST-116
ST-117 ST-118 ST-119 ST-120 ST-121
ST-127-1 ST-130
ST-132
ST-151
ST-157 ST-175 ST-176
ST-178
ST-181
Plug Rejection Exhaust Valve Guide I.D. (See Table of Limits) Plug Valve Guide OD (Replaced by ST-431-5) Plug Valve Guide OD (Replaced by ST-431-1) Plug Valve Guide OD (Replaced by ST-431-2) Plug Valve Guide OD (Replaced by ST-431-3) Hub and Cone Assembly, (Replaced by ST-415) Wrench No. 30 Spline (Replaced by ST-38) Club Test (Replaced by 64783) Gage, Plug Valve Guide OD (Replaced by ST-431) Gage Dry Tappet Clearance (Replaced by ST-279) Reamer, Rocker Shaft Bushing Hole (Replaced by ST-427) Bolt Propeller (See 64801 or ST-456) Flange, Propeller (See 64801 or ST-456) Handle, Offset Spark Plug Wrench (Replaced by ST-345) Wrench Cylinder Base Nut (Replaced by ST-375) Wrench Cylinder Base Nut (Replaced by ST-374) Socket Universal Joint (No Replacement) Gage, Valve Clearance Dry Tappet (Replaced by ST-23) Fixture Spotface, Mill Contour of Stretch Bolt in Connecting Rod Cap (No Replacement) Drill Special Flat Bottom Core, Mill Contour in Connecting Rod Cap for Stretch Bolt (No Replacement) Pilot Valve Seat Cutter (No Replacement) Pilot Valve Seat Cutter (No Replacement) Pilot Valve Seat Cutter (No Replacement) Gage Ring (No Replacement) Fixture Drill Jig (No Replacement) Reamer Valve Guide OD (No Replacement) Gage Counterweight Hole Location (No Replacement) Weight Counterweight Master (No Replacement) Drift Crankshaft Oil Plug (No Replacement) Fixture Ream and back spotface reduction gear housing (No Replacement) Puller Remove Sludge Tubes from Crankshaft (Replaced by 64784) Gage, Flat Plug Rejection Exhaust Valve Guide I.D. (See Table of Limits) Gage, Flat Plug Rejection Intake Valve Guide I.D. (Replaced by ST-81) Gage, Flat Plug Rejection Exhaust Valve Guide I.D. (See Table of Limits) Gage, Flat Plug Rejection Exhaust Valve Guide I.D. (See Table of Limits) Gage, Flat Plug Rejection Exhaust Valve Guide I.D. (See Table of Limits) Fixture, Test Density Controller Calibration (Replaced by ST-282, ST-282-38) Drill, Piloted Counterbore Crankcase for Oil Seal Retainer (No Replacement) Meter Fuel Flow (No Replacement) Reamer Hand Valve Guide ID (Short) (Exhaust) (Replaced by ST-338) Driver Dowel Crankcase (Replaced by ST-332) Reamer, Crankcase Vent Hole (No Replacement) Fixture, Reaming Valve Guide Hole in Cylinder Head (No Replacement) Reamer (Piloted) Rework Valve Guide Hole in Cylinder Head (No Replacement) Reamer, Valve Guide I.D. Exhaust (Replaced by ST-181-1 and ST-181-2)
Gage, Gage, Gage, Gage, Gage,
Flat
44
OBSOLETE SERVICE TOOLS (CONT.)

Tool No.
Description
Wrench
ST-182 ST-183
ST-185
Wrench
ST-186 ST-187 ST-188 ST-189 ST-190 ST-190-1 ST-192 ST-193

ST-194
Cylinder Base Nut 3/8" (End Spline) (No Replacement) Cylinder Base Nut 1/2" (End Spline) (No Replacement) Plate, (4 Cylinder) Crankcase Body Fit Stud (No Replacement Bushing Bushing Plate, (6 Cylinder) Crankcase Body Fit Stud (No Replacement) Drill Jig, (4 Cylinder) Crankcase Bushing Pin (No Replacement) Drill Jig, (6 Cylinder) Crankcase Bushing Pin (No Replacement) Counterbore, Crankcase Bushing "O" Ring (No Replacement) Wrench Injector Nozzle (Replaced by ST-190-2) Wrench Injector Nozzle (Replaced by ST-190-2) Gage, Flat Plug Rejection Exhaust Valve Guide I.D. (See Table of Limits) Fixture, Test (Adjustable) Absolute Pressure Controller (Replaced by ST-282,
ST-282-38) Fixture, Test
Absolute Pressure Controller
(Replaced by ST-282, ST-28238)
ST-200 ST-202
ST-204 ST-205 ST-206
ST-207 ST-208
ST-209 ST-214 ST-218 ST-219 ST-238

ST-258
Rings, Engine Mounting (Replaced by 64759) Shroud, Cooling (Replaced by 64612 and ST-352) Reamer, Valve Guide ID (Exhaust) (No Replacement) Gage, Plug, Valve Guide ID (Exhaust) (No Replacement) Reamer, Valve Guide ID (Exhaust) (No Replacement) Gage, Flat Plug Rejection (Exhaust) (No Replacement) Gage, Flat Plug Rejection (Exhaust) (No Replacement) Gage, Plug, Valve Guide ID (Exhaust) (No Replacement) Wrench Cylinder Base Nut (No Replacement) Bearingizer Internal Thru 2.4210/2.4205 Dia. (No Replacement) Bearingizer Internal Thru 2.2875/2.2870 Dia. (No Replacement) Skid, Engine A-Frame Overhaul (Replaced by ST-278) Reamer, Valve Guide O.D. (No Replacement)
(See Latest Revision of S.L. 184) System (See Latest Revision of S.L. 184) Test Stand (See Latest Revision of S.L. 184) Driver, Bearing Dowel (Replaced by ST-291) Reamer, Hand Short Valve Guide (Replaced by ST-338) Driver, Intake Pipe Pin (No Replacement) Reamer, Crankcase Thru-Stud Dowel (No Replacement) Gage, Plug and Depth, Crankcase Thru-Stud Dowel (No Replacement) Gage, Plug and Depth, Crankcase Thru-Stud Dowel (No Replacement)
Test Stand Kit Vacuum
ST-282
ST-282-37 ST-282-38 ST-290
ST-308
ST-311
ST-328-1 ST-330 ST-331

ST-335
ST-336 ST-337 ST-387 ST-373

ST-391 ST-392 ST-393 ST-394 ST-395
ST-414 ST-430
81-432
Replacement Replacement Fixture No Replacement Wrench, Cyl. Base Nut (Replaced by ST-374) Fixture No Replacement Bushing Pilot, (Reamer) Oil Cooler Bypass Valve Housing (No Replacement) Driver, Seat Thermostatic Control Valve (No Replacement) Bushing Pilot, (Reamer) Oil Cooler Bypass Valve Housing (No Replacement) Wrench, Cyl. Base Nut (Replaced by ST-375) Tester, Magneto Pressurization (No Replacement) Extractor, Hydraulic Lifter Plunger (Replaced by 91-4743 Reamer, Valve Guide O.D. (No Replacement) Reamer, Valve Guide O.D. (No Replacement)
Counterbore
No
Counterbore
No
02
R ECIPRO CA TING
ENGINE
TROUBLE
Sn00TIlllL;
G~UIDE
~NILLIAIMSPORT PENNA.
1975 SSP-475
HECEIVED BY
INDEX
Page
No.
1.
2.
HARD STARTING
ROUGH IDLE
ENGINE WONT
5
9
6 IDLE
UNLESS BOOST PUMP
3.
ON
10 11 12
13
4.
5.
ENGINE WONT
POOR
IDLE
UNLESS BOOST PUMP OFF
IDLE
CUT-OFF
6.
7.
8. 9.
HIGH FUEL FLOW LOW FUEL FLOW ENGINE WILL NOT TURN STATIC RPM
14 16
17 19
15
18 20
ENGINE
SURGES
10.
11. 12. 13.
FAILURE OF ENGINE TO DEVELOP RATED POWER

LOSS OF POWER GOING TO ALTITUDE
21
26
29
25
28
CANNOT REACH SPECIFIED CRITICAL ALTITUDE

LOW OIL PRESSURE HIGH OIL CONSUMPTION HIGH CYLINDER HEAD TEMPERATURE SPLIT IN M.P.
33
36
39
34
37 40
14.
15.
41
16.
17. 18.
19.
(TWIN ENGINE)
42
43
HIGH OIL TEMPERATURE
44
45
46 47
HIGH M.P.
AT IDLE
HIGH OIL PRESSURE
INTRODUCTION
TROUBLE-SHOOTING
i.
the
to
Trouble-shooting
cause
for
way
A
solve rule
step-by-step procedure used to determine given problem and then selecting the best and quickest that problem. The use of turbochargers and automatic
a
is
the
complicated the trouble-shooting procedures. good trouble-shooting is to always start by disthe problem with the pilot and the facility management people cussing to assist you in narrowing the problem to as few possibilities as In the case of twin engine aircraft, lets make sure you possible. are working on the correct engine. After a thorough discussion and
to
controllers
has
somewhat
follow when
verbal
are
analysis of the problem, you are ready to go to work. If you experienced mechanic, you may be able to automatically eliminate of the probable causes. some If you are new on the job, you will have to go through all of the possibilities available to you. The important thing to remember is always start with the simple and inexpensive things first and work toward the more complicated, time consuming, and expensive things later.
an
2.
After the mechanic has received all possible information from pilot and management people, a quick observation of the external condition of the engine may give him an indication of the problem. Some areas to look are the intake and exhaust pipes for leaks, the ignition harness, breather, and the engine compartment for excessive oil stains, gas stains or exhaust stains. More information may be gained rather quickly by doing a compression check to locate any low Do a boroscope inspection to determine the compression cylinders. the
condition of the
combustion chamber.
presence
Some
obtained
is:
the
of
excessive
carbon deposits
information that may be indicates
high
oil
consumption;
the
continuous
cylinder compiled by removing

Note:
lean engine operation or detonation; walls may indicate broken rings. More
the
lack of carbon deposits may indicate scratched or scored

and
out
spark plugs
came
use
observing
of which
information may be their condition.
Keep track of which plugs

is
must
cylinders.
Another
be in the analysis program from develop a useful history of periodic The program must be carried samples of oil that were analyzed. by experienced and reputable people in the oil analysis field. extended
good trouble-shooting tool To be effective the engine

period of time
the
of
spectrometric oil analysis.

an
to
out
3.
The
following
we
list
of
problems,
it
selected because
believe
causes, and solutions was represents the more common and re-
curring problems encountered by mechanics when doing trouble-shooting. It should be noted that the list is general in nature, and does apply to both normally aspirated and turbocharged engines. The sequence in which the lists are arranged is not necessarily the exact step-by-step procedure -to use, but should be used as a guide to determine all of the possible causes and solutions to a problem and then decide on his own the exact procedure, always keeping in mind to do the simple and inexpensive things first, then prr,ceed with the more complicated and expensive things later.
1-
HARD STARTING
Cause
Solution
i.
Refer
Procedure
to
for
Solution
is
i.
Technique
operators
i.
Solution
self-explanatory.
manual
recommended start-
ing procedures.
2.
Flooded
2.
Clear engine
2. full
Crank
engine
with
throttle
in idle
open and mixture
cu~toff.
3.
Throttle valve
3.
Set
for
approximately
3.
Solution is
self-explanatory.
open
too
far.
800 RPM.
4.
Insufficient
prime
4.
Increase
same.
4.
not
Note:
Make
sure
primer
is
(may
be accompanied
by
leaking.
backfire).
5.
Mag impulse couplnot
5.
Remove
and
check for
5.
Remove mag
and check that broken and
ing
operating
binding,
or
broken im-
spring
is
not
fly-
properly.
pulse spring,
weights
torque
move
freely.
Check
nut.
on
coupling retaining
to
If unable
locate
and
problem,
check accord-
remove
coupling
S.I.
ing
6.
or
to
1096 and SI
1189.
Defective
spark plugs
6.
Inspect and replace
6.
Remove
plugs, inspect, clean,

as
ignition wire,
or
repair
as
necessary.
and/or replace
necessary.
harness
Visually inspect ignition

for breaks leads and
cracks.
Test
by removing
distributor
block from mag and
using
tester
or
Bendix
high
tension
or
lead
No.
11-8888
lent
11
8888-1
equiva-
type equipment.
HARD STARTING
7.
Low
(cont)
at
voltage
input,
7.
Check with voltmeter and

if necessary,
7.
Measure
voltage
between
"in"
vibrator
replace battery,
vibrator terminal marked

and
(Be
sure
battery
tight,
terminals are also check
ground
terminal while
Must
clean and
operating
least
starter.
be at
leads
for
condition.)
8 volts
on
12 volt
sy-
stem,
or
13 volts
on
24 volt
system.
8.
Inoperative
or
8.
Check and replace

if necessary,
8.
If
voltage
is
o.k, listen
of vi-
defective vibrator.
vibrator,
for interrupted
brator
buzzing
during starting.
is
If
no
buzzing
brator
circuit
heard, either
defective
or
vi-
is
the
from the
"output"
to
terminal
on
the vibrator
the retard contact

is
assembly
open.
Check both switch

Also
and retard circuit. check for
good electrical
ground.
9.
in
Retard
contact
assy.
9.
Check all connections
at
9.
Retard
due
points may
to
not
be
magneto
not
operating
Engine
may
switch and vibrator. retard
Adjust
appropriate
closing
justment
improper adhave
a
electrically.
kick back
points.
See for
or
may not
during cranking.
Bendix Manual
procedures.
good electrical
circuit.
connection in
Check for
good
con-
tact
of
switch and retard
leads
at
magneto and vibrator.
Check condition of wire.
3
10.
Vibrator
not
Magneto
10.
Check and
replace,
if
10.
Disconnect
Starter
and
all
in
combination
putting
necessary.
Spark Plug Leads.
Turn
engine
out
electrically.
right
open
direction until
retard
points
on
~1 cylinder firing posiHold ~1
tion.
plug
lead
approxi-
mately 3/16"
vibrator
from
ground, energize
switch
to
by turning
start.
Plug
of
lead
should
throw If
shower
sparks
weak
or
to
ground.
spark
is
missing, replace
for
vibrator.
Also check mag
correct
internal
timing.
of
Proper
may
in
duration of
shower
sparks
switch
be
checked
by holding
start
position,
until
and hand
turning
Degrees
prop of
sparks stop.
prop
rotation may be measured

to
or
estimated
determine
if
re-
tard
points
are
adjusted properly.
must
Note:
All checks
and
be made with
starter
plug
leads
disconnected.
11.
Magneto improperly
to
11.
Check mag timing
as
11.
Disconnect
starter.
Turn
timed
engine.
per
engine manufacturers
engine
in proper
rotation
to
~1
instructions.
cyl.
firing position.
to
Attach
timing light
primary leads
of mag
Rotate
(marked switch)
lead
until
to
and
ground
engine.
engine
advance
points break,
-4indicated
by timing lights going

on,
out
or
coming
depending
Observe
dn
type of light used.

when
that
points break,
are
timing
marks
on
engine
marks
aligned.
located
on
Engine timing
are
engine
as
follows:
Direct Drive Line
starter
on
ring gear
TIGO
to
dot
on
starter
hsg.
Degree markings
to
on
crank-
shaft
split
of
case
observed
at
top front of Engine.
Geared
mounted
Supercharged
to
Pointer
accy.
hsg.
to
lined
bevel
tooth
on
camshaft
side
gear of
observed
on
right
engine
in accy.
housing
from
12.
Magneto internal
not
12.
Adjust magneto
timing,
if
or
Remove mag
to
engine
and
turn
timing
adjusted
E"
gap
of
internal
mag
~1
firing position, attach

turn mag
properly
or
replace points
either follower
timing light,
rotation.
in
proper
drifting because
point
or
or
Observe
that when
lights
the
follower
wear.
points
are
worn.
go
out,
built-in
pointers
in
in
magneto
are
aligned
the
observation window
provided.
(See
Bendix Maintenance
Instruction
Manual
13.
for your
particular mag.)
from
13.
Impulse coupling
mag,
Repair
or
replace
13.
Remove
magneto
engine,
on
inoperative.
impulse coupling,
turn
in
proper
direction
by
hand
and
observe
that
flyweights
contact
in
impulse coupling
If this
stop pins.
condition does
not
exist,
flyweight
ively
be
in and
axles
are
worn
excess-
impulse coupling
If
must
replaced.
flyweights
rotate
are
good condition,
times
to
mag
several
snap
impulse
and
determine
not
that
impulse spring
on
is
broken.
Check torque
nut
to
impulse coupling
it is
not
be
sure
binding
due
to
an
over
torque condition.
For
complete
information
on
maga
neto
impulse couplings, get

the
copy of IMPULSE
booklet, "I
~M YOUR
COUPLING", fL-1019
Sidney,
N.Y.
from
Bendix at
6
RBUGH IDLE
Cause
Solution
to
Procedure
for
Solution
mixture is
i.
Mix
rich
is
or
lean
i.
Adjust
idle mixture
i.
too
Lean
engine if
(If
poor
mixture
lean,
rich.
and
Engine will smooth

up
RPM
as
acceleration may
out
pick
it
is
be
noticed).
leaned.
If mixture
is
too
lean,
more
condition will become
aggravated
as
engine
proper
is
leaned.
mixture
Adjust
for
by turning scalloped
side of
wheel at
injector
to
either rich
or
lean
condition,
and
as
indicated
by
arrow
letter "R"
located
Note:
on
injector
linkage.
is
After mixture idle
set,
re-adjust
speed
to
desired RPM,
if necessary.
2.
Plugged
nozzles
2. with
Cle
an
nozzles, inspect
before
is
2.
Wash in acetone
or
MEK,
(Usually accompanied by
indicated
magnifying glass
if
blow out with compressed air.

Note:
high
fuel
flow).
cleaning
found,
to
contamination
Flow-check nozzles
of
in
con-
remo~e
same.
No
need
tainers
equal
or
size
to
lo-
check further.
Note:
May
cate
plugged
partially
(S.I. 1275)
locate
problem by feeling for
plugged
nozzles.
cold 3.
Induction air
of
cylinder.
Check
leak
3.
previously
and
mentioned
3.
Solution is
self-explan-
at
one
the
following
locations
tighten
or
re-
atory.
locations:
place
and
as
necessary.
a) b) c) d) e)
Hoses
hose
clamps.
Cracked
Bad
int,
pipes.
gaskets. Loose flange bolts Loose plugs in int. of cylinders.
port
f) Fuel
drain valve
not
seating properly.
4.
Cracked
engine moun~s
bush-
4.
Replace
same
4.
Solution
is
self-explanatory,
or
defective mount
ings.
5.
Mount
bushings
installed.
im-
5.
Install
as
per
manu-
5.
Solution
is
self-explanatory.
properly
facturers
instructions.
6.
Internal
injector leak
to
6.
Replace injector.
6.
Check
by disconnecting
at
(Usually
injector
hold
unable
adjust
or
induction system
injector
at
idle)
wont
inlet
to
observe
throttle
impact tubes,
in
adjustment,
then
put
full
for-
ward
position and mixture in

rich
full
line
position, cap fuel

turn
to
flow divider,
pump,
on
boost
and
if
fuel
is
observed
coming
out
of
impact
internal
tubes, then injector

leak and must be
has
replaced.
7.
and
Fuel
vaporizing
in
lines
7.
I(eep ground operation

a
7.
Solution is
self-explanatory,
distributor, (encountered
at
to
minimum and
operate
in
only
high
ambient
temperopera-
with cowl
flaps
full
atures
and.prolonged
low
or
open
positions.
(If
tion at
idle
RPM).
necessary,
operate with
booster
pump
on.)
8.
Nozzle
screen
and
8.
Replace nozzle.
8.
Remove
nozzles
from
cylinder
shroud deformed
it
to
ex-
so
that
they
may be
adequately
tent
blocks
or
inspected.
air
partially
blocks
bleed hole.
9. fuel
Sticking
valve
in
9.
Disassemble and
clean.
9.
Remove
divider
from
engine.
dirt. hand
flow divider.
Disassemble and
flush out
Also divider valve may be
lapped
burrs
Never
in seat
to
remove
any
Note:
that may be
present. fuel
interchange
and do
flow divid-
er
parts
not
damage dia-
phragm.
10.
Uneven
cylinder
10.
Differential
to
check if
10.
Differential compression
compression.
cylinders
further
determine
check is
accomplished by rotating
to
disassembly
are
and
cylinder
on
be checked
to
T.D.C.
repairs
necessary.
compression stroke and intro80 psi airinto

how much
ducing
and
cylinder
is
re-
observing
tained.
Step-by-step procedures
and equipment requirements will

be found
in S.I.
1191.
11.
Improper fuel
11.
Adjust
as
necessary.
11.
Minimum
and maximum
limits
airframe
pressure.
are
found
in
engine
and
manufacturers
operatess
manual.
12.
Faulty ignition
12.
Check mag drop and
12.
Set
engine
prop
to
produce 50-65%
min.
system.
condition of leads.
plugs
and
power with
at
angle.
Check both mags
for
excessive
dropoff.
Note:
Smooth dropoff indicate
that exceeds lean
limits may
or
ridh
injector
must
or
car-
buretor.
Leads
be checked
block
by removing distributor
from mag and
using
Bendix
high
-9-
tension
lead
tester, ~11-8888
or
11-8888-1
or
equivalent, type
determine
equipment
dition.
to
lead
con-
A visual
check is also
The difference
is
helpful.
in
Note:
drop between
as
mags
just
as
important
the
total mag
drop
(not
more
than 50 RPM difference
between
mags).
Fuel
too
Pressure
13.
Adjust
to
at
least found
13.
Note:
If unable
to
adjust
low.
minimum pressure
in
as
pressure,
replace
pump.
Operators
Manual.
10
ENGINE WONT IDLE UNLESS BOOST PUMP ON

Cause
Solution
Procedure
i.
of
Turn
for Solution
i.
Idle mixture lean.
ex-
i.
at
Richen idle mixture
scalloped
toward
wheel
at
side
tremely
injector,
injector
Arrow
rich condition.
Note:
on
linkage
Idle
indicates
rich and
lean.
speed will
no
doubt have
to
be adjusted.
2.
Engine fuel
or
pump
2.
Replace
fuel
pump,
as
or
2.
Solution is
self-explanatory.
failed,
too
pressure
adjust
ary.
pressure
necess-
low
at
idle
speed,
"x3.
fuel
Fuel
pump
by-passing
(Note:
3.
Replace
fuel
pump.
3.
Solution is
self-explanatory.
internally.
AN type
pump).
11
ENGINE WONT
IDLE
UNLESS BOOST
PUMP
XS
OFF
Cause
Solution
Procedure
for
Solution
i.
Idle mixture
rich.
i.
at
Lean
idle mixture
i.
of
Turn
scalloped wheel
toward
at
side
extremely
injector.
injector
Note:
lean condi-
tion.
Arrow
on
linkage
Idle
to
indicates
rich and
lean. have
speed will
no
doubt
be
adjusted. by
Condition indicated
excessive black smoke.
2.
Engine
pump
too
fuel
2.
Adjust fuel
pump
pressure
Re-
2.
Solution is self-
pressure
set
high.
at
if AN type.
pump
explanatory,
place fuel
if
dia-
phragm type.
-12POOR IDLE CUT-OFF
Cause
Solution
i.
Procedure
same,
for Solution
i.
Improper rigging of
Adjust
i.
Solution is
self-explanatory.
mixture control
linkage.
2.
Mixture
control
2.
Disassemble and
scratches
re-
2.
Remove mixture
control
valve
scored
or
not
move
and burrs.
if
assembly
cut-off
from
injector lap idle

valve
seating properly,
"O" ring
broken
or on
or
Replace "0" ring, jet

necessary,
jet
and
assembly
a
mixture
on
good lap plate using

all
deformed,
mild abrasive until and burrs
scores
are
removed.
Clean
thoroughly
and
re-assemble.
condition of the control
Also observe "O" ring

Note:
the
on
mixture
jet.
Check for
fuel
leak
by
dis-
connecting
to
line at entrance
flow divider.
and
Keep throttle
boost pump
no
and mix off
on.
There
should be
fuel
flow.
3.
Vapor in lines.
3.
Avoid
prolonged ground
at
3.
Solution is
self-explanatory.
operation
idle.
cool
low RPM and
Keep nacelle
as
as
possible.
pump,
Note:
Use
boost
if necessary.
4.
hole
Dirt
of
in air bleed
4.
Remove
and clean.
4. blow
Wash in acetone
out
or
MEK and
nozzle.
with
compressed air.
5.
Fuel
jets
in nozzle
5.
Replace nozzles.
5.
Nozzles may be
test
tested
by
Lmproperly located.
fabricating
in S.I.
rig
as
explained
1275.
Note:
No visual
check of
jets
is
possible.
13
6.
Valve in flow divider
6.
Remove
and
clean.
6.
Remove
flow divider
from
sticking.
engine and disassemble.

out
Flush present.
any dirt
that may be
Flow divider valve may be hand
lapped
Clean
Note:
in seat
to
remove
any burrs.
thoroughly
Never
and reassemble.
interchange
flow
divider parts.
7.
Loose
fuel
line
at
7.
Tighten all
fuel
7.
Check main fuel

fuel
line
at
flow Also
flow divider
Note:
or
nozzle.
connections.
divider and
injector.
Engine may be rich
all fuel nozzles.
lines
Make
at
divider and nozzles
at
idle.
sure
are
tight
in
cylinders and
not
cross-
threaded.
3.
Mixture
valve
stuck,
seat.
8.
to
Disassemble enable
carburetor
8.
Solution is
self-explanatory,
(corroded)
to
valve
cleaning land
if
(carbureted engines)
lapping,
mixture
necessary)
the
valve and seat.
-14HIGH mTEL FLOW
Cause
Solution
Procedure
for
Solution
i.
Plugged
nozzles.
i.
Clean
or
replace
same.
i.
Plow-check nozzles
of
in
con-
Ins pect with
magnifying
tainers
equal
size
to
locate
lens
first.
plugged
wash
nozzles.
If
plugged,
in acetone and blow out
with compressed air.
2.
Air
leak
or
restric-
2.
Locate
and repair.
2.
and
Pressure
check to gage
Ibs.
in
tion
in deck
pressure
observe
for drop
gage
line
(airframe).
pressure.
3.
Injector
rich.
3.
Replace
same.
Check
3.
Run
engine
full
at
given
power
mags
for excessive
smooth
setting
fuel
rich.
Observe
to
drop in
RPM.
Recalibrate
flow and
compare
fuel
and/or
an
overhaul
injector
at
flow requirements
power
for
that
in
approved facility,
setting
as
found
operators
manual.
4.
Faulty
gage.
4.
Replace
same.
4.
Prove
by installing
running engine
master
gage and
compare
to
gages.
5.
too
I.D.
of
fuel
lines
5.
Replace lines.
5.
Lines must be
I.D.
between
.085
small.
-.090 be
Check with gage and

to mark
sure
not
inside all
of
fuel
lines.
Make
sure
nozzles
are
the
same
I.D.
in
all
cylinders (except 10-540 Cormnander).
in Aero
15
6.
Incorrect
nozzle
6.
Replace nozzles.
6.
Flow-check nozzles in
of
flow.
containers locate
equal
size
to
problem nozzles.
Flow deter-
rate
of nozzles may be
mined
set
by following procedures
1275.
forthin S.I.
"7.
fuel
Cracked
or
broken
nozzle
.k7.
Replace defective line.
*7.
While
pressurizing system
pump,
injector
Note:
with boost
give it
line.
Separation
good visual inspection for
may be at silver solder

connection.
signs of fuel dye.
Jr8.
line
Deck pressure
gage
6;8.
Remove
any obstructions.
Jc8.
Disconnect
line
from gage
plugged (turbo-
and
engine.
to
Use
compressed
to
charged),
air
blow
through lines
remove
any dirt that may be
present.
-16Low FUEL now Cause
Solution
i.
Procedure
same,
for
Solution
i.
Dirty fuel filter
Clean
i.
Remove
and clean in acetone
screen.
or
MEK.
Blow out with
com-
pressed air.
2.
Injector lean.
2.
Replace
or
same
or
recali-
2.
Run
engine
at
given
Ob-
brate
overhaul at
approved
power
setting
fuel
full rich.
facility.
serve
flaw and compare for

in
to
fuel
flow requirements
that
power
setting
Manual.
as
found
Operators
crease
An in-
in
cyl.
head
temp, EGT
an
or
oil
temp, may be
a
indica-
tion of
lean
injector.
3.
Faulty
gage
3.
Replace
same.
3.
Prove
by installing
master
gage and running engine

compare
to
gages.
4.
not
Flow divider does

open all
4.
Disassemble,
and
check for
dia-
4.
NOTE:
NEVER INTERCHANGE
the way
not
occur
dirt,
drag
on
FLOW DIVIDER
PARTS.
THEY ARE
(problem may
at
phragm
may be insure
stem.
Also
parts
to
FLOWED AS AN ASSEMBLY.
all
times).
lapped together
free
operation.
~5.
Fuel
line
to
fuel
5.
Repair
or
replace line.
5.
To
detect broken
fuel
or
loose stains.
dis-
flow gage
or
broken, loose
line check for

To
dye
plugged.
check
plugged line,
at
connect
gage and
injector
and blow out with compressed

air.
*6.
Low
fuel
pressure.
6.
to
Increase
fuel
pump
pressure
6.
Solution is
self-explana-
limits
in
Operators
Manual
tory.
and also check for
leaks.
17 ENGINE WILL NOT TURN STATIC RPM
Cause
solution
in-
Procedure
for Solution
i.
Restriction in
i.
Inspect and
remove
i.
Solution is
self-explanatory.
duction air system,

correct
in-
restriction.
airbox,
or
air-
box
improperly
installed.
2.
Injector
rich
or
lean.
2.
Replace
or
same
or
recali-
2.
Run
engine
full
at
known power
Observe fuel
brate
overhaul at approved
setting,
fuel
rich.
facility.
flaw and compare

as
to
requirements
tors Manual.
if
too
found
in
Opera-
Lean
injector,
rich
engine
run
will pick If
up RPM and
smooth.
injector
is
too
lean, engine aggravated.
will become
more
3.
ment
Prop
out
of
adjust-
3.
Adjust
same.
3.
Solution is
self-explana-
(low pitch). linkage

4.
tory.
4.
not
Governor
Adjust
for
full travel.
4.
Solution is
self-explana-
adjusted properly,
tory.
5.
Crankshaft to
cam-
5.
and
Remove
accessory
housing
5.
This
condition may be
shaft
timing off.
time
correctly,
checked
starter.
by
first
disconnecting
top spark
on
Remove
plugs
and rocker box inder.

Turn
cover
~2 cylT.D.C.
on
engine
to
compression stroke
on
~1 cyl-
inder,
in
observe
that when
piston
T.D.C.
~1 cylinder goes
over
on
compression, the
intake valve
in
to
~2 cylinder is just starting

open
and
the
18
exhaust
is
just closing.
not
If this
condition does
crank
to
cam
exist, the
is
timing
off.
~6.
Exhaust muffler baffles broken exhaust
6.
Remove muffler
for
and
6.
and
Note:
If baffles
to move
are
broken
in
internal
and
thorough inspection
replace same,
if
are
free
around
blocking
necessary.
muffler, engine
and
may turn static sometimes due

and
outlet.
develop
times
power
other
it may
not
to
the
restricted
flow
of
exhaust
gases.
Strike muffler with rubber mallet soft
or
object
and
listen for
rattle
in muffler.
,(7.
air
Excessively dirty
filter.
7.
Replace
at
regular
between
7.
Note:
Sometimes
an
new
filters
intervals. filter
Time
may have
excessive
air
drop
changes
will de-
through
is
them.
If this
condition
pend
on
operating
of
con-
suspected,
engine
to
remove
filter and filter
ditions
individual
run
F.T.
without
aircraft.
installed
to
observe whether the
engine performs better.

test
(This
in
a
should be
performed
and
on
a
dust-free
area
hard
surface).
-19ENGINE SUR~ES
Cause
Solution
nozzles
Procedure and clean.
for Solution
i.
Injector
dirty.
i,
Remove
i.
Clean
by flushing
in
acetone or MEK and blow out
with
compressed air.
2.
Faulty
governor.
2.
Replace
governor.
2,
Solution
is
self-
explanatory.
3.
Air
in oil
lines
or
3.
Bleed system.
3.
Engine
will
usually
bleed
wastegate
actuator,
air out of actuator and control If this lines
turbocharged
system by running.
does
not
work,
loosen
and bleed system.
4.
Breather
plugged.
4.
ions
Remove
any obstruct-
4.
Solution is
self-
from breather,
explanatory,
5.
Injector nozzle
5.
Repair leak
5.
Check all hose
connections,
pressure reference
"0" rings, tubing, and hoses

for breaks
or
system leaking (turbo-
loose connections.
charged).
Jr
6.
Incorrect prop
6.
Replace
Gov.
6.
Gov.
NOTE:
to
Check Part No.

sure
someone
of
governor
be
did not
put wrong Gov.
on
engine.
-20-
J(
7.
Defective oil pump.
7.
Repair
or
replace
oil
7.
Erratic
oil pressure may
pump.
be traced to the fact pump may be
that
sucking
air.
On
TIO and TIGO-541
engines
on
inspect "O" rings
inlet
also
and outlet of pump,

press
high
oil relief at pump may NOTE:

To
remove
be defective.
oil pump
sump must
from 541 be
engines,
the
dropped.
Jr
8.
Prop blades sticking
8.
Remove
and overhaul
8.
Check
for prop blade and
in hub
intermittently.
prop.
movement
sticking.
on
Check
stops and angle

when
blades
against flat pitch stops.
21-
FAILURE OF ENGINE TO DEVELOP RATED POWER

Cause
Solution
in
Procedure
and
for Solution
i.
Leaks
induction
i.
Tighten all plugs

and
i.
Solution is
This
self-explanatory,
more
system and exhaust system.
clamps
replace any
parts,
Note:
condition is
at
(Turbocharged engines)
defective
noticeable
alt.
2.
Improper fuel flow.
2. and
Check
screen
and
gage,
if
2.
Remove
screens
and
flush out
and
in-
replace injector,
dirt.
Disconnect gage
to
necessary
stall master
of aircraft
determine
accuracy
instrument.
3.
let
Restriction
in air
in-
3.
Check and
clean
or
3.
Note:
Always
make
sure
air
or
manifold.
repair
as
necessary.
filters
are
kept clean
in
and
there
allow
air
are
no
breaks
ducting
or
to
foreign
material
heated
from nacelle
to
enter
induction
system.
4.
Improper fuel.
4.
Drain
tanks
and
refill
4.
Note:
Never
use
lower
than
with recommended
octane
recommended
grade
of
fuel.
Consult
fuel.
S.I.
1070.
5.
Controllers
out
of
5.
Adjust
same.
5.
is
Variable absolute
controller
adjustment,
adjusted by turning adjustment

at
cam
(Turbocharged)
screw
end
of
controller
increase decrease
counter-clockwise
to
boost,
boost.
obtain
and clockwise
to
Controllers
are
set
to
specific
MP
and
no
compensation for density and temp

is necessary.
Required
in
MP
settings
Manual.
will be
found
Operators
Adjust for full throttle setting only.
22
Density
for
controllers
do
compensate
temperature and pressure and

to
require special equipment
adjust.
S.I.
and
1187 sets
forth
procedures
ment
required equipcon-
for
adjusting density
in the
trollers
field.
Differential
pressure
controllers
are
set
to maintain
6" differen-
tial
between deck and MP,

is
special
equipment
required for adjustThis

is
not
ing.
Note:
normally
adjustable
in the
field.
6.
Damaged
turbo
im-
6.
Visually inspect
and check for
for free
Disif
6.
Note:
If
turbo wheel
of blades
is
peller, binding
tight
or
damage
damaged
missing,
or
tips
are
turbo wheels,
rotation of
turbo.
turbo must
be
replaced
(Turbocharged)
assemble and
clean,
because this
cause
condition will
necessary,
turbo
to
become unbalanced
the turbo
and
severely
wear
bearings
failure.
causing complete
7.
Throttle
lever
not
7.
Check and adjust,
as
7.
Solution is
self-explanatory.
properly adjusted.
necessary.
8.
Excessive
dirt build-
8.
Inspect and clean.
8.
Solution is
Excessive
self-explanatory.
dirt
up
in compressor
housing
Note:
buildup
create
on
or
on
compressor wheel,
compressor wheel may
an
(Turbocharged)
out-of-balance accelerate
condition and
bearing
wear.
-239.
oil Kinked
or
restricted
9.
Remove
and
inspect
necessary.
9.
Solution is
self-explanatory.
lines
from
engine
actuator
to
or
replace,
as
actuator,
~o
and
controller.
10.
Wastegate
out
of
10.
Adjust
same
to
correct
10.
to
~The wastegate
is
adjusted
adjustment.
open and
closed
limits.
full closed position first,

To
(Turbocharged)
then full open.
adjust
full
closed,
and
cap
off
outlet
60 Ibs.
of actuator oil
apply
50 to
pressure
to
inlet.
When oil
pressure
closes wastegate,
clearance between butter-
measure
fly
is
and
housing.
If
adjustment
improper, disconnect linkage
and
lengthen
or
shorten
as
re-
quired.
ment
After
full closed
adjust-
is
correct,
set
full open
by disconnecting
oil
supply
and
allowing spring
open wastegate.
in actuator
to
Again,
measure
clearance between
butterfly
is
and
housing.
per, inder
If
adjustment jam
nut
at
improof
loosen
end
cylout
and turn
adj.
rod
in
or
as
required
to
obtain proper
full
open
setting, then retighten jam
nut.
11.
Inlet orifice
in
11.
Remove
inlet
line at
11.
Note:
If orifice
is
plugged
to
re-
~ctuator
plugged,
actuator
a~d
clean orifice.
tight,
move
it may be
necessary
(Turbocharged)
cylinder
from actuator
to
enable
thoroughly cleaning
orifice.
-2412.
Wastegate
stuck
12.
Remove
actuator
and
12.
Wastegate butterfly
may
be
open.
loosen wastegate
butterfly.
freed
and
by removing
a
from
engine,
the
(Turbocharged)
using
wrench
on
butterforth
fly shaft.
until
and
Rotate
back and
all corrosion is
removed
butterfly
moves
freely.
This
operation may be aided by using

corrosion
penetrant
to
help
penetrant
the
loosen
used
butterfly.
some
One
by
people
in
field
is
mouse
milk,
manufactured
by
Worldwide Aircraft
Filter Corp.,
1685 Abram Ct.,
San
Leandro, CA
94577.
used
at
This
each
penetrant could be
25-hour
inspection
A shaft
as
preventative
measure.
little at each end

may
of
the
help keep
shaft
from
binding.
13.
Piston
seal
in
13.
Disassemble,
and
clean
13.
Note: is
Any
time
wastegate
or
wastegate
actuator
cylinder,
or
replace seal,
actua-
actuator
disassembled
the
full
parts
and
leaking.
excess
Noted
by
replace wastegate
assy.
are
replaced,
closed
open
oil
coming
tor
full
positions
be
of
the
out
of
drain,
butterfly
reset,
should
checked
and
(Turbocharged)
if necessary.
to
(Reset
Jr
according section)
item marked
of
this
14.
Oil
pressure
too
14.
to at
Adjust
oil
pressure
14.
Check to make
oil
pressure
sure
that
the
ow
to
close wastegate.
least minimum
in manual.
low
proper
relief
it
is
spring
not
(Turbocharged)
limit
is
in
engine
or
and
that relief
broken,
that
valve ball
25
does
not
have
the
any dirt under
it
causing
15.
low oil
pressure.
Injector and
con-
15.
1211
Adjust
to
as
per
S.I.
15.
S.I.
Procedures
1211
set
forth in
of
troller
linkage
not
ad-
get full travel
include
the
ST
use
justed properly.
on
both controller and
two
special tools,
318 and
(541
series
engine)
injector.
ST
319,
to
position the
cross
shaft and establish the clearance
settings
idle when
at
full
throttle and
making linkage adjustproce-
ments.
Thesestep-by-step
should be
accurate
dures
insure
followed
to
linkage adjust-
ment.
s16.
Broken Baffles
16.
and
Remove
from engine
16.
is
PJote:
If
section of baffle
in muffler.
replace muffler
sy-
loose
in
muffler, engine
at
may
and
(Normally aspirated
engines)
stem.
operate
may be This
satisfactory
low
on
times
power
at
other
is
times
indicates baffle
in
moving
ex.
around
muffler, blocking
and
out
gases way
at
sometimes
other
of
the
times
allowing
an
unrestricted
flow of exhaust.
J17.
Poor
combustion
17.
Do
diff.
comp.
check
17. this
Do
top overhaul
to
correct
and
borescope inspection
to
problem.
locate
excessively leaking
valve guides
or
valves,
and
to
rings
locate any broken rings.
Butterfly
gate warped.
in waste-
18.
Replace wastegate.
18.
Solution is
self-explanatory.
26
LOSS
OF POWER GOING TO ALTITUDE
Ca~
i.
Leak
in
Solution
turbo
Procedure
for Solution
system
i.
Check all
clamps and
i.
Observe that all clamps
bolts
on
induction and
are
tight
on
turbo
induction
exhaust system,
Note:
air
and
exhaust
system.
and
Inspect
Make
sure
alternate
all
gaskets
pipes
"0"
be
rings
sure
on
door closes
completely,
is
pro-
intake
in
to
they
and
suck-open
door
are
place
and
properly
on
perly adjusted
is
not
and
gasket
seated.
Check for cracks
damaged.
both intake and exhaust system.

Green stain
on
induction system leak,
indicates
induction
White stains
on
exhaust system leak.
indicates
Make
sure
an
exhaust
that all nuts

are
on
exhaust stacks
that
tight
and
no
exhaust gaskets
out.
are
burned
2.
Density controller
follow
curve
2.
Replace controller.
2.
To
check
density controller,
con-
does not
to
disconnect differential
~roller
oil
altitude,
from system and block
lines.
Fly
aircraft
to
altitude and
you
observe
rise
that
in
get
steady
pressure
manifold
exceed
not
to
airframe manufacturers
If
no
limits,
rise
is
in-
dicated, density
controller
must
27
be replaced.
extreme
Note:
Exercise
caution
as
there will
be
at
severely staggered throttles

part throttle conditions.
3.
Oil
line to actuator
or
3.
Remove
line.
Clean
or
3.
Solution is
self-
inlet kinked
blocked.
replace
and
elimidate
explanatory.
kinked condition.
4.
Actuator piston seal
4.
Disassemble,
and
clean
4.
Note:
is
Any time wastegate

disassembled you
full closed
of
failed and
leaking
cylinder,
seal
replace
actuator
excessively.
must
check the
and
full open positions

If
the wastegate.
ment
adjust-
is
necessary,
full closed
always
first then
adjust
full open.
(Never plug
actuator
the
wastegate
drain
as
it may cause
hydraulic lock).
5.
Differential
con-
5.
Replace differential
5.
Apply
80
psi oil
to
inlet
troller
poppet valve
controller.
port of differential
con-
leaking.
troller, only
minute
drainage
should be observed at drain port.

If
excessive,
oil
is
28
observed
this
at
drain port, controller oil

at
indicates
valve is
leaking
all
times and must be
replaced.
J6.
Poor
combustion.
6.
and
Do
diff.
comp.
check
6.
Do
top overhaul
this
to
borescope inspection
to
correct
problem.
locate excessively
leaking
or
valves,
rings
valve guides
and to
locate any
broken rings.
~7.
Binding turbo.
7.
Overhaul
or
replace
7.
Solution is self-
turbo.
explanatory.
Jr8.
Lean
injector.
8.
Replace injector
or
or
re-
8.
Solution is
self-
calibrate
overhaul at
explanatory.
approved facility.
-29-
CWNNOT REACH SPECIFIED CRITICAL ALTITUDE

Cause
Solution
air
Procedure
for Solution
Also check for any
i.
Dirty induction
i.
Beplacesame
i.
Note:
filter.
type of blockage in induction

system.
2.
or
Damaged
compressor
2.
Replace
or
overhaul Determine and
2.
Visually inspect
or
to
see
if
turbine wheel.
turbo.
reason
Note: for
the turbine
compressor
(Turbocharged)
damage
wheels
are
damaged missing.
or
tips
of
eliminate.
blades
has
is
are
If this
happened,
turbo replacement this

dam-
necessary because
a
age causes
severe
out-c~-
balance condition which will
rapidly
wear
out
the
turbo
bearings.
3.
Wastegate
to
does
not
3.
If
ildjust for full travel.
3.
When setting closed and
go
full closed posi-
butterfly
is
sticking,
corro-
open
positions, always
set
full
tion
(turbocharged).
work free and apply sion penetrant. seal is
closed position first,
then
If actuator
full open.
The
procedure for
leaking, disassemble,
and
checking
is
to
full closed position
clean
seal,
cylinder
replace
cap off actuator disIbs.

oil
charge, apply 60-65

pressure
to
inlet.
When waste-
gate
closes,
measure
clearance
between
butterfly
is
and
hsg.
If
adjustment
connect
necessary,
and
dis-
linkage
as
lengthen
To
or
shorten
required.
release
oil
check
full open,
pressure
and allow wastegate

and
measure
to
open
full
clearance between
-30CANNOT REACH SPECIFIED CRITICAL ALTITUDE
butterfly
and
housing.
If ad-
justment is necessary,
loosen
jam
turn
nut
at
top of cylinder and

in
or
adjustment
out
as
required.
If
Re-tighten jam
is
nut.
butterfly
sticking,
looser
by manually moving back

forth until
cate
and
free,
then
lubripene-
with
corrosion
trant mouse
milk, manufactured
and
sold
bl Worldwide Aircraft
Filter
Corporation, 1685 Abram

Leandro, CA.
as
a
Ct.,
San
May
also be used
preventative
shaft
If
by applying
at
to
butterfly
25 hr,
inspections.
actuator
cylinder
clean
is
leaking,
and
disassemble,
replace seal.
cylinder
If any parts
are
replaced,
limits
as
check open and closed described above.
4.
Bad
bearings
in turbo.
4.
Replace
or
overhaul turbo.
to
4.
Check radial and axial bearas
Note:
Spin turbine by hand
ing limits,
per
AiResearch
check for free rotation.
Turbo Manual.
5.
Suck-open
door
on
5.
Adjust magnet properly.
so
door
5.
Observe
that
no
physical
to
compression discharge
closes
Replace
damage has
no
occurred
door and
housing
or
not
fully
closed
gasket.
foreign
material
is
lodged
door gasket
damaged
between door and gaskets.
(TIO-540 engines).
-316.
Faulty
controller.
6.
Repair
or
replace.
6.
Absolute Va~iable.
consider
If
engine loses
valve
power,
oil
leaking poppet
or
leaking
into
induction system beRemove
cause
of broken boot bellows.
controller and check for oil
in
in-
duction
housing.
In either case,
con-
troller will have to be replaced.
Density Controller. Check

tion ~2 under
as
per
solu-
"Loss of Power Going
to
Altitude.
Differential oil
to
Controller. port.
Apply
80
psi
inlet
Observe that only

at
minute 7.
draining
occurs
drain port.
Improperly adjusted
7.
Adjust
same,
7.
Absolute Variable.
The variable
is
controllers,
absolute pressure
sensitive
to
controller
only
so
no
pressure
settings
special equipment is necessary for adjustment.

turn To
increase manifold
at
pressure
adjusting
screw
cam
end of
con-
troller counter-clockwise,
To
decrease
MP,
turn
adjusting
screw
clockwise.
for
~These
adjustments
to
be made
full
throttle power settings
only.
MP
settings
Manual.
will be
foundin
Operators
Density Controller is sensitive
to
temperature and pressure and does
require special equipment

Procedures trollers for
to
set.
setting density
forth in S.I.
con-
are
set
1187.
32
Differential Controller
If
differential controller is
critical altitude would not
leaking
be
80
reached.
oil
to
Check
by applying
psi
inlet
port and
oil
observing
is
seen
that
only
minute
at
drain port.
seen
If
excess
oil
is
at
drain port,
at
controller is
and must be
leaking
all
times
replaced.
8.
Insufficient
to
oil
8.
Adjust
oil
pressure
8.
Check to be
is
sure
the
proper
pressure
close
to
specifications found
spring
in
the
oil
pressure
was
tegate.
in
Operators Manual.
or re-
relief valve and
is
not
broken
is
or
Check for kinks strictions
that
no
foreign
material
under
in actuator
the relief ball.
Eliminate
re-
supply line,
strictions
line and
in actuator
supply
eliminate
route
line
to
any kinks.
9.
Damagetocomor
9.
Replace turbocharger.
g. for
Irisually inspect
turbo wheels
presser
turbine wheel.
damage
such
as
bent
or
broken
blades,
or
rub marks
on
compressor
turbo
housing.
missing,
If
parts of
blades
are
check for
caused
excessive
bearing
wear
by
severe
out
of balance
condition
when turbo
turns
at
high speed.
-33-
10.
Leaks
in exhaust
10.
Repair
or
replace
as
10. bolts
Tighten
on
all
clamps
and
system.
required.
turbo system.
Check
gaskets for good condition

and
proper
seating.
Also
inspect
be
for any cracks
(may
located
by
the
presence
of white
stains
on
exhaust all nuts
system).
on
Make
sure
exhaust stack
and
flanges
are
are
tight
no
gaskets
burned out.
*11.
Poor
combustion.
11.
Do
diff.
comp.
11.
Do
top overhaul
to
check and
borescope
to
correct
this
problem.
inspection
locate
excessively leaking
valves,
or
valve
and
guides
to
rings
locate
any broken
rings.
-34~ROBLEM LOW OIL PRESSURE
Cause
Solution
i.
Procedure
tank
for
Solution
i.
Insufficient oil.
Fill oil sump

proper
or
i.
the
Note:
Make
sure
you
are
using
of
to
level.
correct
grade
and
weight
oil.
2.
of
Pressure
relief out
2.
to
Adjust
proper
oil
pressure
2.
On
external
oil
adjustable type
by turning
and
adjustment.
limits.
increase
pressure
adjusting
to
screw
clockwise,
decrease
turn
counter-clockwise
tower
On types with solid
standard
to
flat washers
trol oil
are
used
con-
pressure.
Add washers
and oil
to
increase
oil
pressure
re-
move
washers
to
decrease
pressure.
On short
tower,
maxi-
mum
of
three washers may be tall tower,

a
used
of
on
maximum
nine washers
may be used.
3.
Dirt
or
metal
chips
re-
3.
Remove,
disassemble,
Solution is
self-explanatory.
under oil
pressure
and clean.
lief valve.
4.
Damaged oil
seat,
pressure
4.
Replace
or
repair.
4.
On
engines
seat may
with the be
removable
out
relief
seat,
pulled
and
another
pressed
into
place.
On
engines that have

in the
seat machined
case,
repairs
must
be made
with
by repairing existing
seat
special Tools ST-2.43, ST-248
anti
S-340 that make up the reseating

tool assy.
(Ref.
S.I.
1172)
35
5.
High
oil
temperature.
5.
Check all
lube
areas
that
5.
for
Inspect the following

trouble:
areas
involve
lube
oil
system and
(a) Proper
and
oil
level
of
cooling system.
(b) Proper grade
weight
oil
(c) Thermostatic by-pass working properly

squarely. plugged
cooler.
and
valve
seating
or
(d) Plugged
cooler
partially
or
oil
lines
oil
(e)
duct
Excessive
blowby.
(f)
or
Air
to
cooler blocked
covered.
cooler
partially
(g)
Defective temperature gage.
6.
side
Restriction at
of
inlet
6.
Remove
and
clean
oil
6.
Solution is
self-explanatory,
oil
pump.
suction
screen
and
oil
passage
oil
to
inlet side
if
of
pump,
necessary.
7.
Excessive
of
internal
7.
Check the
following
oil
7.
Solution is
self-explanatory.
spill-off
oil.
areas
for excessive
flow and
repair
or
re-
place.
(a)
in
Loose
or
missing plugs
oil
galley.
(b)
Piston
cooling squirts
Note:
Low
blocked open.
pressure
oil
usually
occurs
at
low
or
idle RPM.
(c)
(d)
Excessive
bearing
clearance.
in
area
Cracked
crankcase
of oil
galley.
3i8.
Relocating
the
oil
8.
Use
only
the
o.p.
takeoff
8.
Solution
is
self-explanatory.
pressure
takeoff
point
on
point approved by the engine

manufacturer.
the engine,
~9.
Oil
in
pressure
relief
9.
Remove
and
replace
seat.
9.
Solution is
self-explanatory.
seat
crankcase
cocked,
or
(could
flat
be
cage
type
type).
37
PROBLEM
HIGH
OIL CONSUMPTION
Cause
Solution i. Consult
for
Procedure
for
Solution
S.I.
i.
Improper grade of oil,
Operators
type and weight
i.
Note:
Consult
1014
for
Manual
of
information
on
approved lubricating
oil,
oils
for
Lycoming engines.
2.
Failure
of
new
rings
2.
Use
correct
grade
of
2.
On
new
and
remanufactured
oil
until
en-
to
seat
properly.
oil
and
proper
operating
gines,
use
mineral
con-
procedures.
sumption stabilizes
50
to
(usually
from
100
hrs.)
A.D.
then if
desired,
the
change
series
to
oil.
On
541
of
engines, A.D.
the
oil must
be used
from
beginning.
1014
for
re-
Note:
Consult S.I.
commended best
lubricating
oils.
For
ring seating, always

throttle
the
use
full
for
takeoff wher-
ever
application applies
is
(the
only exception
the
geared
takeoff
supercharged engines where

power
is
limited
by
specific
Also
use
a
manifold
pressure).
power
high
cruise
setting for
break-in
"75%"
3.
Failed
or
failing
3.
Replace
same.
3.
Disassemble engine
for
in-
bearings,
spection and replacement
of
bear-
ings.
cessive
Prior
to
disassembly,
wear
ex-
bearing
the
may be deterof metal oil

in
mined oil
by
presence
suction
screen
or
filter.
-384.
Worn
piston rings and/or
4.
Remove
cylinders
and
de-
4.
Prior
to
disassembly,
rings
a
the
cyl. barrels.
glaze barrels, replace with

new
condition of the
may be
piston rings,
determined by doing
tial
differenThis
compression check.
is
accomplished by rotating the

to
cylinder
on
be checked
to
T.D.C.
compression stroke.
that the
After
insuring
not
prop will
turn,
introduce 80 psi air

and
in
cylinder
observe how
Air
much is
retained. be
leaking
by rings
can
detected by
listening
for
a
at
breather entrance
sound in crank-
hissing
case
indicating
rings.
air
escaping
equipment
con-
around
For
required and procedures,

sult S.I.
1191.
5.
Worn valve
guides.
5.
Replacesame.
5.
Remove
cylinders
out
from
en-
gine
and
take
valves.
if
Measure
guides
and
worn
beyond tolerances allowed

the will
in
table have
of
limits,
be
the
guides
Use
to
replaced.
forth
procedures
cable
set
in~appli-
overhaul manual.
6.
Excessive
oil
leaks.
6.
Inspect
external
of
en-
6.
Solution is
self-explanatory.
gine for leaks and repair

same.
39
,t7.
from
Oil
being siphoned
in
7.
Insure
that
oil
and
filler
oil
7.
Solution is
self-explanatorg
engine
flight.
cap
is
on
tight
access
door
closes
pro-
perly.
Also be
sure
that
the breather hose
is
cut
properly
there
is
and
located
chance
from
of
so
no
siphoning
oil
engine.
48.
Expander in oil
8.
When using oil control

with corrugated
sure
8.
Solution
is
self-explanatory
control
ring improperly
or
ring
type
ends
installed
tension.
lost
its
expander, make
expander
not
are
of
butted together When using

with
overlapDed
control
oil
ring
spiral
wound
type expander,
is
ring
improper
design
assy.
such that
is
not
likely.
40
Jn~
HIGH CYLINDER TEMPERATURE
cause
Solution
i.
Use
Procedure
for
Solution
i.
Spark plugs of imheat
only approved spark

your
i.
Note:
Consult S.I.
1042
for
proper
rating
in-
plugs for
engine.
approved spark plugs.
stalled in engine.
2.
Cooling baffles
or
miss-
2.
Insure
that
all baffles
and
2.
Note:
Never
attempt
to modi-
ing broken
installed.
improperly
are
installed
properly
fy,
relocate
or
eliminate
any
not
broken.
cooling
baffles.
3.
Partially plugged
fuel
3.
Clean in M.E.K.
and
or
ace-
3.
Solution is
self-explanatory
nozzles.
tone
blow-out with
com-
pressed air.
4.
I.D.
Fuel
lines
of
improper
4.
Fuel
line
I.D.
should be
4.
Note:
Primer
lines
have
being
used.
.085-.090.
same
threaded
connections
as
fuel
lines but
I.D.
are
of much
smaller
Note:
The
is
only exception
to
this
rule
the
IO-540-E1B5 used
500S.
in
the Aero
Commander
This
engine
fuel
uses
primer lines for

and
lines
they
are
.060
I.D.
5.
Engine improperly
5.
Check mag to engine

and insure
5.
Note:
Even
though
mag synif
en-
timed,
timing gine
no.
that
en-
chronization is
correct,
is
timed
to
the
correct
gine is timed
should be
at
250 ETC when it
of
degrees
B.T.C.
200 ETC, engine will
run
hotter.
-41-
6.
sted
Engine being
oper-
6.
Check
operators
manual
6.
Note:
If
this
condition
is
excessively
lean.
for minimum fuel

various
flows
for
and
suspected,
chamber
If there
for
check combustion
power
settings
carbon deposits.
none,
never
go below them.
are
this
to
is
sufficient
reason
be
suspicious of
lean
continuous
engine operation.
7.
Mix control
impro-
7.
Rig
for
complete
Note:
Even
though
mix
control
to
perly rigged.
travel.
lever at pilot seat appears

have
full
travel,
carb.
or
be
sure
to
check at
injector
is
to
insure
that mix
the
lever
F.R.
go-
ing against
(full
rich)
stops.
and
I.C.O.
(idle cut-off)
-42-
INM.P.
(Twin Engine)
Solution
Procedure
Cause
for Solution
i.
ProDeller blade
angle
i.
Adjust angle
props
for
correct
i.
Solution is
self-explanatory
not
adjusted properly,
blade
when
against flat
pitch stops.
2.
Controllers
out
of
2.
Adjust
to
proper
limits.
2.
Variable abs.
is
press.
con-
adjustment.
troller
fic M.P.
adjusted
found
in
to
spcci-
(Turbocharged)
as
Operators
Manual with
no
compensation for
temp.
Density controllers
are
ad-
justed
as
per
S.I.
1187.
Where
procedures and equipment quirements

are
re-
set
forth
on
density
some
controlled
in MP.
engines,
may have
to
split
be acdepted
tions in
because
of varia-
turbo
efficiency.
are
Note:
Both controllers
for
adjusted
setting
full
throttle
condition
only.
3.
Excessively dirty
air
3.
Replace
with
new
filer.
3.
Note:
Problem may be
more
filter.
noticeable when aircraft flown to altitude because

the
decrease
in
is
of
air
density.
4.
Alternate
air
door
4.
Replace
door
or
adjust
4.
Note:
Although
close
door may
leaking
for
complete closing,
appear
the
to
completely
on
ground,
it may be
opening
-43-
slightly
tion
mine
or
in
flight
due
to
vibradeter-
air
currents.
To
if
this
is
happening, tape
fly
alternate air door shut and

aircraft to altitude and
manifold
pressure.
observe
5.
Incorrect
hydraulic
5.
Replace hydraulic
5.
Note:
On
turbocharged
no
en-
lifters
lifters
too
or
hydraulic
down
lifters.
gines M.P.s will,
doubt,
gets
come
bleeding
back together when M.P. above

30"
rapidly,
on
turbocharged engines.
6.
Restriction in air-
6.
Inspect and
remove
6.
Solution is
self-explanatory,
frame
or
engine
induction
restriction.
system.
7.
Leaks
in airframe
7.
Inspect and repair
7.
Solution is
self-explanatory.
or
engine induction
leaks.
system.
-44OIL TEMPERATURE Cause
Solution
oil
Procedure for.Solution i. Solution is
i.
Insufficient
i.
Check oil at regular
self-explanatory,
supply.
intervals and maintain

proper
level.
2.
air,
Insufficient cooling
2.
Check air
inlet and
2.
Solution is
self-explanatory,
outlet to cooler and
re-
place
or
repair parts and

as
ducting
required.
3.
Improper grade of oil.
3.
Use
only grade
of oil
and
3.
Note:
Consult
S.I.
1014 for
of oils
weight
for
specified
proper
grades and weight
engine.
used
in
Lycoming engines.
4.
Oil
cooler
or
lines
4.
Remove
cooler and flush out.
4.
Solution is
self-explanatory,
plugged plugged.
or
partially
lines
and
5.
Thermostatic by-pass
not
5.
Replace thermostatic
valve.
5.
Note:
If valve
the
is
not
seating
valve
operating
pro-
by-pass
properly,
have
to
filter base may
perly
or
seating squarely.
be replaced also.
6.
Excessive
blow-by.
6.
(Do
top overhaul)
This
6.
Note:
To
locate is
exactly
condition
usually
caused
by
where
the
do
blow-by
a
originating
worn
or
stuck
rings.
from,
check
differential comp.
in S.I.1191.
as
described
7.
Defective temp.
gage.
7.
Replace
same.
7.
Solution is
self-explanatory.
45
**HIGH MANIFOLD PRESSURE AT IDLE
Cause
Solution
fuel
Procedure
mixture
for Solution
i.
Improperly adjusted
or
i.
Adjust idle
get
a
i.
Note:
Speed may have

also.
to
be
injector
carburetor.
to
25
to
50 RPM
adjusted
rise when
moving mix.
to
control
from F.R.
I.C.O.
2.
Incorrect
hydraulic
2.
Replace
no,
with correct
2.
Solution is
self-explanatory.
lifters installed.
part
lifters.
3.
Hydraulic
lifters
3.
Replace with
lifters.
new
hy-
3.
Note:
Any
time
hydraulic
from
an
en-
bleeding
down too
rapidly.
draulic
lifters
are
removed
gine for cleaning and inspection,

be
sure
to
keep
the
cylinder
an
and
plunger together
as
assy.
do
not
If
they become separated,
just arbitrarily assemble
any
be-
body
cause
and
plunger together
you may
On
change
twin
the
leak-
down rate.
engine inin M.P.
stallations,
will
no
split
doubt be
noticed
during
acceleration.
4.
Air
leak in
in-
4.
Check ind.
system and
4.
be
Note:
Engine will,
at
no
doubt,
duction system.
repair leak,
rough
idle also.
-46OIL PRESSURE
Cause
Solution
pressure
Procedure
to
for
Solution
i,
Oil
i.
Adjust
within min. found
i.
On external
adj. type
oil
improperly adjusted.
and max.
range
as
pressure
relief
adjustment,
in
Operators
Manual.
turn
adjustment counter-clockto
wise
decrease
oil
pressure.
On
engines using
is
the
pressure
relief that
not
externally
the
pressure
adjustable,
relief valve
and take
remove
from the
engine
from
out
washers
behind spring.
2.
Improper weight
2.
Use
the
suggested
for the
in which
2.
~onsult S.I.
oil
1014 for recommendations.
of oil,
weight
of
oil
lubricating
ambient temp.
the
engine
is
being
operated.
3.
Oil passage
from
3.
oil
Remove
blockage
from
3.
from
Remove
pressure
relief
soft
pressure
to
relief valve
passage.
engine
and
run
sump
plugged.
copper wire
down
through
if
oil
passage
to
sump;
blockage
Note:
is
found,
remove
same.
If
blockage persists,
have
to
sump may
to
be removed
clear
passage.
4.
Incorrect
pressure
4.
Replace
with correct
4.
Solution is
self-
relief spring
used.
being
pressure
relief spring.
explanatory.
-47-
Relocating
pressure
the
oil
5. off
Use
only
on
the
O.P.
take-
5.
Note:
If
the
oil
pressure
takeoff point
on
point
engine approved
takeoff
moved
point
on
the engine
oil
is
the engine.
by manufacturer.
closer
to
pump dis-
charge,
rise
in oil
pressure
will be noted.
6.
Oil
temp.
too
cold.
6.
Allow oil
temp.
to
in-
6.
Solution is
self-explana-
crease
before
increasing
tory.
throttle.
03
TEST EqUIPMENT
Q80088000~Q
baob
66b
YCOMING DIVISION
SSP 1169
VVILL~AMSPORT, PA. 17701
34
3, 1: 5
J/
0
42
43~
36
~O 0800
a o
I"
39 38
3
12
19
B B
is
d
B
B
it--"
t Ile~
Sa
tl--
16
14
25-18
26--11~
a
a B
-26-21 22
24
27
Engine Test Stand Instrument Panel consists of:

1.
Line Fuel Pressure 0 to +60
Gage
0 to +30
Psig.
2. Engine Fuel Pressure Gage "Differential"
Psig.
0 to +30 Psig. Gage 4. Oil Filter Pressure Gage 0 to +30 Psig. 5. Oil Scavenge Pressure Gage "Compound" 30 to +30 Psiff.
3. Oil
Supply
Pressure
6. Engine Oil Pressure Gage 0 to +100 Psig. 7. Governor Oil Pressure Gage 0 to +100 Psig. 8. Torque Meter 0 to +250 Psig. 9. Diversion Pressure Gage 0 to +60 Psig. 10. Waste Gate Pressure Gage 0 to +60 Psig. 11. Electrical Control Panel, includes:
Pilot Lights Master Switch
Thermocouple Selector Switches Iron Constantan Cylinder Head Temperature Venturi Air Temperature Compressor Output Air Temperature (Deck Temperature) Ambient Air Temperature Air from and Air to Sonic Cooler Temperature Induction Air Temperature Fuel Temperature Circulating Oil Temperature 20. Engine Throttle
21.
Mixture Control
19.
22. Air Throttle 23. Toggle Valves 24. Sonic Air Cooling System 25. Steam Control Pressure Gages 26. Steam Pressure Shut-Off Valve 27. 28. 29.
30.
Oil
Oil
Supply Pump
Switch
Scavenge Pump Switch
Fuel Valve Switch Fuel Pump Switch Water Valve Switch Starter Voltage Selector Switch Starter Vibrator Selector Switch
Test Stand
Fuel Manifold
Main Air Shut-Off Valve +5 to +62" Abs. Manometer

Manometer Manometer
+5 to +62" Abs.
HG
HG
31. 32. 33. 34.

35.
+5 to +62" Abs. 0 to +90" H2O 0 to +90" 1120
HG
Elapsed Time Indicator
Manometer Manometer Manometer Manometer Manometer
Ignition Switch
12.
Safety
Glass Window
0 to +50 Lbs.
0 to +60" HG
+5 to -25" HG
13. Oil Weight Scale 14. Oil Tank
36.
+5 to -25" H2O
0 to
15. Oil Tank Shut-Off Valve 16. Cylinder Head Temperature

Iron Constantan
37. Potentiometer
+600F.
50 to +300~ F. 50 to +300" F.
Gage
0 to
+600;F.
38. Dial Temperature Gage 39. Dial Temperature Gage
17. Exhaust Temperature Gage Chromel Alumel 18. Chrono Tachometer
0 to +2000" F.
40. Differential Pressure Gage 0 to +60 Psig. 41. Clock 42. Flowmeter 90 to +500 PPH 43. Flowmeter 25 to +130 PPH 44. Flowmeter 3 to +21 PPH
TEST STAND BASIC DRY SUMP SYSTEM
SCAV PUMP
AIR SEPARATOR CHECK VALVE AFTER COOLER TEMP.
OIL WEIGH VALVE
1
BY-PASSVALVE
SCAV. PR. OR VAC.
OIL SCALE
II
AIR
SEPARATOR
SCALE TANK
FILTER PRESSURE
1
I I I
SUPPLY PRESSURE
t
OIL
10 GAL. OIL RESEVOIR
COOLER
SHUT OFF VALVE HEATER PUMP

I
FILTER r
IENG~NE1
OIL IN TEMP
OIL OUT TEMP
TEST STAND BASIC WET SUMP OIL SYSTEM OIL SCALE

SCAV PUMP CIRCULATING TEMP
SCALE TANK
to GAL.
I I
I I I
I
Ij
OIL IN
OIL OUT
TEMP
TEMP
OIL RESEVOIR
BY PASS VALVE
t
f
I I I FILTER
ENGINE
SHUT-OFF
VALVE
HEATER I
PUMP
Fl LTER PRESSURE
SUPPLY PRESSURE
SCAV. VAC.
SCHEMATIC DIAGRAM OF GASOLINE SUPPLY FOR TEST CELL

PUMP
HAND VALVES-2 AND 3 PRESSURE GbUGE
VAPOR VENT LINE RETURN SHUT OFF VALVE
PRESS. REGULATOR 5-MICRON FILTER

ELEC.OPERATED VALVE HAND VALVE
eB15t
~n IEn I~n
7~
I
6IHIGH FLOAtGA
ENGINE
FUEL SUPPLY HAND VALVES- 4 AND 5

I
llOW FLOAT~ IA
HAND VALVES
6 AND 6A
HAND VALVE FLOW METERS

HAND VALVES-IAND 6
FUEL MANIFOLD OPERATION l,lA,3,4,5,6 AND 6A-OPEN VALVE 2 2,3,4,6 AND 6A-OPEN VALVES I,IA AND 5 TO RUN ON BOOSTER PUMP-CLOSE VALVES 2,5,6 AND 6A-OPEN VALVES I, IA,3 AND 4 TO RUN ON HIGH FLOAT BOWL-CLOSE I,IA,2,3 AND 4 OPEN 6, 6A AND 5
TO RUN ON LINE PRESSURE-CLOSE VALVES
TO RUN ON LOWER FLOAT BOWL-CLOSE VALVES
FUEL SYSTEMS REQUIRING VAPOR VENT MUST BE RUN ON HIGH FLOAT
HAND VALVE
ELECTRIC CONTROLLED SOLENOID VALVE TO OIL SUPPLY PUMP
AUTO. STEAM VALVE
HEAT EXCHANGER
STEAM SUPPLY
AUTO. TEMP REGULATOR
AIR PRESS.
REGULATOR
PRESS. GAUGE
I/4"VALVE
AIR SUPPLY
SCHEMATIC DIAGRAM OF SYSTEM FOR HEATING OIL IN TEST CELL
COOLING SHROUD
MOUNTING STAND
AIR
AIR THROTTLE VALVE
FLOW
~P1
BLOWER------\
TRANSITION ASSY,
PIEZORAETER RING AIR THERMOCOUPLE
~ATMOSPHERIC
PRESS. INLET
FOUR BLADE TEST CLUB
WATER COOLING COIL HEATING COIL FILTERS
LAIR
BELT GUARD
MEASURING VENTURI
~-2
HP MOTOR INSIDE BEARING PEDESTAL
AIR INDUCTION AND COOLING SYSTEMS
4~
1 i B, r14
~111
~-12
75 71
68
/I
4
494~
27
33
111 1
48
,5Q,
NOTE-ALL DIMENSIONS APPROXIMATE
6)

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01

~n"\cO LYCON1ING VVILLIANISPORT DIV1510N

L~AVCO LYCOMING ENGINE GROUP

SPECIAL SERVICE TOOLS FOR AVCO LYCOMING PISTON ENGINES

REALIZING THE WEALTH OF

WELCOME ANY AND ALL COMMENTS AM) ADDITIONS

PERSONNEL AND THE MORE HELPFUL HOPE

LOOK FORWARD TO HEARING FROM YOU AND

1976 EDITION BIGGER AND BETTER.

AVCO LYCOMING WILLIAMSPORT DIVISION AVCO CORPORATION

AVCO LYCOMING SERVICE TOOLS

SSP578 dated November, 1978.

appearance of the tools but

illustration has been used to

with "crosswise accessories"

Tools must be ordered

AVCO LYCOMING SERVICE TOOLS

Adapterdynafocal mounts -64898, ST-88 engine overhaul assembly ST-165,

Club -test- 64773, 64783, 64801, 64802, 64803,

64807, 64988, 64990, ST-241, ST-297, ST-298, ST-351,

propeller shaft flange sludge tube removal

64840, 64979, 64980, 64981, 64989, 64991,

pipe bore salvage spark plug pad ST-370

crankshaft front oil crankshaft crankshaft

oil relief valve

salvage fretted crankcases

Ba11s- sizing- ST-147-1, ST-147-2, ST-300-1, ST-300-2, ST-300-3

shaft in accessory housing

crankshaft, oil tubes -64548, 64648, ST-44

cylinder holding 64526, 64526-1,

propeller 64982, 64983, 64984 engine lifting 64758

Drillcrankcase thru-stud dowel dowel hole in crankcase Cable ST-379

piloted, exhaust valve guide plate, turbocharger ST-135

AVCO LYCOMING SERVICE TOOLS

tapper body magnaflux

turbocharger, holding ST-133 valve guides, replace 64501, 64644,

valve rocker valve seat

oil relief valve seat

ST-291, ST-305, ST-306, ST-307,

counterbore, intake pipe

pipe bore salvage

valve seat cutters

counterweight, Expander piston ring 64528, 64560,

valve clearance valve

62700, ST-23, ST-279

bearing dowel hole fuel injector ST-319 grind bushing 64878

pipe bore salvage ST-227, locating and reaming ST-149

AVCO LYCOMING SERVICE TOOLS

base nut wrench

engine mounting ST-47 impeller nut 64715

thread -475-B, 72762, ST-86, ST-87

Inserting Tool 64594 Installer, seal ST-443

spline bushing 64772 counterweight bushing

Jaws, slide hammer puller

welding, by-pass valve Jig, drill 64599