LYC 60294 9 2 Overhaul 76series1975 1996 PDF

Overhaul Ma aua I
P~ C O I ~C O IVI I RI G
76 Series Engines
Approved by EA.A.
L~AVCO LYCOMING WILLIAMSPORT DIVISION

AVCO CORPORATION
WILLIAMSPORT, PENNSYLVANIA 17701
Second Printing Pa rt No. 60294-9
Aug ust 1980 Price $23.00
Island Enterprises
652 Oliver Street
Williamsport, PA 17701 U.S.A.
7171323-6181 TECHNICAL
PUBLICATION REVISION
REVISION NO. PUBLICATION PUBLICATION NO. PUBLICATION DATE
60294-9-2 76 Series Engine Over- 60294-9 August 1980

haul Manual
furnished herewith intended to replace the corresponding page(s) of the publication indi-
The page(s) are
cated above.
Previous revisions to this publication This revision consists of:
June 1996
February, 1992 i
Island Enterprises
OVERHAUL MANUAL TEXTRON LYCOMING 76 SERIES ENGINES
TO THE OWNER OF THIS MANUAL
IN ADDITION TO THIS MANUAL AND SUBSEQUENT REVISIONS, ADDITIONAL

OVERHAUL AND REPAIR IS PUBLISHED IN THE FORM OF SERVICE
BULLETINS AND SERVICE INSTRUCTIONS. THE INFORMP~ION CONTAINED IN
THESE SERVICE BULLETINS AND SERVICE INSTRUCTIONS IS AN INTEGRAL PART
CONTAINED
OF, AND IS TO BE USED IN CONJUNCTION WITH, THE
IN THIS OVERHAUL MANUAL.
THIS OVERHAUL MANUAL, THE ENGINE OPERATOR’S MANUAL, AND ALL AP-
PLICABLE SERVICE BULLETINS AND INSTRUCTIONS ARE ISSUED IN COM-
PLIANCE WITH EA.R 21.50, AND SHALL BE USED BY MAINTENANCE PERSONNEL
WHEN PERFORMING ACTIONS SPECIFIED IN EA.R 43.13.
For a period (3) years new and revised pages for this manual will be furnished to
of three
it to Textron Lycoming. Registered owners
owners, who fill out the registration card and return
of this manual will be notified of any changes in revision policy or cost of revisions.
Service Bulletins, Service Instructions and Service Letters are available from all Textron Ly-
Textron
coming Distributors or from the factory by subscription. Consult the latest revisions to
Lycoming Service Letter No. L114. Textron Lycoming also publishes an Index of Service Bulle-
order
tins, Instructions and Letters that lists all Bulletins, Instructions and Letters in alphabetical
list of Bulletins, Instructions and Letters applicable to each engine
by title and topic as well as a
series. Consult the Service Publication Section of the latest revision to Service Letter No. L114
for the current part number of the index.
SPECIAL NOTE
The illustrations, picturesdrawings shown in this publication are typical of the subject
and
matter they portray; in no instance are they to be interpreted as examples of any specific engine,
equipment or part thereof.
Revised June 1996
Island Enterprises
OVERHAUL MANUAL LYCOMING 76 SERIES AIRCRAFT ENGINES
TABLE OF CONTENTS
SECTION PAGE SECTION PAGE
1. INTRODUCTION 1´•1 5. CYLINDERS. PISTONS AND VALVE TRAIN

(CONT).
2. GENERAL DESCRIPTION
Disassembly 5-1
Cylinders 2´•1 Cleaning 5´•3
Valve Operating Mechanism 2-1 Inspection
Crankcase 2´•1 Cylinder 5´•1
Crankshaft Counterweight 2-2 Pistons 5´•5
Connecting Rods 2´•2 Valve Rockers 5´•5
Pistons 2´•2 Push Rods 5d
Lurication System 2´•2 Valvae 5´•B
Cooling System 2´•2 Hydraulic Lifter 58
Induction System 2´•2 Valve Springs 8´•7
Ignition System 2´•2 Repair and Replacement
Spark Plug Inserts 5´•7
3. GENERAL OVERHAUL PROCEDURES Valve Seat 5´•8
Valve Refacing 5´•9
General 3´•1 Valve Guide CB
Cleaning Nitrided Cylinder Blrreb 1´•10
Degreasing 3´•1 Chrome Plated Cylinder Barrels B´•10
Removal of Herd Carbon 3´•1 Valve Repairs C10
Inspection Warped E~uust Flanges 5´•10
General 3´•2 Reassembly
Bearing Surface 3´•2 Assembly of Pistons 5´•10
Gears 3-2 Assembly of Cylinders 8´•11
Corrosion 3´•2 Installation of Cylinder and Pistons 0´•11
Screwed Fittings 3´•2 Intercylinder Baffles b12
Magnetic 3´•2
Corrosion Prevention 3´•2 6. OIL SUMP AND FUEL INDUCTION
Repair and Replacement
Damaged Parts 3´•2 General 8´•1
Painted Parts 3´•3 Disassembly
Replacement of Studs 3´•3 Intake Pipes 6´•1
Corrosion Prevention 3´•3 Carburetor 8´•1
Reassembly Oil Suction Screen 8´•1
Corrosion Prevention 3´•3 Oil Sump 8´•1
Pre-Lubrication of Parts 3´•3 Cleaning
Oilite Bearing 3´•3 Oil Sump 6´•1
Table of Limits 3´•4 Carburetor 6-1
Oil Seal and Gaskets 3´•4 Inspection
Arbitary Replacement of Parts 3-4 Oil Suction Screen 6´•1
Carburetor 6´•1
4. IGNITION SYSTEM Repair and Replacement
Carburetor 6´•2
General 4´•1 Reassembly
Dual Magneto 4´•1 Intake Pipes 6-2
Engine Firing Order 4´•1 Oil Suction Screen 6-2
Ignition Harness 4´•1
Spark Plugs 1´•1 7. CRANKCASE. CRANKSHAFT
Removal and Disassembly RECIPROCATING PARTS
Ignition Harnesa I´•1
Magneto I´•1 General 7´•1
Inspection Disassembiy
Ignition Harness 4´•1 Oil Pump and Vacuum Pump 7´•1
Magneto 4´•L Starter Ring Gear Support 7´•1
Repair and Replacement Tachometer 7´•1
Ignition Harness 1´•2 Governor Drive 7´•1
Magneto 1´•2 Crankcase 7´•1
Reassembly Camshaft 7´•2
Magneto 1´•2 Crankshaft 7´•2
Timing Magneto and Engine 4-2 Counterweighb 7´•4
Ignition Harness 1´•3 Cleaning 7´•4
Inspection
5. CYLINDERS, PISI~ONS AND VALVE TRAIN Bearing 74
Crankcaae
General 5-1 Visual 7J
Removal from Engine br Dimensional 7-4
Crankshaft
Visual 7´•4
Dimensional 7´•1
Island Enterprises
OVERHAUL MANUAL AVCO LYCOMING 76 SER IES AIRCRAFT ENGINES
TABLE OF CONTENTS (CONT.)
SECTION PAGE
7. CRANKCASE, CRANKSHAFT
RECIPROCATING PARTS (CONT.)
Camshaft
Visual 7-5
Dimensional 7-5
Connecting Rods
Dimensional 7-5
Parallelism Check 7´•5
Squareness Check 7-5
Counterweight Bushing Wear 7-5
Crankshaft Counterweight Bushing Wear 7-5
Repair and Replacement
General 7-5
Crankshaft
Bearing Surfaces 7-5
Propelled FLange Straighting 7-6
Oil Seal Surface 7-7
Crankshaft Counterweight Bushing 7-7
CounteMreight Bushing 7-8
Connecting Rod Bushing 7-8
Starter Ring Gear 7-8
Crankcase 7-8
Reassembly
Crankshaft
Expansion Plugs 7-8
Propeller Flange Bushing 7-9
Counterweight Assembly 7-9
Connecting Rods 7-9
Camshaft 7-9
Crankcase 7-10
Oil Pump and Vacuum Pump Drive 7-10
Tachometer Drive Adapter 7-11
Oil and Vacuum Pump
Oil Cooler Adapter 7-11
Oil Filter Adapter Assembly 7-11
Crankshaft Oil Seal 7-11
Generator or Alternator Drive Belt 7-12
8. TEST PROCEDURE
General 8-1
Test Limits 8-1
Run-In Procedure 8-2
Run-In Schedule 8-2
Oil Consumption Run 8-2
Idler Speed and Mixture Adjustment 8-2
Preservation and Storage (Engine) 8-2
Preservation Run 8-3
Preservation and Storage Carburetor 8-3
9. TABLE OF LIMITS
Island Enterprises
SECTION
INTRODUCTION
Island Enterprises
OVERHAUL MANUAL AVCO LYCOMING 76 SER IES AIRCRAFT ENGINES Section 1
Introduction
SECTION 1
INTRODUCTION
I-1. This manual contains the necessary information for L-8 Service bulletins, service instructions and service let-
the major overhaul of the Aveo Lycoming 16 series ters issued from time to time whenever the engine is
are
engines. Unless otherwise noted the information and data modified or overhaul procedures revised. When received.
willapply equally to all models. The portions of the tent these publications should be inserted in the rear of this
applying toany one particular modelwill be identified. manual or maintained in a separate file for ready
reference
1´•2. The main portion of the text is divided into sections
corresponding to the basic enginecomponents Additional
sections are provided for general description, preservation 1-6 The
following procedures should be followed for any
and storage information, and other items of anon-specific that parts are to be returned to Avea I´•ycoming for
reason
nature, warranty. The proper forms must be completed by your

Avco Lycoming Distributor, including the engine model.
1-3. The tools required for overhauling the engine lex´• serial number, number of hours in service, the reason the
eluding the ordinary mechanic’s teals found in mast parts are being returned, and any other pertinent informe-
overhaul shopsi are listed in the Special Service Tool tion concerning the parts
Catalog No. SSP2172 inspection gages are also listed in
the same catalog. Any special information required eon´•
cerning the tools may be obtained by writing to Service 1-7. In this manual all references to locations of various
Department. Avco Lycaming Division. Avco Corporation, components will be designated when viewing the engine
Williamsport. Pa 17701. When requesting information from the rear. The power ta~e off end is considered the
concerning any of these tools refer to the tool name and front and the accessory drive end the rear. The mi sump is
part number, considered the bottom Cylinders are numbered from

front to rear with odd numbered cylinders on the right
1´•4. Parts catalog for models of 76 series engines
specific side and even numbered cylinders an the left side.
may be ordered from the department listed in paragraph

1´•3. Because of product improvement it is almost impassi´•
ble to call out attaching part numbers in the overhaul L´•8. The direction of rotation of the crankshaft, as viewed
manual. Therefore. it is recommended that a parts catalog from the rear, is clockwise on all models. All references to
be used in conjunction with the overhaul manual. when direction of rotation of the various accessory drives are as
reassembling the engines, viewed facing the accessory drive mounting pad.
Figure 1-1. Typical 4 Cylinder Engine
1-I
Island Enterprises
SECTION
GENERAL
DESCRIPTION
Island Enterprises
General Description
SECTION 2
GENERAL DESCRIPTION
2-1. The engines covered in this manual are direct drive, Instruction No. 1037 lists the approved piston, piston
four cylinder, horizontally opposed, air cooled models, ring and cylinder assemblies for all models while the latest
edition of Service Instruction No. 1042 lists the approved
2-2.Cylinders. The cylinders are of air cooled construction spark plugs. Consult these publications for correct ap-
with two major parts, head and barrel, screwed and plication to you particular installation.
shrunk together. The head is made from an aluminum
alloy casting with a fully machined combustion chamber.
Valve guides and valve seats are shrunk into machined 2-6. Valve Operating Mechanism. A conventional type
recesses in the head. The rocker box is an integral part of camshaft is located above and parallel to the crankshaft.
the cylinder head which forms the housing for both the in- The camshaft actuates the hydraulic lifter which operates
take and exhaust valve rockers, the valve through the push rod and valve rocker. The
valve rocker is held in place by the use of the rocker arm
2-3. The cylinder barrels are machined from a chrome fulcrum. The valve spring bears against hardened steel
nickel molybdenum steel forging with deep integral cool- seat and is retained on the valve stem by the use of split
ing fins. The interior of the barrels are ground and honed key. A rotator cap is used on the stem of the sodium cool-
to a specified finish. ed exhaust valve. The hydraulic lifter automatically keeps
the valve clearance at zero thus eliminating the need for
2-4. Avco Lycoming incorporates a color code painted on any valve clearance adjusting mechanism.
cylinder heads designating differences in the cylinder bar-
rels and spark plug lengths. It is essential that personnel 2-7 Crankcase. The crankcase consists of two reinforced
be familiar with this code as described in the latest edition aluminum alloy castings with the accessory housing as an
of Service Instruction No. 1181. integral part, fastened together by means of thru bolts,
studs and nuts. The mating surfaces are joined without
2-5. Damage will result with the use of incorrect piston use of gaskets and the main bearing bores are machined
rings or spark plug lengths. The latest edition of Service for use of precision type bearing inserts.
Desaiotion of Engine Model Code

Example: n0 541 EIB4D
J
PREFIX DISPLACEMENT SUFFIX
L Lefthand Engine Rofation 000* E Fbwer Secfion 8

Cubic in.
T Turbocharged I -Nose Section
V -vertical Helicopter B -Accessory Section
H -Horizontal Helicopter 4 coun~weism Application
A Aerobotic D --Duol Mogneto

L~s Note: (001) "I"Indicates integrol
I -Fuel Injected accessory drive
G Gewed Nose Section

Subsequeutchanges to Models
S are reflectedin this Section

SrpDercharged
O opposed Cylinder
Figure 2-1. Description of Engine Code
2-1
Island Enterprises
Section 2 OVERHAUL MANUAL AVCO LYCOMING 16 SER IES AIRCRAFT ENGINES
General Description
2-8.CZankshaft. The crankshaft is made from a chrome for schematic of the oil system for a typical 76 series
nickel molybdenum steel forging and all journal surfaces engine.
are nitrided.
2-13.Cooling System. These engines are designed to be

2-9.Crankshap Counterweights. A system of dynamic cooled by air pressure built up on one side of the cylinder
counterweight, to eliminate torsional vibration, is and discharged, with accompanying pressure drop,
employed on some four cylinder engines. Consult the through the cylinder fins.
latest edition of Service Instruction No. 1012 for the pro-
per combination and location of the crankshaft.
2-14 Induction System. The engine is equipped with a
2-10. Rods. The connecting rods are made in
Connecting float type carburetor having a manual mixture control.
the form of "H" sections from alloy steel forgings. They Particularly good distribution of the fuel-air mixture to
have replaceable bearing inserts in the crankshaft ends each cylinder is obtained through the center zone induc-
and split type bronze bushings in the piston ends. The tion system, which is integral with the oil sump and is
bearing caps on the crankshaft end of the rods are retain- submerged in oil, insuring a more uniform vaporization of
ed by two bolts through each cap secured by a nut, fuel and aiding in cooling the oil in the sump. From the
riser the fuel-air mixture is distributed to each cylinser by
2-!1. Pistons. The pistons are machined from an individual intake pipes.
aluminum alloy forging. The piston pin is the full floating
type with a plug located in each end of the pin. Consult 2-15.Ignition System. Dual ignition is furnished for the
Service Instruction No. 1037 for proper piston and ring engine by two electrically independent ignition circuits in
combinations. a single magneto housing. A single four pole rotor pro-
vides the magnetic energy for both circuits. Consult the

2-12 Lubrication System. All subject engines employ a latest edition of Service Instruction No. 1042 for a list of
full pressure wet sump lubrication system. See figure 2-3 Avco Lycoming approved spark plugs.
TACHOMETER DRIVE GEAR
RATIO .50 1.00
PROP GOV. DRIVE GEAR

NO. OF TEETH 34
i
RATIO .50; 1.00
CAMSHAFT GEAR
NO. OF TEETH 42
RATIO .50:1
PROP GOV DR. GEAR

CRANKSHAFT GEAR
NO. OF TEETH
,RATIO I:I ii´• i I~ NO´• OF TEETH ~I
OIL PUMP IMPELL
NO. OF TEETH 12
RATIO 131:1
VACUUM 8 OIL PUMPDR. GEAR
NO. OF TEETH 16
RATIO 1.31:1
IDLER GEAR
NO. OF TEETH 22 MAGNETO GEAR
NO. OF TEETH
RATIO I:I
f ~--VACUUM PUMP DR. GEAR
NO. OF TEETHIO
;r
t Rarlo 1.31:1
HYDRAULIC PUMP DR. GEAR
NO. OF TEETH 10
OPTIONAL DUAL DRIVE GEAR BOX
RATIO 1.31:1
MOUNTS ON VACUUM 6 OIL PUMP DR SHAFT
Figure 2-2. Gear Train Diagram 4 Cylinder Engine
2-2
Island Enterprises
OVERHAUL MANUAL AVCO LYCOMING 76 SERIES AIRCRAFT ENGINES Section 2
General Description
PROPCLLER
4 r-------;
r----I
’6~-
r--1--’---~
O
i AN FUEL d_ GOV IDLER BRG
I PUMP I- NO.I
MAIN SPLASH OIL ON
*N FUEL PIC FUEL PUMP PLUNGER
AND ECC GbY
PUMP BRG. VI-7 G--m---J
p NO.I
MAIN
ND.I CAM BRG
w
a C(
g Ct NO.2 CRANKPIN
(NO.2 I -A 2 CAM BRt

NO
X o MAIN
i; X
HO. 3 CRANKPIN
a
pr I
,I m
c( NO.~ CRANKPIN
’I
n
NO. 1
NO.5 C*H BRG
\MnlN
v, EXH.VPILVETRP~IN
a TIPPETS PUSH
in
RIGHT ROD
BANK SOCKETS
INT. VALVE TRAIN

ROD
TAPPETS
RMI LEFT OIL TEMP OIL PRESS
SOCKETS BANK GAGE CONN CAGE CONN.
EXH VALVE TRAIN
I 1 Y I ~SPLASH OIL
OIL PRESS VALVE

ML COOLER OIL FILTER
GAGE CONN.
PUSH
HID PUMP
THER)IIO OIL PRESS.

vAC, PUMP PRESS RELIEF
ROCKER RELIEF VALVE
BY-PASS VALVE BY-PASS VALVE
SPLASH OIL
VALVE Zy OIL PUMP V
OIL COOLER OIL SCREEN
’~f--
OIL PRESS
V RELIE~VILVE
a
OIL SUMP
SUCTION
SCREEN
Figure 2-3. Oil Lubrication Schematic
a-3
Island Enterprises
SECTION
GENERAL OVERHAUL
PROCEDURES
Island Enterprises
General Overhaul
SECTION 3
GENERAL OVERHAUL PROCEDURES
3-1. This manual will describe in separate sections the treme care must be exercised if any water-mixed degreas-
complete major overhaul procedures for each individual ing solutions containing caustic compounds or soap are
portion of the engine, thus dividing the manual for all used. Such compounds, in addition to being potentially
practical purposes, into a series of individual handbooks dangerous to aluminum and magnesium, may become im-
dealing in turn with each component part. Since there are pregnated in the pores of the metal and cause oil foaming
various overhaul practices and instructions of a non- when the engine is returned to service. When using water-
specific nature, which apply equally to all basic engine mixing solutions therefore, it is imperative that the parts
components, these general instructions will be grouped be completely and thoroughly rinsed in clean boiling
together and described in this section, thus avoiding water after degreasing. Regardless of the method and
repetition. type of solution used, coat and spray all parts with
lubricating oil immediately after cleaning in order to pre-
3-2. No attempt shall be made to include overhaul pro- vent corrosion.
cedures for the various trade accessories. These ac-
cessories are covered in overhaul manuals published by 3-10 Removal ofhlard Carbon. While the degreasing solu-
their respective manufacturer. Only such assembly and tion will removedirt, grease and soft carbon, deposits of
disassembly as required by engine installation will be hard carbon will almost invariably remain on many in-
covered. terior surfaces. To facilitate removal, these deposits must
first be loosened by immersion in a tank containing a
3-3. Just prior to immediately after removing the
or decarbonizing solution (usually heated). A great variety of
engine from the airframe, remove the oil drain plug and commercial decarbonizing agents are available, including
drain the oil from the engine. such products as Gunk, Penetrol, Carbrax, Super-
Chemaco, Gerlach No. 70, and many others. Decar-
3-4. Attach the engine lifting cable to the engine and bonizers, like the degreasing solutions previously men-
remove from the airframe. tioned, fall generally into two categories, water-soluble
and hydrocarbons, and the same caution concerning the
3-5. Attach the engine overhaul adapter (ST-165) on pro- use of water-soluble degreasers is applicable to water-
peller flange. Mount the.dynafocal mounting adapters soluble decarbonizers.
(64898) on the engine mounts and place mounting ring
(64759) on mounting adapters.
CA UTION
3-6. Place the skid (ST-278) on engine overhaul stand EJctreme caution should be enercised when using a deca~
(ST-162) and lower engine into position on skid and stand. bonizing solution on magnesium castings. It is recom-
Remove the lifting cable. Specific disassembly instruc- mended that the use of heated solutions be avoided unless
tions are contained in the applicable section for each com- the operator is thoroughly familiar with the particular
ponent. solution being used. In addition, the operator is strongly
advised against immersing steel and magnesium parts in
3-7. Inasmuch visual inspection should be made while
as the same decarboniring tank, because this practice often
disassembling and immediately after disassembly, all in- results in damage to the magnesium parts from corrosion
dividual parts should be laid out in an orderly manner as
they are removed from the engine. No cleaning operation
should be performed until this initial visual inspection has
3-11. Decarbonizing will usually loosen most of the hard
been completed. All loose studs, cracked cooling fins,
carbon deposits remaining after degreasing; the complete
loose or damaged fittings, and the like, should be carefully
removal of all hard carbon, however, generally requires
noted and tagged to prevent their being overlooked dur-
ing regular inspection. brushing, scraping or grit-blasting. All
of these operations
demand the part of the mechanic to avoid damage
care on
to machined surfaces. In particular, wire brushes and

CLEANING metal scrapers must never be used on any bearing or con-
tact surface.
imperative to clean all engine parts thoroughly to
3-8. It is
facilitateinspection. Two processes are involved in clean- 3-12. When grit-blasting parts do not use sand or any
ing engine parts; degreasing to remove dirt and sludge metallic abrasives. It is recommended instead that mildly
(soft carbon) and the removal of hard carbon by decar- abrasive organic substances such as rice baked wheat,
bonizing, brushing or scraping and grit-blasting. plastic pellets, or crushed walnut shells be used. All
machines surfaces must, of course, be adequately masked
3-9 Degreasing. Degreasing is accomplished by immers- and all openings tightly plugged before blasting. The one
ing spraying the part in solution of white furnace oil
or exception to this is the valve seats, which may be left un-
(38-40 specific gravity) or a suitable commercial solvent protected when blasting the cylinder head combustion
such as Varsol or Perm-A-Chlor. Operators are warned chamber. It is often advantageous to grit blast the seats,
against the use of solvents with which they are un- since this will cut the glaze which tends to form (particular-
familiar, since there are may products on the market ly on the exhaust valve seat) thus facilitating subsequent
which are injurious to aluminum and magnesium. Ex- valve seat reconditioning. Under no circumstances
3-1
Island Enterprises
Section 3 OVERHAUL MANUAL AVCO LYCOMING 76 SERIES AIRCRAFT ENGINES
General Overhaul
should the
piston ring grooves be grit blasted. If 3-21. Gears. All gears should be examined for evidence of
necessary, soak the piston in petroleum solvent and pitting and excessive! wear. These conditions are of par-
scrape with a wooden scraper. When grit-blasting hous- ticular importance when they occur on the involute of the
ings, plug all drilled oil passages with rubber plugs or teeth; deep pit marks in this area are sufficient cause to re-
other suitable material to prevent the entrances of foreign ject the gear. Bearing surfaces of ail gears should be free
matter. from deep scratches. However, minor abrasions may be
dressed out with fine abrasive cloth.
3-13. The decarbonizing solution will generally remove
most of the enamel from exterior surfaces. All remaining 3-22 Corrosion Stressed Areas. Fitted surfaces in
on
enamel should be removed by grit-blasting particularly in highly stressed resulting from corrosion can cause
areas
the crevices between the cylinder cooling fins, ultimate failure of the part. The following areas should be
carefully examined for evidence of such corrosion; interior
3-14. At the conclusion of cleaning operations, rinse the surfaces of piston pins, the fillets at the edges of
parts in petroleum solvent, dry and remove any loose par- crankshaft main and crankpin journal surfaces, and
tides by air-blasting. Apply a liberal coating of preser- thrust bearing races. If pitting exists on any of the sur-
vative oil to all surfaces. faces mentioned to the extent that it cannot be removed
by polishing with crocus cloth or other mild abrasive, the
partmust be rejected.
INSPECTION 3-23. Screwed Fittings. Screwed fittings (any parts such

as threaded fastenings or plugs) should be inspected for
3-15. The inspection of engine parts during overhaul is condition of threads. Badly worn or mutilated threads
divided into three categories, visual, structural and must not be tolerated; the parts should be rejected.
dimensional. The first two deal with the structural defects However, small defects such as slight nicks or burrs may
in parts while the third is concerned with the size, shape be dressed out with a small file, fine abrasive cloth, or
and fit. stone. If the part appears to be distorted, badly galled, or
mutilated by over-tightening, or from the use of improper
3-16. Visual inspection should precede all other inspection tools, it must be replaced with a new one.
procedures. Do not clean any parts prior to visual inspec-
tion, since indications of dangerous operating conditions 3-24 Magnetic Inspection. All ferro-magnetic steel parts
canoften be detected from the residual deposits found in should be inspected by the magnetic particle method. The
some particular recess of the engine, successful detection of structural failure by magnetic in-
spection demands skill and experience on the part of
3-17. Structural failures be determined by several dif-
can operating personnel. It must be remembered that almost
ferent methods on the part involved. The
depending any fabricated steel part will shown indications of some
following are a few of the methods employed: magnetic kind, and it is important that the operator exercise good
particle, dye penetrant, penetrant, x-ray and various elec- judgement in evaluating the indications. Too rigid an in-
tronic methods. terpretation may result in the rejection of a sound part,
while on the other hand, a part showing a dangerous in-
3-18. Dimensional inspections should be carried out in ac- dication may be returned to service as a result of a too
cordance with the measurements and tolerances as called casual diagnosis. In general, areas of stress concentration
out in the Table of Limits (SSP2070). must be watched closely for fatigue cracks. These areas
include such locations as keyways, gear teeth, splines,
3-19. It is recommended that an inspection and overhaul roots of threads, small holes and fillets.
form, containing a list of all engine components, be utiliz-
ed when disassembling an engine. This form should be 3-25. Proper judgement must also be used in determining
prepared so that all inspection and overhaul procedures the amount of current (amperage) applied; too little cur-
can be checked off and remarks noted. This will also rent will not sufficiently magnetize the part, while too
assure that no part is inadvertently overlooked. heavy an application will permanently damage the pare by
overheating and burning thin areas adjacent to the elec-
trodes. Again, skill and experience on the part of the
3-20 Rearing Surfaces. All bearing surfaces should be ex- operator are of the utmost importance. Consult the latest
amined for scoring, galling and wear. Considerable scrat- edition of Service Instruction No. 1285 for proper
ching and light scoring of aluminum bearing surfaces in amperage.
the engine will do no harm and should not be considered
cause for rejection of the part, provided it falls within the 3-26 Corrosion-Prevention. Upon completion of inspec-
clearances set forth in the Table of Limits. Even though tion, parts with preservative oil.
coat all steel
the part may come within specified limits it should not be
reassembled into the engine unless inspection shows it to REPAIR AND REPLACEMENT
be free of other serious defects. Ball bearings should be ex-
amined visually and by feel for roughness, flat spots, flak- 3-27 Danaged Parts. Abnormal damage such as burrs,
ing or pitting of races and for scoring on the outside of the nicks, scratches, scoring, or galling should be removed
races. All journal surfaces should be checked for galling, with a fine oil stone, crocus cloth, or any similiar abrasive
scores, misalignmene and out-of-round condition. Shafts, substance. Following any repairs of this type, the part
pins etc. should be checked for straightness. This may be should be carefully cleaned in order to be certain that all
done in most cases by using vee blocks and a dial in- abrasive has been removed and then checked with its
dicator. mating part to assure that the clearances are not ex-
3-2
Island Enterprises
General Overhaul
cessive.Flanged surfaces that are bent, warped, or nicked broken, damaged or loose, replaced. The method
must be
of removing studs depends the type of stud and man-
may be repaired by lapping to a true surface on a surface on
ner in which it is broken. The procedure for removing and

plate. Again the part should be cleaned to be certain that
all abrasive has been removed. Defective threads can replacing studs is as follows:
sometimes be repaired with a suitable die or tap. Small
nicks can be removed satisfactorily with Swiss pattern a. If there is sufficient thread area available on stud, use
files or small, edged stones, pipe tapped threads should a collet grip tool consisting of a tapered collet that
not be tapped deeper in order to clean them up, because threads onto stud and a housing that slips over the
this practice will invariably result in an oversized tapped collet. Tighten bolt on top of the housing and draw
hole. If scratches or galling are removed from a bearing collet into housing to lock puller on the stud wit.h a tight
surface of a journal it should be buffed to a high finish. grip.
(;enerally it is impossible to repair cracks; however,
b. If the collet type tool cannot be used, drill a small hole
welding operations may be performed in some parts of
into the stud. Employ a pilot bushing to guide drill into
housings, providing the area is not a stressed section of
center of stud when stud is broken beneath the surface
the part. For example, almost any area of a rocker box
of the crankcase. Redrill the hole to enlarge it to ac-
maybe welded, but no part of the cylinder head except the
commodate the proper size extractor. Using the extrac-
fins may be welded.
tor, remove the stud.
3-28. Painted Parts. Parts requiring use of paint for pro- c. After studs have been removed, check for size and
tection or appearance should be painted in accordance
condition of threads in stud holes to determine whether
with the following recommendations using material from
oversize studs must be used for replacement. Coat
the following list of approved material. Thinner Toluene
threads of studs with thread lubricant. Specification
or equivalent (AMS3180 or equivalent Federal Spec. TT-
JAN-A-669, and drive stud to correct depth by using a
T-548). Primer Zinc chromate (AMS3110 or equivalent suitable stud driver.
MII,-P-8585). Enamel Phthalate resin type (AMS315C or
equivalent MIL-E-7729). 3-34. Corrosion-Prevention. At the conclusion of all repair
operations and subsequent inspection, coat all steel parts
NOTE with preservative oil.
A II machines bosses should be masked before pain ting. Do REA SSEMBL Y
not paint areas under hold down nuts where torque is re-
quired. 3-35. Corrosion-Prevention. Prior to assembly of

subassemblies, all parts should be cleaned to remove all
3-29. Aluminum and Steel Parts. Parts shall be cleaned traces ofpreservative oil and accumulated foreign matter.
and degreased prior to painting. Apply one coat zinc During assembly, cover all steel parts with a heavy coat of
chromate primer, thinned with approximately two parts preservative oil. This mixture should be used on all
toluene, and air dry. Apply one coat of enamel and bake at machined surfaces, especially on bearing surfaces,
2500F., to 3000F., for one-half hour. Enamel may be allow- cylinder bores and piston rings. The practive of using
ed to air dry but an inferior finish will result. Parts from plain lubricating oil during assembly is not recommended.
which paint has not been removed may be repainted omit-
336. Pre-Lubrication of Parts Prior to Assembly. Many
ting the primer coat.
premature failure of parts have been traced directly to im-
330. Magnesium Parts. Magnesium parts should be clean- proper pre-lubrication of engine assembly. If parts are not
properly lubricated, inferior lubricant is used, many
or an
ed thoroughly with a dichromate treatment prior to pain-
of the become scored before the engine
engine parts will
ting. Thistreatment consists of cleaning all traces of oil
oil goes through its first cycle and has had a change to
and grease from the part by using a neutral, non-corrosive
lubricate the engine. This, of course, will lead to
degreasing medium followed by a rinse. After which the
for 45 minutes in a hot dichromate solu- premature parts failure prior to normal service life, and in
part is immersed
tion (3/4 Ibs. of sodium dichromate to one gallon of water
some cases, lead to engine failure before normal service
hours have been accumulated. It is of utmost importance,
at 1800F. to 200"F., quantity as required). The part should
then be washed thoroughly in cold running water, dipped therefore, that the following recommendations be adhered
to a engine assembly. Consult the latest edition of Service
in hot water and dried in an air blast. Immediately
I"struction No. 1059.
thereafter the part should be painted with a prime coat
and engine enamel in the same manner as prescribed for
3-37. Coat the camshaft lobes, face of tappet bodies and
aluminum parts.
rocker tips with lubri-bond (A) or equivalent.
3-31. Shroud Tubes. Shroud tube should be thoroughly 3-38. Coat the valve stems and the interior of the valve
cleaned and dipped in zinc chromate primer thinned to guides with Texaco Molytex "O" or equivalent.
spraying consistency. After the primer is dried the shroud
tube should be painted on the outside with engine enamel. 3-39. All other parts should be coated with a mixture of
15% pre-lubricant (STP or equivalent) and 85% SAE No.
3-32. Allpaint applied in the foregoing operations should 50 mineral base aviation grade lubricating oil.
preferably be sprayed; however, if it is necessary to use a
brush, care should be exercised to avoid an accumulation 3-40 OliteBushings. During overhaul cleaning operations
of pockets of paint. possible to wash the oil from these bushings; also, if a
it is
bushing has been replaced and either reamed or broached,
Studs. Any studs which bent, its porosity may be affected. Therefore, before the
333. Replacement of are
3-3
Island Enterprises
Section 3 OVER HAUL MANUAL AVCO LYCOM I NG 76 SERIES AIRCRAFT ENGINES
General Overhaul
bushings are reassembled into the engine they must be All engine oil hose
impregnated by immersing then for at least fifteen Alloilseals
minutes in engine oil that has been heated to 1400F. All gaskets
All circlips, lockplates and retaining rings
3-41. It is strongly recommended that all overhaul Piston rings
facilities adapt a firm policy of checking pitch alignment All exhaust valves (except Inconel alloy valves)
of bevel gears at the same time backlash is adjusted dur- All exhaust valve retaining keys
ing engine overhaul. Crankshaft sludge tubes (where applicable)
3-42. Table
Cylinder fin stabilizers
oflimits. The table of limits SSP1776 should All bearing inserts (main and connecting rods)
be consulted whenever it is desired to determine the
backlash and end clearance of gears, the clearance bet-
Magneto drive cushions
Stressed bolts and fastenings
ween mating machined parts, the clearance between Camshaft gear attaching bolts
mating parts which are in close contact with each other
and the torque limits for various nuts, screws and fasten-
Connecting rod bolts and nuts
Crankshaft flange bolts
ings.
Damaged ignition cable
All laminated shims
3-43. Oil Seals and Gaskets. When building up an engine
Crankshaft counterweight bushings
during major overhaul, replace all oil seals and gaskets Piston pin plugs
throughout the engine. For complete replacement sets of A.C. diaphragm fuel pumps
seals and gaskets available for these engines, consult ap-
plicable parts catalog.
3-44.Arbitrary Replacement ofParts. It is recommended

that certain parts throughout the engine be replaced at
normal overhaul regardless of their apparent condition.
Consult the latest edition of Service Bulletin No. 240 for
information on the replacing of parts at overhaul. Includ-
ed among these are the following:
3-4
Island Enterprises
SECTION
IGNITION SYSTEM
Island Enterprises
Ignition System
SECTION 4
IGNITION SYSTEM
4-1. General. All four cylinder engines are equipped with REMOVAL AND DISASSEMBLY
high tension ignition systems which deliver high tension
current directly to the spark plug outlets. 4-6 Ignition Harness. Remove the terminals from the top
and bottom spark plug. Detach all clips, clamps and grom-
4-2.DualMagnetos. The magneto features two electrically met plates securing the leads to the engine. The ignition
harnesson the dual magneto cannot be removed from the
independent ignition circuits in one housing. A single four
pole rotor magnetic energy for both circuits,
provides the magneto without removing the cover from the magneto.
The magneto uses an impulse coupling to provide reliable
ignition at engine cranking speed. At engine cranking NOTE
speed the impulse coupling automatically retards the
magneto until the engine is also at its retard firing posi- Before detaching clamps, clips, grommet plates etc., mark
tion. The spring action of the impulse is then released to the location of each. Differences in various installations
spin the rotating magnet and produce the spark to fire the make it impossible for this manual to poin t out the correct
engine. After the engine starts, the impulse coupling acts attaching points.
as a straight drive and magneto fires at the normal firing
4-7. Magneto. remove the two 5116-18 nuts,
Loosen and
position of the engine.
lockwasher and which hold the magneto to engine.
clamps
43. Engine Firing Order. Four cylinder engine 1-3-2-4. Remove magneto and harness from the engine.
Left hand rotation engine 1-4-2-3.
INSPECTION
4-4. Harness. The harness is composed of the
Ignition
magneto terminal assembly, the ignition cable and the 48. Ignition Harness. Unless the harness assembly is in
obviously new condition and is known to have been
spark plug end assembly.’l’he number of lead in the
the number recently installed, it is recommended that the harness be
harness assembly is of course determined by
of cylinders on the engine. replaced at overhaul.
4-5. Spark Plugs. For information relative to approved 4-9 Magnetos. As previously mentioned, this manual will
sparkplugs for the subject engine consult the latest edi- not endeavor to describe overhaul procedures for trade
tion of Service Instruction No. 1042.
7. Gasket
1. Spark Plug
8. Cushion
2. Magneto B 9. Cushion Retainer
3. Ignition Harness
4. Nut 1D. "O" Ring Seal
5. Lockwasher 11. Gear
6. Clamp
Figure 4-1. Magneto and Harness Assembly

4-1
Island Enterprises
Section 4 OVER HAUL MANUAL AVCO LYCOM I NG 76 SER IES AIRCRAFT ENGI NES
Ignition System
accessories. Consult the manufacturer’s applicable REASSEMBLY

overhaul manual for inspection procedures.
4-15 Magnetos. Before assembling the magneto gear or
REPAIR AND REPLACEMENT drive coupling (whichever is applicable) to the magneto
drive shaft, apply a light coating of Go-Jo-No-Lox No. 72
4-10.Ignition Harness. Unless the harness assembly is in compound or equivalent to the tapered section of the
obviously new condition and is known to have been magneto drive shaft. This compound is manufactured by
recently installed, it is recommended that the harness be Gojer, Inc. Akron, Ohio, 44309. After assembling gear or
replaced at overhaul. Avco Lycoming does supply in- coupling, wipe excess compound from the drive shaft.
dividual leads in two lengths, (48 or 72 inch) finished at
the spark plug end and available from your local 4-16. See figure 4-1. Assemble "o" ring in groove on the in-
distributor. The following steps will describe the pro- side of magneto gear. Install gear in bushing of crankcase.
cedure for replacing a lead. Install magneto drive cushion retainer in the magneto
gear. Assemble magneto drive cushions in retainer. In-
4-11. Removal of Condemned Lead. Remove clamps and stall magneto gasket and magneto. Install clamps,
brackets from applicable lead assembly. Cut cable ties lockwasher, and 5116 plain nut. Tighten slightly until the
from assembly and discard. Remove the cover from final timing is completed.
magneto.
4-1 7.Timing Magneto to Engine. Rotate the crankshaft in
4-12. Cut off condemned lead flush with the outer surface direction of normal rotation until no. 1 cylinder is on the
of the cover. Grip eyelet of lead with a pair of pliers and compression stroke and approximately 350 ETC. Clamp
pull short
length of conductor out of grommet and cover. the ignition timing pointer (64697) on the advance timing
Using a 3 inch
long, 0.270 inch diameter drift, applied at mark on the rear of the starter ring gear. The starter ring
outer surface of cover, drive out tapered ferrule and re- gear may be marked at 200 and 250. Consult engine
maining pieces of insulation and shielding, nameplate for correct advance timing mark to use. Con-
tinue rotating the crankshaft until the timing pointer and
4-13 Replacement of Condemned Lead. To replace a con- the parting flange of the crankcase align. Leave the
demned lead, proceed as follows: crankshaft in this position until the magneto is installed.
a. Thread pre-stripped end of lead through magneto 4-18. In the event that an igntion timing pointer is not
cover, available an alternate method may be used. Rotate the
crankshaft in direction of normal rotation until no. 1
b. Scrape 1/2 inch of blue coating from braid being cylinder is on the compression stroke and continue
careful not to cut braid. rotating the crankshaft until the correct advance timing
mark on the front of the starter ring gear is in exact align-
c.Push back braid and thread a new ferrule over wire ment with the small drilled hole located at the two o’clock
and under braid until braid covers knurling. See figure position on the front face of the starter housing. Leave the
4-2. crankshaft in this position until the magneto is installed.
BRAID TO NOTE
1/2INCH COATING DGE OF KNURLING
SCRAPED FROM BRAID
The advance timing mark is specified on the engine

nameplate.
F-nB´• -k~- 4-19. Remove the inspection plug from the magneto and
eLuE rotate the drive shaft in direction of normal rotation until
COP~TINO-/
I the painted chamfered tooth on the large distributor gear
is aligned in the center of the inspection window. The
Figure 4-2. Ferrule Position Under Braid shaft on the impulse coupling magnetos can be turned by
depressing the pawl the coupling. Be sure the magneto
on
d. Pull the lead back into the cover to wedge the braid gear does not move from this position and secure each
between the taper of the cover and ferrule, magneto finger tight. The magnetos are now ready for
final timing.
e. Place cover on proper support and seat ferrule using
Bendix tool 11-7074 (ferrule seat tool) and mallet. Fer- 4-20. Final Timing D-2000 Dual Magneto. Using a battery
rule must be driven straight into cover and fully seated. power timing light, attach the red lead of timing light to
the left switch terminal, green lead of timing light to right
f. Place grommet over pre-stripped end of lead. Place switch, black lead to an unpainted portion of the engine.
new eyelet on conductor and cramp. Rotate the magneto in its mounting flange to a point
where the light comes on, then slowly turn it in the op-
g. Pull lead to seat parts in proper place and remove posite direction until the red light goes out. Tighten the
slack from braid. magneto clamps evenly.
4-14. Magnetos. As previously mentioned, this overhaul 4-21. Back off the crankshaft approximately 100 so the
manual will not endeavor to describe overhaul procedures timing light goes on. Bring the crankshaft slowly back in
for trade accessories. Consult the manufacturer’s ap- the direction of normal rotation until red light goes out.
plicable manual for overhaul procedures. Indicating the left main breaker opening at no. 1 firing
4-2
Island Enterprises
Ignition System
position. The right main breaker monitored by the green

light must open within 2 engine degrees of the no. 1 fir-
ing position. Completely tighten nuts to specified torque.
4-22.Ignition Haness. Prior to inserting spark plug lead

in plug barrel use flurocarbon spray MS-S122 (available
from Miller-Stephenson Chemical Co., 16 Sugar Hollow
Rd., Danbury, Conn. 06813). Assemble the leads into pro-
per spark plug. Consult wiring diagram figure 4-3. Torque
nuts to 110 120 inch pounds.
Figure 4-3. Ignition Wiring Diagram

(Four Cylinder Engine)
4-3
Island Enterprises
SECTION
CYLINDERS, PISTONS
AND VALVE TRAIN
Island Enterprises
Cylinder, Piston
and Valve Train
SECTION 5
CYLINDERS, PISTONS AND VALVE TRAIN
5-1. The piston, being a reciprocating part, is normally piston of no. 1 cylinder at top center of the compression
grouped with the crankshaft in a theoretical breakdown of stroke. This will place the valves in closed position and
the engine into basic components. However, from a prac- the piston extended away from the crankcase to avoid
tical standpoint, it is felt that the piston should be con- damage when cylinder is removed.
sidered with the cylinder insofar as overhaul procedures
Fj-9. Remove the 5116-24 self-locking nut (11) from the
are concerned. For example, the basic configuration of the
valve rocker fulcrum (10). Remove the valve rocker arms
engine requires the removal and reassembly of the pistons
and fulcrum from cylinder. Remove the square washers (9)
at the same time the cylinders are removed or replaced,
from the stud. Remove the push rods (2) by grasping the
5-2. For the purposes of the manual, the valve train will be end and pulling through the shroud tube. Remove the
considered as all parts of the valve operating mechanism 1/4-20 plain nut (7), lockplate (61 and spring (5). Pull
shroud tubes out through the cylinder head and discard
beyond the camshaft, beginning with the hydraulic lifter
assembly, the shroud tube seals (3).
5-10. Remove the cylinder base hold-down nuts; then

5-3, Although subject engines employ parallel valve
the cylinder by pulling straight away from the
cylinders with down exhaust, basic overhaul procedures remove
are the same for all cylinders. The overhaul procedures

crankcase. As the cylinder is pulled away, catch and hold
described in this section will be applicable to all cylinder the piston to prevent it from falling against the crankcase
assemblies except as noted. and being damaged. Discard the cylinder base oil seal
rings.
5-4. Either plain steel, chrome plated, or nitride hardened
steel cylinders may be employed on the engines discussed
5-11. Pistons. Remove piston pin plugs from the piston.
in this overhaul manual. The color code for these cylinders Using a piston pin puller (64843), pull pin from piston and
is as follows: remove piston.
CA UTION
a. Plain steel All grey

After the removal of a cylinder and piston the connecting
rod must be supported to prevent damage to the rod and
b. Chrome plated Orange paint on cylinder
crankcase. This is done by supporting each connecting rod
fins below spark plug
with torque hold down plate ST-222, rubber band (discard-
hole.
ed cylinder base on seal rings) looped around the cylinder
fins base studs shown in figure 53.
c. Nitride hardened Blue paint on cylinder as
steel below spark plug hole.

5-12. Removal of the other cylinders and pistons may be
d..010 inch oversize Green when applied to done any desired order,
in but less turning of the
plain cylinders customer overhaul en- crankshaft is involved if the cylinders are removed suc-
gines, cessively in the engine’s firing order 1-3-2-4. Left hand
rotation firing order 1-4-2-3.
e..020 inch oversize Yellow when applied to

5-13. Hydraulic Lifters. Remove the hydraulic lifter from
the crankcase. Place each lifter as removed from
plain cylinders customer overhaul en-
crankcase in its proper location in the cleaning basket.
gines.
The hydraulic lifters must be replaced in the same loca-
tion in crankcase from which they were removed.
NOTE
DISASSEMBLY
A yellow color, on fins ABOVE spark plug hole, indicates
that long reach spark plugs are used. 5-14. Cylinders. Place cylinder over the cylinder holding
block (64526-2), assemble valve spring compressor
REMOVAL FROM ENGINE (ST-419) on cylinder, and compress valve springs far
enough to remove the valve retaining keys.
5-5. It is assumed that the ignition harness, intake pipes
and primer lines have been previously removed. NOTE
5-6.Intercylinder Baffles. (where applicable) Using the in- If keys are stuck tight in spring seat, a light blow with a
leather mallet top of compressor will release keys.

tercylinder baffle tool (64885), release the baffle retaining on
hook so that it disengages the retainer. Remove the inter-

5-15. Remove all valve spring seats and springs from
cylinder baffle and hook from between the cylinders.
rocker box, keeping parts for each valve separate. Hold
5-7. Oil Drain Tubes. Loosen hose clamps at lower end of valves by the stem to keep them from dropping out of the
tube and slide tube out of hose. Loosen gland nut at cylinder, and remove cylinder from holding block. Now
cylinder head fitting and remove drain tube. reach inside of cylinder and remove valves. If difficulty is
experienced in pulling the tops of the valve stems through
5-8. Cylinder. See figure 5-1. Remove the rocker box cover the valve guides, push the valves back in position and
(13) and gaskets (12). Rotate the crankshaft to place the clean the carbon from the stems.
5-1
Island Enterprises
V1
15. Clamp o
9.
16. Tube
17. Cylinder Base Oil Seal
2
18. Intake Valve o
19. Exhaust Valve

20. Valve Seats O
21. Valve Guide
22. Lower Valve Spring ;0
Seat I
4
29. Outer Valve Spring
24. Auxiliary Valve
Spring r
25. Outer Valve Spring Seat

26. Exhaust Rotator Cap
27. Valve Retaining Keys C
8
9 r
(j(i 12
27 n
~80io "Be
I" -/b
15’ 88 V)
16
Island Enterprises
m
25
,,Pr 24
23
;o
m
v,
22
i. Hydraulic Lifter
2. P;sh Rod
3. "0" ;O
Ring Seal
4. Shroud Tube 1
5. Spring -I
m
6. Lockplate
7. Nut ~sr. 01
8. Rockers Z
9. Square Washers m
19 v,
10. Rocker Fulcrum
11. Self-locking Nut
12. Gasket
13. Rocker Box Cover
14. Drain Back Tube Figure 5-1. Cylinder Assembly
Cylinder, Piston
and Valve Train
I’ i
6
di"
10
4. Connecting Rod Bolt

i. Nut 5. Connecting Rod 8. Oil Regulating Ring
2. Connecting Rod Cap 6. Piston 9. Compression Ring
3. Bearing Insert 7. Piston Pin Plug 10. Piston Pin
Figure 5-2. Piston and Connecting Rod Assembly
CA UTION
Do not drive the valves through the Ruides.
5-16. Place each valve, with its springs, seats and keys in
its proper compartment of the cleaning and inspection
basket (64553). No further disassembly of the cylinder is
the replacement of
necessary unless inspection warrants
valve guides, valve seat, or primer nipple.
5-17. Using the piston ring expander (647131,

Pistons.
remove the rings from all pistons. Remove the rings in
order, starting with the top ring and working down. Be
careful not to scratch or score piston when removing
rings.
:I
5-18. Hydraulic Lifters. Place the hydraulic lifter
assembly in the fixture (ST-233). Compress the plunger
assembly until the spring clip is loose. Remove the spring
clip from the lifter body. Remove the socket and plunger
assembly from the body. In the event that the fixture is
not available, the hydraulic lifter may be disassembled as
follows: Insert suitable tool into the socket and push the
a
plunger assembly until oil is forced out of the vent hole

and the pressure is released from the spring clip. Using a
pair of needle nose pliers remove the spring clip from the
lifter assembly. Remove the socket and plunger assembly
from the lifter body.
;C
NOTE
Some hydraulic lifters employ a circlip retaining ring in

d
place or the spring clip as stated in paragraph 5-18.
CLEANING
5-19. Clean all cylinder, piston and valve train parts in ac-
Figure 5-9. Two Methods of Supporting
cordance with the general instructions described in Sec-
Connecting Rods
tion 3. Specific instructions follow:
5-3
Island Enterprises
Cylinder, Piston
and Valve Train
bb. Maximum removal in accordance with
figure 5-4.
cc. No burrs or sharp edges are permitted.

MAX. FIN REMOVAL
TO THIS LINE ONLY( dd. Minimum fillet at the root of the removed
NEVER ENTER- portion of the fin in one quarter inch radius.
BASE METAL, Minimum corner at top of fin adjacent to the
removed portion is one half inch radius.
Figure 5-4. Maximum Fin Removal
(b) Fins other than the above may be accepted
provided not more than one crack per fin and its
5-20.Hydraulic Lifters. Use the cleaning basket in order
depth is no closer than 1/4 inch from the base of the
to keep the valve operating mechanism parts separate. metal and a fin stabilizer is used to reduce vibration
Dip the basket, with all parts contained in their proper and further deepening of the crack.
compartment, in petroleum solvent.
CA UTION 2. Physically damaged, broken or bent fins.
(a) The blended for any one fin shall not exceed
It is imperative that various parts of each lifter assembly area
318 square inches, 3/8 inch in depth.

be kept together during the overhaul operations, in order nor
that all component parts may be reassembled with their

(b) No than two blended fin.
original mating parts and each completed assembly in- more areas on any one
serted in its original location in the crankcase. In the

intermixed discard and install new (c) No more than four blended fins on the push rod
event parts are
assemblies. side of the head. No more than six blended fins on

the anti-push rod side of the head.
INSPECTION
(d) In addition to the above, it is recommended that
5-21. Inspect all cylinder, piston and valve train parts in
a fluorescent penetrant inspection of the cylinder be
accordance with the general instructions described in Sec- made. Pay particular attention to the following
tion 3. Specific instructions will be found in the following areas.
paragraphs, possible revisions will be found later in the

section. (1) Between the 15th and 20th cylinder fin
(counting from the top) on exhaust port side of
5-22. Cylinder Head (I/isual Inspection). Examine the
cylinder.
cylinder head thoroughly, checking for the following
possible defects.
(2) The area around the lower spark plug
otherwise damaged valve counterbore.
a. Loose, scored, pitted or
seats. (Mark for replacement).

5-23. Head (Dimensional Inspection). Check the
Cylinder
b. Loose or damaged studs. (Replace with 0.003, 0.007 ID of each intake valve guide tit is recommended that ex-
or 0.012 oversize studs), haust valve guides be replaced at overhaul) with the flat
plug rejection gage (ST-81). Check the diameter and out-
c. Loose or damaged spark plug hell-coil inserts. (Mark of-roundness of the guide bore by checking with the gage
for replacement with oversize insert. at a minimum of two position 900 apart. If the gage enters
the guide at any of the positions tested, mark the guide
d. Loose, cracked or scored valve guides. (Mark for
for replacement.
replacementl.
e.Nicked, scored or dented mounting pads. (Intake and 5-24.Cylinder Barrel (Visual Inspection). In addition to a
exhaust ports, rocker box covers.) thorough inspection of the cylinder barrel to ascertain its
general condition, make the following specific checks,
f. Cooling fins. The following standards shall prevail
insofar as acceptance or rejection of cylinder heads are
THIS PART OF PISTON
concerned. HAS LARGER DIAMETER
THAN RING LANDS.
i. Cracked fins. STRAIGHT EDGE MUST
BE USED AS SHOWN.
(a) Fin adjacent to the exhaust port flange. ´•I~ I FEELER GAGE
a 3116 inch diameter hole through

(1) Stop drilling,
the end of the crack is permissible providing the
end of the crack is at least 1/4 inch from the base
of the metal.
(2) Fin removal to eliminate crack and reduce STRAIGHT EDGE
vibrating mass is permitted provided:

Figure 5-5. Method of Checking Piston
as.Maximum removal is no more than one half
the total fin width.
Ring Side Clearance
5-4
Island Enterprises
OVERHAUL MANUAL AVCO LYCOMING 76 SERIES AIRCRAFT
and Valve Train
a. Fins. It is recommended that notches or

Cooling 5-26 Piston (Visual Inspection). Examine the top of the
nicks be profiled with a hand grinder or file. A cracked piston for excessive pitting, cavaties or surface distortion.
cylinder barrel is cause for rejection of the cylinder. The latter may be evidence of detonation, particularly if
the piston has been in service for a relatively short time.
b. Cylinder Skirt. Replace any cylinder having a bent, Other critical points which must receive thorough visual
cracked, broken corroded skirt.
or
examination are the piston ring lands and grooves, piston
pin holes, and piston pin holes bosses.
c. Check mounting flange for cracks, nicks, warping, or
corrosion.
5-27 Piston lDimensional Inspection). Make the following
d. Inspect interior of barrel for scoring or corrosion. dimensional checks oneach piston (the numbers in paren-
Minor damage can be repaired by regrinding or honing; thesis refer to the applicable reference numbers in the
deep scoring or pitting, however, is cause for rejection Table of Limits).
of the cylinder.
e.Inspect interior of nitrided barrel for barrel glaze and Side clearance between piston ring and piston (514,
a possible ring wear step at the point where the piston 515 and 516). Pistons for Avco Lycoming opposed
reverses travel at the top of the stroke. Repair of these
engines are ground with a slight taper from the skirt to
items is fully described in Service Instruction No. 1047.
the head, with the exception of the lands between the
Dimen- top compression and oil control rings, which are ground
5-25. Cylinder Barrel /Dimensional Inspectionl.
sional inspection of the barrel consists of the following parallel. The clearance on wedge type compression
measurements (the numbers in parenthesis refer to the ap- rings therefore must be measured as shown in figure
5-4 in order to obtain a true check of the side clearance.
plicable reference numbers in the Table of Limits):
a. Fit between piston skirt and cylinder (519). b. Inside diameter of piston pin hole (5121.
b. Maximum taper of cylinder walls (520). c. Clearance between piston skirt and cylinder and
piston diameter at top and bottom (519).
c. Maximum out-of-roundni´•as (521).
d. Bore diameter (522). 5-86 Piston Pin and Piston Pin Plugs. Check OD of piston
pin against ID of hole in piston (reference 512, Table of
NOTE Limits). Measure fit between piston and plugs and check
OD of plugs (reference 513, Table of Limits). Examine in-
All measurements involving cylinder barrel diameters terior surfaces of piston pin for corrosion or pitting.
must be taken at a minimum of two position 900 apart in
the particular plane being measured All measurements of
nitr’ded barrels must be made in the straight portion 529 Valve Rockers. Damaged, badly worn, pitted or
below the starting point of the choke, or at least two in- scored top and push rod sockets warrant replacement of
ches below the top of the barrel, the rocker. Rockers that are scored at the point of contact
with the fulcrum must be replaced.
NICKS OR SCRATCHS
IN THIS AREA ARE CAUSE looseness
690 Push Rods. Inspect push rods for wear or
FOR REJECTION BUT NORMAL
WEAR CAUSED BY THE VALVE ot ball ends. If ball ends are loose, replace the rod. Rod
KEY IS ACCEPTABLE must be straight within .010 inch.
~31. Valves. Remove the valves from the cylinder and

clean to remove soft carbon and examine visually for
002 IN. UNDERSIZE DIA. physical damage, damage due to burning or corrosion.
PERMISSIBLE IN THIS
Valves that indicate damage of this nature must not be
AREA ON INCONEL
VALVES ONLY. reused.
NOTE
Exhaust valves (except Inconel exhaust valvesl should

never be reused Inconel exhaust valves may
be reused if
they comply with reguirements of the following inspec

tion
5-32. Do not valve in which stem diameter midway

reuse
of valve less than that measured at the key end;

measures
excepting inconel valves which may be 0.002 inch under-

Figure 5-6. Area to Inspect Valve Stems size on stem diameter as shown in figure 5-6.
&5
Island Enterprises
Section 5
OVERHAUL MANUAL AVCO LYCOMING 76 SERIES AIRCRAFT ENGINES
Cylinder, Pirton
and Valup Train Y~UE Ti~Ct M NOT NCLUOE
5-33. Check runout of valve lace. See figure 5-7 WHLN hlE48URINb T*ICXNEEE
mnout must not exceed .0015 inch Uo nut reuse;lny

valves that exceed this limit
S
5-54. Measure edge thickness of intake valve heads See
r
figure 57 it, after is less th;ln U6!1 the
valve must not be reused.
~I
No~a
I’igure 5-X Section l‘hrough Edge of Valve
pl,e od~p o/ intokr uoive hpod´• ore gunrroliy /orm~d os
~ihown is Fgare 5R i%e thickness "A con 6r31 6e valve, 1See inspection of hydraulic lifler´•.l Chreh the
mposured iuith opticoi comporotul hoiuuvur, i, con
on be clearance between the valve stem and guide lreference
msurarPd with rumeionl occumey 6y mean ul a dioi in L2X. ~L‘able of i.imits for exh;alst valves. and reference 528
dicator and a surfocP plaf e. u~ rhown in 59 for intake valvesi.
5-93 inspect the hydraulic lifter for evidence of the

following wear patterns:
a Spoiling if the fice of the lifter shows small nick, or
indentolinns near the center at the i;lca it is considered

pitied or spalled. l~he pillinl: will constitute small ir
regular holes. nat to be confused with Hockwoll hard-
Fe~E OF VPILVE MUST RUN ness check marks. which are round and even l‘he urea
TRUE WITH STEM WITHIN covered by spelling will vary with different lifter. hut
.00151 1 regardless of the de~ees of spalling the litter must l,u
replaced
b Sconnp ~Phr lifter face is scored whell small scratch-

like lines are ioulld near the outer edge of the face and
will appear to radiate from the center (Ither scoring
marks may be present and exlmd to the cellter of the
face phe lifter with this canditian must be replaced
e Liprr ~aca Weer l‘he operation of the lifter provides
q during the wiping action at the

that the lifter rotates
camshaft lohe. This action will form a groove or path
across the face of the lifter. Deeper penetration will be
noted at the center of the face. If the is excessive it
T
wear
will be noticeable to the touch, if a fingernail is rubbed

across the lifter face. This condition reguires replace-
Figure Showing
5-7. Valve i,ocations far
ment of the litter.
Cheering Kun´•Out and Sectian for
Measuring lidge Thickness
5-35. Using an aptical magnifier, examine the valve in the

stem area and the tip for evidence of cracks. nicks, tool
marks. other indications of damage, Damage of this
or
nature seriously weakens the valve, maring it liable to

failure. Any valve having a nick, with ragged edges more
than 1116 inch in length should not be reused A nick or
tml mark of any sort in the keeper groove of an exhaust
valve is sufficient reason for not reusing the valve, See
figure 5-6.
5-36. If superficial nicks and scratches in the valve in-

dicate that the valve be cracked. it should be in-
might
or dye penetrant method,
-:ia
spected by a magnetic particle
Dye penetrant procedures should be carried out strictly
within the recommendation of the manufacturer of the
penetrant. ;ii-
areas include the face end tip both of wluch

5-37. Critical
should be examined for pitting and excessive wear. Minor
pitting on valve faces can sometimes be removed by
regrinding: otherwise the valve should be rejected.
Replace any valve that has operated with a collapsed Figure 5-9 Methad of Checking Valve Edge
hydraulic tappet, regardless of the number of hours on the Thickness with Dial indicator
Island Enterprises
Cylinder, Piston
and Valve Train
NOTE this will engage the insert in threaded end of
slightly;
sleeve. Continue to rotate the mandrel while holding the
Indications of non rotation of the hydraulic lifters is not sleeve thus securing the insert firmly on the inserting
for rejection unless the lifter face is marked as tool. The insert may then be wound through the threaded
described in Par. 5-38 b
a, or c.
portion of the sleeve within one half turn from the end of
the coil.
5-:39. When the hydraulic lifter is rejected because of spall-
ing or scoring, a visual inspection of the nose of the cam 5-45. The adjustable brass screw on the sleeve tends to act
lobe with a magnifying glass (min. 10 power) must be as abrake, preventing the insert from unwinding. It is im-
made. Any indication of distress surface irregularity, or portant that the insert be kept tight on the mandrel to
feathering of the edge of the cam lobe is cause for rejec- facilitate its assembly in the threads of the cylinder head.
tion of the camshaft. The insert should be wound so that the adjacent turns of
the insert are in contact with each other. This will
NOTE eliminate the possibility of crossed threads.
Whenever the camshaft is replaced, either with one that is NOTE

reconditioned by grinding the cam lobes or a new cam-
shaft, all hydraulic lifters must be replaced with new When inspection reveals the necessity of replacing a spark
lifters, plug hell-coil insert, it must be replaced with a .010 inch
oversize insert. A .010 inch bottoming tap (6459~1) is
5-41~ Valve Springs. Check the condition of all valve spr- available.
ings on a suitablespring tester, using the loads and deflec-
5-46. When screwing the insert into the hole in the
tions as given in reference 800 and 80l,’rable of I,imits.
cylinder head, be sure that the first coil picks up the first
thread. As the tool is turned,the insert will advance into
REPAIR AND REPLAC~MENT
the hole. When the face of the sleeve is approximately 1116
inch from the face of the boss, the inserting tool should be
5-41. General instructions for the repair of cylinder, piston
held tightly by the handle and the sleeve rotated counter-
and valve train parts will be found in Section 3. Specific
clockwise with the other hand, freeing the last half-turn of
instructions follow.
the insert. By sliding the sleeve toward the top of the
5-42.Spark Plug Thread Inse~ t. Spark plug thread inserts mandrel, the end of the insert can be seen projecting
which were rejected during inspection are removed and
above the boss. The mandrel should then be rotated in a
clockwise direction until the insert disappears from sight.
replaced as described in the following paragraphs.
When this position is reached, the turning action should
5-43. Insert the extracting tool (64595) in the spark plug be stopped and the tool withdrawn.The top of the insert
hole so that the edges of the tool cut into the top thread of will be approximately one half turn from the face of the
the insert. Rotate the tool in a counter-clockwise direc- boss. However, if it is not, the tool should be reassembled
tion, unscrewing the insert from the hole. and the insert turned until it is about one half turn from
the face of the boss.
5-44. A new insert may be installed by use of the inserting
tool Withdraw the mandrel part of the tool
(64594). 5-47. The tang of the insert can be broken off with needle-
beyond the recessed section of its sleeve. The insert may nose pliers at the location of the notch. Then using the ex-
then be assembled into the recess and the mandrel ad- pending tool (64593), secure the insert firmly in the spark
vanced to engage its slotted end with the tang of the in- plug holes. The limit of expansion can be kept within the
sert. Rotate the mandrel clockwise and press forward thread gage limits by fixing the stop nut on the
"n" __
"e"
300-01 45"-0’
"G
29"-30’ I A J- 44"- 30’
15" 15"
75"
INTAKE ‘ORIGINAL OUTLINE OF SEAT EXHAUST
MODEL "A" INTAKE "B"EXHAUST "C" INTAKE "D" EXHAUST
0-320-H 2.154/2.155 1.74011.750 .0761.117 .0581.077

0, LO-360-E 2.15412.155 1.74011.750 .076/.117 .0581.077
Figure 5-10. Valve Seat Dimensions for Reconditioning
5-7
Island Enterprises
Section 5
Cylinder, Piston
and Valve Train
expanding tool at the correct position. After expanding 5-52. I/alve Seat Removal and Replacement. Valve seats
the insert, it may be staked by assembling the staking that are loose, damaged or worn to the extent that they
sleeve over the mandrel until the sleeve meets the boss. A cannort be reground to the dimensions shown in figure
slight blow on the top of the sleeve will impress a slight 5-10 must be replaced.
chamfered edge around the periphery of the tapped holes.
The staking sleeve may then be removed and adjusting NOTE
screw released, and the expanding mandrel removed from
the insert. When it is necessary to replace intake or exhaust valve

seats, the recess in the cylinder head must be cut .010, .020
5-48. Seats. See figure 5-10. The ID of the
Grinding Valve or .030 oversize and the corresponding oversire seat in-
valve guide is used as a piloting surface for all valve seat stalled
reconditioning operations. Grind valve seats, using
suitable grinding equipment, to 300 angle on intake valve 5-53 Valve Seats. "Allison" type seat employed on all cur-
seats and 450 angle on exhaust valve seats. Grind to the rect subject engines.
dimensions called out in figure 5-10. Proceed in the follow-
ing manner. 5-54. Place the applicable valve seat replacement fixture
on suitable surface and fasten securely. Fabricate a
a
removal tool in accordance with the material and dimen-

sions shown in figure 5-12.
REPLACE SEAT IF 150 NARROWING
WHEEL of GUD"F, and
5-55. Heat cylinder to a temperature secure
to fixture. Soak the sponge of the removal tool in cold

HERE
water. Insert the tool down through the valve seat, the
seat will shrink and cling to the sponge. Withdraw the
SEAT tool being careful not to cock the seat. This entire pro-
cedure should be performed as swiftly as possible after
PILOT
removing the cylinder from the heat.
ALVE GUIDE
5-56. Measure the ID of the valve seat recess in the
cylinder head. Compare the measurement with the
Figure 5-11. Rejection of Valve Seat original manufactured diameter of the recess (see Table of
I,imits) and determine which oversize seat is to be install-
5-49. On intake valve seats, grinding wheel to
use a 15" ed.
grind the top surfaces of the valve seat to produce the
outer face diameter (dimension "A"). Bring the face of the 5-57. Refer to Table 5-1 and select the proper cutter and
intake valve seats to the specified width (dimension "C") pilot.Install the pilot in the cutter, tighten and install cut-
by narrowing the throat with a 750 wheel. ter in drive. Install on drill press and proceed to
special
cut the in the cylinder head to proper size. Note
recess
5-50. On exhaust valve seats, use a 15" grinding wheel to that the pilot engages the ID of the valve guide hole in the
grind the top surface of the valve seats to produce the cylinder head. Remove no more metal from the bottom of
outer face diameter (dimension "R"). The width of the ex- the recess than is necessary to clean up the major
haust valve seats should now conform to dimension "D". diameter.
5-51. If seat wear has progressed to the extent that the en- 5-58. In the event the seatsare to be cut by hand, install
tire face of the 15" narrowing wheel must be

brought into the hand drive adapter over the special drive and using a
contact with the seat in order to achieve the specified "T" handle proceed to cut the recesses as described in the
diameter, the seat must be replaced. (See figure 5-11.) preceding paragraph.
NUTS ~2)
1
1/2" BAR STOCK
FLAT WASHERS (2)
SPONGE 2.5" DIA.

2"
Figure 5-12. Valve Seat Removal Tool
5-8
Island Enterprises
Cylinder, Piston
and Valve Train
TABLE 51
VALVE SEAT REPLACEMENT TOOLS
VALVE SEAT RECESS CUTTER
ID Valve Seat Hole in Cylinder Head Part No.

1.733-1.735 ST-52,-1,-2,-3
2.087-2.089 ST-57-1,-2,-3
-1 Indicates .010 inch oversize

-2 Indicates .020 inch oversize
3 Indicates .030 inch oversize
VALVE SEAT RECESS CUTTER PILOT
ID Valve Guide Hole in Cylinder Head Part No.

.5913-.5923 ST-66-1,-2,-3,-5
.6613-.6623 ST-67-1,-2,-3,-5
ST-66 is standard ST-66 is standard

-1 Indicates .010 inch oversize -3 Indicates .030 inch oversize
-2 Indicates.020 inch oversize -5 Indicates .005 inch oversize
VALVE SEAT REPLACEMENT DRIFT
ID of Valve Seat Part No.

1.870-2.060 ST-64
1.474-1.730 ST-65
VALVE SEAT REPLACEMENT FIXTURE
Part No.
Parallel Valve Cylinder Heads ST-250
VALVE SEAT RECESS CUTTER DRIVER
Part No.
Used with all ST series cutters ST-62
Hand Drive adapter ST-63
5-59. Heat the cylinder to 4000 to 4250F. and secure to ap- dance with the procedures described in the following
plicable replacement fixture. Chill new seat and place on paragraphs.
replacement drift (see Table of 5-1 for correct drift) and
drive seat into the recess in the cylinder head by tapping NOTE
end of drift with hammer.
Unless valve guide is in obviously new condition it is bet-
5-60. Proceed to grind the faces of the newly installed ter to replace it. Should the guide be bell mouthed it will
valve seats as described in paragraphs 5-48 thru 5-50. be impossible to get concentric grind of the valve seat.
NOTE 5~3. Valve Guide Removal. Screw the nut of valve guide
puller lST-49) to the head of bolt (314-16). Place the re-
Whenever a new valve seat is installed it is required that tainer over valve guide inside of rocker box. Insert the
its matching valve
guide replaced.
be This will assure con- bolt (3/4-16) into the retainer and valve guide. From
centric grinding of the new seat. cylinder barrel end insert the bolt (318-24) into the end of
3/4 inch bolt. Tighten the 3/8 bolt until snug against the
5-61. Valve Refacing. Place valve in a suitable valve refac- valve guide. Turn the nut in rocker box in a clockwise
ing machine (Snap-On VR-300) or equivalent. Set refacer direction until valve guide is out of cylinder head.
to 300 for intake valves and 450 for exhaust valves. Using
a soft no. 80 grit wheel, remove no more metal than is 5-61. Valve Guide Selection. Check each valve guide hole
necessary to clean up pits in the valve face or to correct in the cylinder head with the applicable valve guide hole
any apprarent warping condition. Round off with a hand plug gage. (See Table 5-2.) Determine if the same size
stone any sharp or burred edges left around the valve face guide may be used or whether the next oversize guide is
after refacing; this is best accomplished while valve is tur- required.
ning in the refacing machine.
6-65. Valve Guide Installation. Mount the applicable valve
5-62. Valve Guide Replacement. Damaged or worn valve guide replacement fixture on a drill press table. Fasten
guides are removed and new guides installed in accor cylinder securely in place on the fixture (64714).
5-9
Island Enterprises
Section 5 OVERHAUL MANUAL AVCO LYCOM ING 76 SERIES AIRCRAFT ENGINES
Cylinder, Piston
and Valve Train
TABLE 52
ACCEPTABLE
VALVE GUIDE REPLACEMENT TOOLS INTAKE VALVE EXHAUST VALVE
GAGE SIZE REAMER
Valve Guide Hole

in Cylinder
1.59131.5923 Hole)
64571 Standard
64507 .005 oversize 64678-2
64509 .010 oversize 64678-3
64511 .020 oversize 64678-4
64639 .030 oversize 64678-5 DESIRED (10 MAX. ANGLEI
INTAKE VALVE EXHAUST VALVE

(.66131.6623 Hole)
64940 Standard 64924

64928 .005 oversize 64924-1 1 1 ~I ~l´•Mnx. I I ´•rl´•Max.
64929 .010 oversize 64924-2
64930 .020 oversize 64924-3
64931 .030 oversize 64924-4
Valve Guide ID
64514 All Intake Valve 64684

64927 .49851.4995 (Ni-Resist) Exhaust
Pilot Diameter
NOT ACCEPTABLE
ST-113-2 INTAKE VALVE EXHAUSTVALVE

.47781.4783
Replacement fixture 64714

Installation drift (intake) ST-304
Installation drift (exhaust) ST-303
Valve guide puller ST-49
5-66. If it has been determined that the next oversize

guide is required, select the appropriate reamer (See Table UNSATISFACTORY SEATING
5-2) and proceed follows. Mount the reamer in the drill

as
press spindle and ream the valve guide hole in the cylinder Figure 5-13. Acceptable, Desired and Non-Acceptable
head. Check the reamed hole with the corresponding gage Valve Contact with Seat Face
(See Table 5-2).
5-69. Reconditioning Chrome Plated Barrels. Although it
5-67. Heat the cylinder to 4000 to 4250F. for a minimum of is not practical to remove wear steps by regrinding, such
one hour. Place the new valve guide, that has been chilled, barrels can be restored by a stripping and replating pro-
on the appropriate valve guide installation drift (See cess. Consult Service Letter No. 159 for facilities approv-
Table 5-2) and insert the guide in the hole in the cylinder ed by Avco Lycoming to perform this chrome plating pro-
head. Drive the valve guide until the drive bottoms on the cess.
lower valve spring pocket. Use driver (ST-303) for exhaust

valve guide and (ST-304) for intake valve guide. Check the 5-70. ~alue Repair. Repairs to valves are limited to
valve guide drive height which is measured from the lower removal of carbon, regrinding of face, and polishing super-
valve spring pocket to the top of the valve guide. The ficial scratches. Bending processes, to straighten and pud-
dimension is .775 for exhaust valve guide and .715 for in- dling to restore the face must not be attempted.
take valve guide. The dimension must be held within
f.010 of the above. Do not measure from the counterbore 5-71. Warped Exhaust Flanges. If a warped exhaust
flange seat. flange is note, the flange should be straightened by grin-
ding.
5-68. Any nitrided cylinder barrel that exceeds the
allowable service limits in diameter, taper, or out-of- REASSEMBLY
roundness must either be rebarreled or reconditioned by
chrome-plating. Consult Service Instruction No. 1047 for 572. Assembly of Pistons. Figure 5-2. Using the piston
information relative to reconditioning nitrided cylinder ring expander, assemble the new rings on pistons in the
barrels. order described in the following paragraphs.
5-10
Island Enterprises
Secfion 5
Cylinder, Piston
and Valve Train
5-73. With the piston lying top up on the workbench, in- in paragraph 3-39. Apply to inside of cylinder barrel and
stall the oil regulating ring equalizer in the first groove to piston and rings working the oil mixture around the
above the piston pin hole. Assemble the regulating ring (8) rings and into groove. Starting with no. 1 cylinder proceed
over the equalizer with its gap 180" opposite the equalizer to install as follows:
gap. Compress the assembly several times with the
fingers to make sure the ring lies free and loose in the 5-79. I~otate crankshaft so that no. 1 piston, when install-
ed, will be approximately at top dead center on the firing
groove. Roth the equalizer and the regulating ring are
symmetrical and may be installed with either side up- stroke; determined by both tappets of no. 1
this is
ward. cylinder t,eing the base circle of the cam lobes. Hefore
on
any attempt is made to rotate the crankshaft support the

5-74. Install the compression rings (9) in the remaining connecting rods as shown in figure 5-3.
top grooves. Thecompression rings are etched on one side
with the word "top", this side must be installed toward 5-80. Figure 5-2. Assemble piston on connecting rod with
the top of piston, piston number, which is stamped on bottom of piston
head, toward the front of the engine. l’he piston pin (101
5-75. Pistons.Upon completion of assembly of the piston should be palm or hand push fit. If the original piston pin
ring, check the side clearance of the rings in the grooves, is tighter than a palm push fit, it is probably caused by
Use feeler gage and straight edge as shown in figure 5-5. nicks or carbon in the piston pin bore of the piston.
slight
If a piston pin or piston is to be installed, select the
new
NOTE pin to give a palln push fit at room temperature of 150 to

’LO"C. 160" to 70"F.). After pistoll pin is in place and central-
Under no circumstances should oversize piston r’ngs be 1!’ located, insert a piston pin plug 17) at each end of the
used in chrome plated barrels. pist.on pin.
5-7C.Assembly of Clylinder. See figure 5-1. Coat the valve 5-81. l’lace a rul,ber cylinder l,ase oil seal
ring (figure 5-1)
guides and valves with a pre-lubricant as described in around the cylinder base assemble the
application piston
paragraph 3-39. Insert the intake (181 and exhaust valve ring compressor over the top piston rings and install the
(19) in their respective guides, The intake valve can be cylinder over the piston, pushing the piston ring com-
identified by the fact that it is slightly larger than the ex- presser ahead with the cylinder barrel. As the cylinder
haust valve. Ilold the end of the valve stems and place the barrel approaches the crankcase, catch the piston ring
cylinder on the applicable cylinder holding block. Install compressor as it drops off the piston skirt. When the base
on each valve a lower spring seat 1221. outer (23) and aux- of cylinder is seated on crankcase pad, secure the cylinder
iliary valve spring (24), and upper valve spring seat 125). with :)iH inch and 1i2 inch cylinder base nuts, tightening
the nuts finger tight only.
NOTE
T,-8’L.’l’o assure proper assembly of the crankcase halves
Assemble the dampener ends ofspn’ngs (close wound coils and to eli mi na te the possil,i ii ty of subsequent loosening of
marked Ic~ith dye or lacquer) downward or next to lower cylinder l,ase a defillite and specific sequence of
spr’nK seats, tightening all crankcase and cylinder base nuts must be
followed. certain that clnnkcase halves have been
5-77 (:ompress the valve spn’ngs u,ith the valve spn’ng. I,rought together, and fastetlings secured as directed in
(S~’-419) and assemble the valve retaining´• Section 7 before installing cylinders.’rhe cylinder base
compressor
keys 1271. If the r,alve is not sea ted properly the value ma~y hold-down nuts are installed as described in the following
be‘seated by using a wooden hammer handle against the paragraphs.
tip of valrle stem and hitting hammer ulith palm of hand.
No other means should be used 5-83. When all cylinders have been initially installed on
the cl´•ankcase as described in paragraph 5-81, begin
NOTE tightening all cylinder base nuts as described below, using
the proper cylinder base nut wrenches and handle in con-
Sodictm-cooled exhn~dsl valves are assembled Nlith special jullction with a suitable torque indicator. Torque wren-
ctntiljust before value ches should employ the flexible beam design hydraulic
k~?’s and caps. I)o not install caps
rockers are installed, principle or a dial indicator with rack and pinion.
WARNING NOTE
I)o not under any circumstances assemble chrome plated Hcfore installing cylinder hold-down nuts, lubricate
piston rings in a chrome plated cylinder barrel. If in doubt c´•rankcasc´• through stud threads with any one of the
as to the proper combination of rings to be used, refer to follou’inR lubricants, or combination of lubricants.
the latest edition of Service Instruction No. 1037 or con- I´• .9(.)Lr(’ SAES 50W enRine oil and 10% STP.
tact the Service Uepartment, A vco LycominR Division. 2´• SAE .70 oil.
I~c´•l-I-’ro Food (:rade AA Anti-Seize Lube.
5-7X. Installation of Pistons and Cylinders. See that all
oil accumulation and piston
on cylinders ?‘ighten 112 inch hold down nuts to 300 inch pounds
preservative a´•
assemblies is washed off with solvent and thoroughly (2,5 foot pounds) torque.
dried with compressed air. Immediately prior to assembly
of piston and cylinder to the engine, space the ring gap b´• Using the same sequence, tighten the 1/2 inch nuts to
and apply a generous coating of oil mixture as described 600 inch pounds (50 foot pounds).
5-11
Island Enterprises
Section 5
OVERHAUL MANUAI, AVCO LYCOMING 76 SERIES AIRCRAFT ENGINES
Cylinder, Piston
and Valve Train
c.Tighten the 3/8 inch hold down nuts to 300 inch 5-90. Install two square washers (9), rocker arm (8) and
pounds (25 foot pounds) torque. Sequence is optional. rocker arm fulcrum (10) seat on stud. Install 5116-24 self-
locking nut (11) and tighten to the proper torque, see
d. As a final check hold the wrench at the correct torque, Table of Limits figure reference (877). Check the dry tap-
on each nut for about five seconds. If the nut does not pet clearance by pressing the thumb on the push rod end
turn, it may be presumed to be tightened to correct tor- of the rocker arm. Record the clearance between the
que. rocker arm and the top of valve stem. Use valve clearance
gage ST-23. Valve clearance is .028-.080 inch. The adjust-
5-84. After all cylinder base nuts have been tightened, ment of the dry tappet clearance is obtained by increasing
remove any nicks in the cylinderfins by filing or burring. or decreasing the number of square washers (9) placed
under the rocker arm fulcrum. Increased number of

5-85. Install some type of vented plug in each spark plug washers will increase the clearance.
hole after assembly of cylinder to prevent entrance of
foreign matter and at the same time to permit the engine NOTE
to be turned easily by hand.
When adjusting the dry tappet clearance it is best to use a
5-86. Install hydraulic lifter (1) in crankcase. (Figure 5-1). plain5/16-24 nut. Then after the proper clearance is obtain-
ed install the 5/16-24 self-locking nut.
5-87. Assemble new shroud tube seal(3) on both ends of
shroud tubes. (Figure 5-1.)
5-91. At of valve clearance check on each
completion
5-88 Parallel Cylinder, (Figure 5-1.)Install each shroud cylinder, recheck clearance on all cylinders and make
tube through its hole in the rocker box and press to firmly necessary corrections. Coat all mechanism parts within
seat the seals in their respective position in the cylinder rocker boxes as described in paragraph 3-37 and 3-39.
head and crankcase. Install shroud tube spring (5), Assemble rocker box cover gaskets and covers on each
lockplate (6), and 1/4-20 plain nut (7) over stud provided in rocker box and tighten to specified torque.
the rocker box. Tighten nut to proper torque and secure
by bending the lockplate up around the nut. 5-92. Intercylinder Baffles. All intercylinder baffles must
be attached with an "S" type retaining hook and a slotted
5-89. Dip the push rod in the oil mixture as described in retainer. Hook the baffle retaining hook through the hole
paragraph 3-39 and insert the full length into the shroud in the baffle. Place the baffle in position beneath and bet-
tube. Press tightly against the outer end of push rod to ween the cylind$rs, running the hook up between the
check spring tension and free travel of the dry hydraulic cylinder barrels. Place a baffle retainer in place between
lifter assembly. the cylinders and using a baffle installation tool 164885),
bring the retainer hook through the slot in the retainer.
NOTE During the operation the retainer is forced down until the
hook comes above the surface of the retainer far enough to
Before installing the exhaust rocker arm be certain that be hooked over the bridge between the slots in the re-
the exhaust valve rotator cap is on the valve stem. tainer.
5-12
Island Enterprises
SECTION
OIL SUMP AND FUEL

INDUCTION
Island Enterprises
Oil Sump and
Fuel Induction
SECTION 6
OIL SUMP AND FUEL INDUCTION
6-1. No attempt will be made to describe the overhaul of 6-6 Oil Sump. Clean the sump according to the general in-
the carburetors used on the engine models covered in the structions contained in Section 3. Clean the oil passages
overhaul manual. Overhaul information for the car- with solvent and a suitable brush and blow out with com-
buretors can be obtained from Marvel-Schebler Products pressedair. Do not clean the oil suction screens until they
Division publication no. MS609/631, have been inspected for metal particles.
DISASSEMBL Y
6-7. Carburetors. Clean the carburetors in accordance with
6-2. IntakePipes. Loosen and the capscrews that
remove the manufacturer’s instructions.
attach the intake pipe flange to the cylinder head intake
port. Loosen the hose clamps and slide the pipe off the INSPECTION
sump connector. Mark the intake pipes as they are remov-
ed from the engine so that they may be reassembled in the
same location. 6-8. Inspect the sump according to the general instruc-
tions contained in Section 3.
63. Carburetor. Remove the carburetor from the moun-
ting pad of the sump. 6-9 Oil Suction Screen. Before the screen, inspect
cleaning
for evidence of metal which could serve as an aid
particles,
6-4. Oil Suction Screen. See figure 6-1 or 6-2. Unscrew the to locate deterioration in some section of the engine. In-
hex head plug and remove gasket and suction screen, spect the screen for distortion or openings of the mesh.
6-ii. Oil Sump. Remove the fastenings from the periphery 6-10. Carburetors. Inspection of carburetors must deter-
of the sump and remove the sump, mine parts serviceability and repair and replacement re-
quirements. Check applicable manufacturer’s publica-
CLEANING tions for limits to be used when conducting inspection.
1
;r’
BE ds
r´• 10. Gasket

1. Intake Pipe
ii. Carburetor
2. Sump Gasket
3. Intake Pipe Gasket
12. Cap
13. Screen
4. Flange
14. Gasket
5. Washer
6. Lockwasher
15. Clamp
7. Bolt
16. Clamp
17. Hose
8. Sump
9. Bolt
Figure 6-1. Oil Sump and Related Parts
6-1
Island Enterprises
Section 6
Oil Sump and
Fuel Induction
REPAIR AND REPLA CEMENT ing to the proper torque as stated in the Table of Limits.
6-11. Carburetor. Allrepair and replacement procedures 6-13. Intake Pipes. See figure 6-1 or 6-2. Slide an intake
must be carried out in conjunction with the pipe flange (4) over each intake pipe (1). Assemble hose
manufacturer’s publication. Consult Marvel-Schebler Pro- (17) and two clamps (15 and 16) over end of intake pipe
ducts Division publication no. MS609/631. and install on sump. Place a new gasket (3) over the intake
port and secure the flange to the cylinder. Tighten hose
REASSEMBL Y clamps on hose.
6-12. When the engine assembly has progressed to the

point where the crankcase has been assembled, the sump 6-14. Install oil suction screen (13), cap (12) and gasket
may be installed on the engine. Using a new gasket assem- (14).
ble the oil sump to the crankcase. Consult the applicable
parts catalog for the correct fastening. Tighten all fasten 6-15. Install gasket (10) and carburetor (11).
nl‘
it
V ~3
8 ;r ‘1
57
6,’0
7
1. Intake Pipe 11. Carburetor

2. Sump Gasket 12. Plug
3. Intake Pipe Gasket 13. Screen
4. Intake Pipe Flange 14. Gasket
5. Plain Washer 15. Large Clamp
6. Lockwasher 16. Hose
7. Bolt 17. Small Clamp
8. Sump 18. Plain Washer
9. Plug 19. Nut
10. Gasket 20. Locknut
Figure 6-2. Oil Sump and Related Parts

0-360
6-2
Island Enterprises
SECTION
C RAN KCAS E,
CRANKSHAFT AND
R E C I P RO CAT ING
PARTS
Island Enterprises
Crankcase, Crankshaft
and Reciprocating Parts
SECTION 7
CRANKCASE, CRANKSHAFT AND

RECIPROCATING PARTS
7-1. At this time it is assumed that the magneto, cylinders figure 7-3) from the crankshaft propeller flange by tapp-
and sump have been removed from the engine, ing lightly on the rear of the assembly. The alternator
drive belt will be removed with this unit.
DISASSEMBLY
7-8. Remove the external retaining ring (12), seal retainer
7-2. Remove the oil pump and vacuum pump body (11) and "o" ring seal (10) from the tachometer drive
assembly by removing the four plain nuts, lockwashers adapter (figure 7-3). The tachometer drive adapter can not
and plain washers, Discard the "o" rings seal and oil seal be removed until the crankcase is separated,
in pump body. Remove the driven impeller from the
crankcase and the driving impeller from the pump shaft. 7-9. On engines equipped with a governor drive, remove
The oil pump shaft cannot be removed until the crankcase the governor drive cover (25), "o" ring (26), and governor
is parted. See figure 7-1. drive thrust washer (27), (Figure 7-3) from the nose of the
crankcase.
7-3. Remove the oil pressure housing and the oil
screen
cooler adapter or the oil filter adapter assembly (where ap- 7-10. The crankcase may be separated by first resting on
plicable) from crankcase. Remove the oil cooler adapter the bottom of crankcase and gently tapping with a soft
from the oil filter adapter. Remove the oil filter and hammer the thru-studs on the loose ends until the
adapter plate. Also remove thermostatic oil by-pass valve. crankcase begins to separate. Place the crankcase on the
Discard all gaskets. left side and continue to remove the right half of
crankcase. Reach down through the cylinder pads and
7-4. Remove the oil relief valve plug, gasket, spring and push the clankshaft bearing insert down on the
ball from the crankcase. crankshaft, so they will not fall when crankcase half is
removed, Separate the crankcase by hand and remove the
7-5. Remove the oil filler tube. bearing insert;s and crankshaft assembly.
7-6. Remove the nuts and bolts from the parting surface of 7-11. Remove the camshaft, tachometer drive adapter and
the crankcase, which hold the crankcase halves together. the crankcase breather baffle. Engines equipped with a
Remove the crankcase from the overhauls stand and place propeller govtlrnor it is necessary to remove the governor
on the work bench. drive gear at the time the camshaft is removed. Also
remove the governor drive shaftgear from the right half of
7-7. Remove the starter ring gear support assembly (16, the crankcase.
98-´• a"
7O
I. Nut
4
3. .2raeGLockplate
4. Driven Impeller
;´•i 5. Key
6. Oil Pump Shaft
7. "0" Ring Seal
3 8. Oil Pump Body
9, Seal
i4S 10. Gasket
Il. Cover
12. Driving Impeller
Figure 7-1. Oil Pump Assembly
7-1
Island Enterprises
Crankcase,Crankshaft
1. Gasket
2. Oil Level Gage
3. Filler Tube
4. "0" Ring Seal
5. Bearing Inserts
6. Oil Relief Valve Plug
7. Gasket
8. Spring
9. Ball
2 10. Crankshaft Seal
O4
()\j
o o
\10
.d 1~3 /s
B
BO
W
Figure 7-2. Crankcase Assembly
7-13. Camshaft. Remove the camshaft gear and the bearing inserts, bolts and nuts. Reassemble each cap with
tachometer shaft. its corresponding rod. Rods and caps are not inter-
changeable.
7-14. Remove the oil and vacuum pump drive shaft by
removing the nut and lockplate. Use service tool ST-416 7-16. Remove the crankshaft oil seal and the expansion
to turn pump shaft while holding nut with open end plug from the crankshaft. Do not remove the propeller
wrench. Remove oil pump drive gear. Remove drive shaft flange bushings from the flange of the crankshaft unless
from crankcase. they are damaged andlor loose.
7-15 Crankshaft. With the crankshaft properly supported NOTE

at front andrear main bearings, remove the nuts securing
the rod caps to the connecting rod. Remove the rods by Engines that are eq uipped with a propeller gouernor drive
tapping on the rod bolts with a soft hammer. Discard the do not employ an expansion plug in the crankshaft.
7-2
Island Enterprises
o
o
i
0 30
0 :_3
28
29
109~
27
6
a
d
47 Y3
\-13
~-5
22
la’9
2
21B2324
14
L17
i. Camshaft 11. Seal Retainer 22. Counterweight

2. Dowel 12. Retainer Ring 23. Crankshaft Gear
3. Camshaft Clear 13. Pin 24. Lockplate
4. Lockplates 14. Crankshaft 25. Bolt
5. Bolts 15. Expansion Plug 26. Cover Plate
6. Tachometer Shaft 18. Starter Plug Gear Support 27. "0" Ring Seat
7. Breather Raffle 17. Plug 28. Thrust Washer
8. Tachometer Adapter 18. Retaining Ring 29. Gov. Drive Gear
9. Seal 19. Washer 30. Gov. Drive Shaft Gear
10. "0" Seal Ring 20. Roller 31. Key
21. Counterweight Bushing
Figure 7-3. Camshaft, Gov. Drive and Crankshaft Assembly
7-3
Island Enterprises
Cran~cale. ClantEhatt
and Reciprocating Partl
CI.EANING
7-19 All crankcase, cranksllaft and reciprocating parts

are cleaned in accordance with the general instructions
outlined in Section 3. When cleaning the cranhshsft, clean
the inside of all crankpin and main bearing journals and
all oil passages with suitable brushes. after which flush
thoraughly with clean solvent and compressed air
INSPECTION
7-20 inspect all cmnkcaso. crankshaft and reciprocating
~s,la in.ranianrlx ih rho~nrs i~lrucuons ioim n

ed in Section 3 Specific inslmelionJ follow.
7-21 Uearings iPrecision l‘ype). All precision type bearing

inserts used for main crankshaft bearings and connecting
rod bearings should he replaced with new bearing inserts
at overhaul
i-2~ Crankcasf (V,saai Inspection) Check carefully for

burrs. nicks and cracks around the bearing support webs
Clieck bearing bores and inspect tang slots for any
roughness that might cause improper seating of bearing
inserts. Cheek all drilled holes
7-23. Fiotting on the contacting surfaces of the bearing

Fi~-uie 7-4. Crankcase Interior Showing Moderate saddle supports in the c-snkcase occurs on some engines
Fretling at Stud I.ucations on Saddle Supports l‘hi? condition is caused i,y Plight motion iletween the con
tacting surfaces and results in erasion of the metal sur-
7-17 ~ounleraewhtr See figure Counterweightr are

7-9 face The affected areas have
tiny pit holes and a frosted
disassombled from the crankshaft merely by removing appearance as contrasted to adjacent shiny unalfectcd
the retaining rings ili(i, after which the washers II’J1. surfaces. See figure 7-1. This condition can be misleading
rollers i2o1 and counterweiphts 1221 may be romoveri from because of its trivial appearance nevertheless it can be
the crankshafl ear
the causo of severe engine damage
7-24 Fralting. by inseif in this area. dues ilot appreciably

NO~‘IS
damage the structure of the metal, bul the metal removed
60
by the fretting action does change the slee of the bearing
ail ond their related purrs mlisl
saddles sufficiently to cause loose thru-studs and under
r~osssmbied in the some iocafion fhnt thev oeeiijiied on
size main bearing bores. If not detected rlurinl! overhaul.
the eiunbrdop before disassrmbly. For example. ~Br rp-
excessively light crankshaft bearing fits will result with
leininp luarhprr lised uiifh fhe counlre~ighfs are solrc- eventual engine failure
tiu~iy fitted to the soshrr seaf in the eallntpnuriphts of
the time o/mnnufocfurr it is aduisob(e therefore, to mur6 7´•~5. (i~nkcae il)immsiunal i,i~pccrion) ~l‘he following
all Cr)illlfelUlpiyhL parts dnn,~ disas´•emhly to insure paragraphs on crankshaft and camshaft dimensions will
positive idenfificatban These marks must be inlpermu- also descrihe dimensional requiromsnt´• of the crankcase
npni No sconng, remlehinq, rtchin~. or other permanent
mor)ing o/ony kind is permissible an the cuunformriyhl 7-26 Clnn)Ehnll (Visuoi inepecrb,ni. Carefully inspect all
surfaces of the shaft far cracks. checking the bearing sur-
pulls
faces with particular care for scoring. galling. corrosion.
7-18. To remove the erankshaft gear 1231 flatten out the pilting or other damage.
lockplate 1241 and remove the hex head scrow or screws
787 Crankshoft I~imansiunol Inspectiani Place the
Ifigure 7-51 Tap the crankshaft gear gently with a fihrr
crankshaft in ~ce blocks supported at the locations called
drift to remove gear from crankshaft Do not remove the
out in Table of ilimits lreference 5561 and using a surface
dowel from roar of crankshaft unless it has been obviously
plate and dial indicator measure the run-out st center
damaged. main bearings if this total indicator reading exceeds the
dimensions given in reference 656 the shaft must not he
NOTE:
reupedThe crankshaft nsnge run-out may be checked at
this time and if tho total indicator roading exceeds the
On some ofthe ~on’ler model of the 76 senes engine. if lu~l
run´•out given in Table of i,imits ireference 6071 the shaft
not recommended to remove thegear ?Ipso must be relected.
can be id.n6liod by the presentence of I ar2 doluels of the
mating surfaee bolwoon the cmnkshop and gear Some CALITION

madels ore equipped with fasten to the
the gear
cronkshop by means of one bolt, lockplote and a locating Any attempt to straighten a bent cmnkshoft will result in
doluel Other gears ore secured by means of f~uo bolts, n~plure of the nitnded lurfaee of the bearing journals, a
loekplote ondo loeotingdowd When bolts arepresent the condition that ruill cause puenfuol /oilure of the
gear can be remoued crankshaft
7-4
Island Enterprises
OVERHAUL MANUAL AVCO LYCOMING 76 SERIES AIRCRAFT ENGINES Section I
Cranlcase. CranLEhaft
and
Reciprocating Pam
1-28 Using new inserts at all main bearing lacations, end of hushing with
connecting hushingradplug gage
assemble erankcase halves together. temporarily torque II’IN fi46S7i I i the gage enters the bushing, bushing must
all thru-bolts to 300 inch pounds and measure the ID of be replaced
the Measure the OD of the crankshaft main
bearings.
bearing journals and compare the resulting clearances 73~ Connucn~ng Rod Parallelism CheeA. See figure 7-5.
with the ~l‘able of i.irmts ireference 5011. Assemble the Using connecting rod parallelism and squareness gage
connecting rods temporarily lusing now bearing insertsi Il’lN 618301. insert tapered sleeves II and 21 in hearing
and check the crankpin journal clearances in the same holes in conlleeting rad. He sure that bearing cap is
manner, see Table of iimits ireferenee 5021. If clearances assomblod properly and seeuroly tightened. Place arbors
do not fail within prescribed limits, the shaft must be iS and 41 through sleeves II and 2 respoetivelyl and place
brought undersize See Repair and Replacement section gage arm to exact distance between arbors and lock
the
~ol- instructions for regrinding ndjustiig screw with nut 171. Then remove gage ann, place
it on other end of arbor 131, and check distance between ar-

7´•2~ (Visual inspection) Carefully inspect all bors. Fol exact parallelism or alignment. the distances
surfaces of the camshaft for creeks, scoring. galling, eor´• checked on bath sides will he the same. See reference 566.
rosion, pitting or other damage; be particularly careful l‘able of i.inlits.
when inspecting hearing surfaces. If a hydraulic lifter has
been reiected for spalling, inspect the eorrespanding cam 795 Connpelinp Rod Squareness Cheek See figure 7-6.
lohe. Any indication of distress, surface irregularity or Vsing the some gage that was used in the parallelism
leathering at the edge of the cam lohe is cause for rejef- check described above, place parallel blocks illon surface
tion of the camshaft plate and. with sleeves and arbors still in place in eonnff-
lillr mil, place ends of arbor on parallel blacks, Check
730 ~omsholt IDimensionol InspPcnnn) Support the cipiirnnce at points 121 where iirl,ors reston parallel blocks.
eamshaft in Vee blocks at its front and rear bearing jour- uri.g it feeler gage. For exact squareness or zero twist, no
nals and cheek the run-out st the center bearing location. elsurooce will exist at the designated paints See rcferenee
See l‘oble of i.imits irelerence 5391. Slight bending opera- 587. l‘uhle of i.imits.
tions permissible an the camshaft providing careful
are
magnetic inspection follows such procedures. Measure the hW. Coun~unuelght Bashing Wear in the eounterweight
diameter of the camshaft bearingjaurnals and check them bushing is usually evident as out-of-round on the inside
against the bearings formed by the erankease. Reference dia,lleter. Check each hushing with the bare gage P/N
537. Table of Limits, sl‘-?S, l‘he diameter should be between .1165 and .7505
inch, Out-of-round should not exceed .0005 inch. The
731. Connecting Rods mimensiunal inspectionl Discard g1‘-75 gage is specially made so that it can be set with a
all eannecting rod bolts and nuts: new bolts and nuts are micromoter if the diallleter of any bushing is ovorJi~e, or
to he used on assembly Cheek condition of bare in large eitcessivoly out´•ol´•rauad all the bushing in the
end for sealing of the bearing inserts. Cheek bore in small counterweight must he replaced
i35. ~ronbshoft Bushing Wear or

raunrpnun~*l
2 damage caunterweighl bushing 1211.
to the crankshaft
4 figure 1-3 located in tho crankshaft counterweight lobes is

almost impossible to detect by narmal inspection pro-
eedures. Reeause of this situation and as damage to the
eaunterweight bushing could cause failure to the
eounlenveight andlor the crank´•baft. it is mandatory that
these bushings he replaced at overhaul The procedure for
the removal and replncenleilt of the crankshaft
eounterweight hushing is contained in paragraph 7-13.
REPAIR ANI) REPLACEMENT
756 Repair all cmnkca´•p, erunah~lr and rpe~pmeonnp

parts in oeeordunep u´•ith the general instructions contoin´•
ed in Spetion 9 Spcc~e inrlructiun lo(iolu
737 Cm.lkrholl IBro"n~ Sariaees) During overhaul of

the crankshafl. the operator InuJt determine if it has stan-
dard or undersize hearing journals. then procoed with its
overhaul ;lecordinkly Undersize erankshafts are idcn´•
tified hy a ccnle symbol stamped on the front of the nange
as a suffix to the part number. In addition to the code
Tapered Sleeve iCrankpin F.ndl 5.Cage Arm symbols the letters I(N are stamped us a suffix to the
2.l‘apered Sleeve iPistan Pin End) 6.Adjusting Screw serial nunlber indicating the shaft has been ralilrided.
3. Arbor Cmnkpin Sleevol 7. Wing Nut l‘ho code symbols are. MUSMP ilnain and crankpin jour-
i. Arbor Il’iston Pin Sleeve) na1s 0.003 inch undersize). M03M imain bearing journals
0.003 inch undersizel. MOSF lerankpin bearing journals
Figure 7-5 Checking Parallelism of 0003 inch undcrsilei. If the maximum service limits are
Canneeling Rods exceeded ire$renee 501 or 502. Table of Linmtsi standard
7-5
Island Enterprises
Cran~ra:tRHAUL MANUAL AVCO LYCOMING 76 SER IES AIRCRAFT ENGINES
sad RseiproEating Pattr

shafts may be polished to 0.003 inch undersize and fitted main bearing surfaces must be ground to same undrrsi.e
with 0.003 inch undersize bearing inserts. Renitrided Main beon’ng surfaces may be ground without affecting
0.003 inch undersize shafts may be polished to 0.006 inch cm"kpi" surfaces and similarly cranhpin bearing surfaees
undersize and fitted with 0.006 inch undersize bearing in- m"Y be ground wilhaut affecting the main bearing sur
serts. Do not allow lathe to exceed 160 IIPM st any

A/ter any grinding operation the emnkshafl must
speed be rpnitrided it is ncommended that the shaft be ~oturn´•
time during polishing operation. ed to AUCo Lyeoming for renitriding
NOTE
739 aankshop Straightening I4angeMsnimum per-
missible run-out is 0.018 inch TIK. If the nange
flange
Note that if one surface is polished to.M9 or.WG under run-out exceeds 0.018 inch the eranrshsft must be re
slee ad corresponding surfaces must be polished to same ~eeted. If the nange run-out is less than 0.018 inch the
sLo. Polishing to undersile is preferrpd to grinding flan.e may be straightened as described in the following
because shafts that an polished do not reg~Uire nnitr´•ding psro~opbs.
WhOlP(ls any Bn´•ndinB operation ´•4sllilOS that the shaft be
renitrided This is necessar)l because of the nonuniformity Before attempting any straightening operations. the
of grinding tools, The possibility exists luherein the;ynn´• nange bushings must be removed. When the surface
distortion of the nange has been reduced as much as
ding whe.l ~uill cut through the niaided surfaces an one or
more of the journal radii causing area of stress conc~ntm-
possible. the front face of the fisnge must be trued up by
grinding However, if the minimum width of the
tian that can develop into fatigue cmcks and uln’molely thsn’lE;
after gnnding IDimension ..A.. figure 7-1 is less
result in a broken cmnkshop dimensions as called out i. Table ?´•l.the shaft must be re´•
jeeted.
1´•38. If it is necessary to make a standard shaft journal
surface more than 0.003 inch undersize or a renitrided TABLE 7´•1
0003 inch undersize than 0.006 inch undersize. the
more
crankshaft must be ground to undersize and renitrided. &NUINF: MODEII MIN. WIDTH OF
Standard shafts may be ground to 0.006 inch or 0.410 inch F L A N G E
undersize, renitrided 0.003 inch undersize shafts must be
0~320´•H .260 inch
ground to U.010 inch undersize. Shafts must be fitted with
the corresponding undersize bearing inserts. Grinding the
D´•360´•F, .370 inch
crankshaft is a delicate operation requiring adequate grin-
ding facilities and a pest deal of skill, A properly dressed CALITION
wheel Csrborundum ICA61-JS-VIO or equivalent) must
be used with generous amounts of coolant. The wheel Extr.mp care must beexercised duringpny straightening
must be fed to the pin very slowly and the final

journal or operation to avoid damage to the nitnded surfaces of the
ground finish maintained during the complete operation, cmnkshoft The nitrided surfaces extend from the front
This procedure must be followed to eliminate possibility face of the slinger to the crankshaft gear mounting sur
of grinding crscks. After grinding, the crankshaft must be i"e’ Those nitnded surfaces an glass hard and wiN cmck
esrefully inspected by the magnetic particle method. If

if shop is bent dmpped or handled carelessly
any cracks or cheeks are found, the shaft must be re´• At the conclusion of any straight ng operations, the
jected, entire crankshaft must be ingpeeted by tB magnetic qsr
tide method paying particular attention to the beanng
surfaces and the fillet areas st the base of the nange. See
Section 3.
DlfiMETER
IMUST RLXI TRUE WITH FRONT
WD REIIR M~IN BEPIRINGS
WTHIN 0011
FLPNGE RUN-OUT HERE PT

PERIPHERY OF CHPIMFER
1. Psrsllel Blocks 2. Cheek Points
Figure 7´•6. Checking Squareness of

Connecting Rods i! LENTIRE
PLI1TE OYER THIS
OIST~NCE ONC(
SURRCE IIRE~ OF CRPNKSHIFT

NOTE IS N TRIDED EYCEPT PL~TEO I\REI\ SIOWN
IND CRINNKSHIFT OEIIR MOUNTING SURF~CE
If cmn)pin bearing surface is ground
one all
cmnkpin bearing surfaces must be ground to same under Figure 7-7. Limits for Straightening Bent
si~o if one main bean~ng surface is gm.nd undersize all Propeller Flange
1-6
Island Enterprises
Sec’ion 7
6. Polish the oil seal of the shaft with crocus cloth
area
REMOVE PROPELLER FLANGE BUSHING BEFORE while the shaft is rotated counter-clockwise when
GRINDING, MASK HOLES BEFORE PLATING. REPLACE
WITH NEW BUSHING AFTER PLATING.
viewed from the Range (front) end of shaft. Do not move
the cloth while polishing because the area must be free
DRESS WHEEL FOR.5O IN. RADIUS of spiral marks.
WHEEL FOR .13 IN. RADIUS
7. Clean the shaft to remove ah traces of grinding dust
and mask the bushing holes in the Range.
\1-- 8. Cadmium plate tin accordance with AMS2400) the

Range and oil seal area of the crankshaft as indicated in
figure 7-8. Do not plate beyond the 0.13 inch radius.
-~-i-------
9. After plating, bake the crankshaft at 2750F. 100F.
for 5 hours to eliminate possibility of surface embrit-
UNDERSIZE MUST NOT tlement.
EXCEED .010 IN. DIA.
NOT PERMIT GRINDING WHEEL

TO TOUGH THESE FACES. applicable Avco Lycoming Parts Catalog for
10. See the
theparticular engine model for correct propeller Range
bushings and install new plated service bushings in the
PLATE OVER THIS AREA
Range. Chill the bushings by refrigeration and install
with Avco Lycoming Service Tool No. ST-115.
Figure 7-8. Reconditioning Crankshaft Oil
Seal Surface 11. Support crankshaft in vee-blocks at the end journals
and measure run-out at refinished area. Total indicated
7-40. After inspection, install the Range bushings and run-out must not exceed 0.002 inch.
then cadminum plate the ground surfaces of the
crankshaft Range. The plating, which should be 0.0005 12. Examine crankshaft by magnetic particle method.
inch maximum thickness, should be permitted to extend
along the crankshaft propel. only in the area shown in 7-43. Crankshaft Counterweight Bushing Replacement
figure 7-7. (Where Applicable). Wear or damage to the crankshaft
7-41. Reconditioning Worn Crankshaft Oil Seal Surface. If

counterweight bushing located in the counterweight lobes
is almost impossible to detect by normal inspection pro-
inspection personnel have found that the crankshaft oil cedures. Because of the possible damage to the
seal surface on the shaft itself is damaged to the extent
that the oil seal might leak, the following procedures are
counterweight andlor the crankshaft from wear or
submitted to recondition this area of the crankshaft. damage counterweight bushing, it is mandatory that the
bushing be replaced at overhaul. The procedure for
1. Remove propeller Range bushings from crankshaft removal and replacement of the crankshaft counterweight
Range and note the locations of long and short bushings bushings is as follows:
replacement. Do not scribe on shaft. Use Avco
Lycoming Special Tool ST-115 to remove Range
bushings.
2. Stripcadmium plate from propeller Range and the COUNTERWEIGHT COUNTERWEIGHT EAR
area of the oil seal by immersing the shaft in a solution ROLLER BUSHING ON CRANKSHAFT
of ammonium nitrate tone pound of ammonium nitrate
for each gallon of water).
3. Set up crankshaft in an external grinder and center

carefully.
4. Use a No. 54 grit wheel and grind the area between
r
I
the propeller flange and the oil seal face to remove nicks ’I
and scratches. Depth of grind must not exceed 0.005 1 I I I I 1; 1110
L
inch (0.010 inch uls diameter). _
_7-
NOTE
The grinding wheel, corner toward the propeller

on the 43
f~ange must be dressed to 0.05 inch radius while the op-
posite side, toward oil slinger, must be dressed 0.13 inch
radius. Both radii must blendperfectly. Do not permit the
side of the wheel to touch the propeller flange or face of oil
COUNTERWEIGHT BUSHING PULLER
slinger. See figure 78.
5. A No. 54 or 60 grinding wheel will produce a finish of
approximately 8 to 10 microns. The surface roughness
of the oil seal area should not exceed 10 microns before Figure 7-9. Removal of Crankshaft Counterweight
polishing with crocus cloth. Bushing
7-7
Island Enterprises
i. (See figure 7-9). Thread the bolt of the counterweight 7-44. Counterweight Bushing Replacement. Consult the
bushing puller PIN 64872 through the puller plate (2) so latest edition of Service Instruction No. 1143 for detail in-
that the recess of the plate will be next to the crankshaft formation relative to rebushing counterweights an subse-
lobe when bolt is inserted through the crankshaft quent inspection.
counterweight bushing. Install the small puller bushing
(3) over end of bolt and install nut (4) on bolt. As the nut 7-45. Connecting Rod Bushings. If the bushing in the
is tightened on the bolt, the counterweight bushing will small end of the connecting rod is worn beyond service
be pushed out of its recess in the crankshaft limits, it can be removed and replaced by accomplishing
counterweight mounting lobe and into the recess of the the following procedure;
puller plate.
1. Clamp the connecting rod on the connecting rod
2. Measure the inside diameter of the hole in the replacement block (PIN 64597) in such a manner that
crankshaft lobe that the bushing was removed from. If the small bushing in the rod is in alignment with the
the hole in the lobe measures .9369 to .9377 inch no hole stamped "Remove Bushing". Use the connecting
reaming of the hole is necessary and a standard size rod bushing removal drift (PIN 64535) and drive the
bushing can be installed. If the hole measures more bushing out of the rod. Move the connecting rod to the
than .9377 inch, the next oversize bushing must be in- "Install and Burnish" position and clamp it securely in
stalled and the hole must be reamed accordingly. See
place. Using the replacement drift IPIN 64536) drive a
Table 7-2 for the proper reamer. new bushing in place in the rod. Be sure the split in the
bushing is located so that it is toward the piston end of

TABLE 7-2 rod and 450 off the centerline.
Hole Size Reamer No. 2. Use a suitable arbor press and the connecting rod
bushing burnisher (PIN 64580) to burnish bushing in
.93691.9377 None place. Pass the burnisher completely through the
.94201.9425 64874 bushing. Remove the rod from the holding block and
.94451.9450 ST-210 finish bore the bushing to diameter shown in Table of
.94701.9475 64875 Limits, reference 510. Check the bushing ID with finish
.9495/.9500 ST-211 ID gage (PIN 64767). Check alignment of the hole in the
.95201.9525 64876 bushing with connecting rod parallelism and squareness
gage (PIN 64530) as described in paragraphs 7-29 and
3. Determine the oversize reamer needed and assemble 7-30. If the assembly does not meet the requirements
the reaming fixture (ST-280) over the crankshaft ear. shown in references 566 and 567, Table of Limits, the
Select the two opening in the fixture to line up with the entire assembly must be replaced.
bushing holes and install the plugs provided to line up
the holes in the fixture with the holes in the crankshaft 7~a Starter Ring Gear. The latest edition of Service In-
ears. Secure the fixture by tightening the set screw. struction No. 1141 contains all information necessary to
Assemble the reamer in a suitable handle and proceed to accomplish the replacement of the starter ring gear.
hand ream the hole in the crankshaft ear to the proper
size. 7-47. Crankcase Fretting. Consult the latest edition of
Service Instruction No. 1112 for information relative to
4. Assemble the to the crankshaft ear
puller (PIN 64872) inspection and repair of crankcases damaged by fretting.
in the same manner asdescribed in Step i, except that
the large puller bushing is used instead of the small
7-48. Crankcase Fretting. The latest edition of Service In-
puller bushing. Place the correct size counterweight struction No. 1123 contains all requirements necessary to
bushing on the puller bolt between the crankshaft ear modifty the crankcase to prevent fretting.
and large puller bushing. As the puller nut is tightened,
the bushing will be forced into place in the crankshaft
REASSEMBLY
ear.
NOTE
7-49. Plug. (Figure 7-3). On engines equipped
for fixed pitch propeller use the expansion plug (15) in-
The inside diameter of the crankshaft counterweight
stallation drift (PIN 64681) to install a new expansion plug
bushing finished at time
is of manufacture and no further
in place in the front of the crankshaft with the convex side
machining of the bushing is necessary. Care must be ener-
cised when installing the bushing so that the finished in- toward the front. Be sure the plug fits firmly against the
circumstances shoulder provided for it on the inside diameter of the
side diameter is not damaged. Under no
be removed installed by the ofa crankshaft.

should the bushing or use
hammer and drift.

750. Plug. On engines equipped for a controllable pitch
5. After the crankshaft counterweight bushing is in- propeller, a is installed at the rear of the bore in the
plug
stalled, check its alignment with the main bearing by front of the crankshaft. If this plug has been removed dur-
placing the crankshaft in vee blocks on a surface plate. ing overhaul, install a new plug by sliding it sideways
Install the wedge blocks PIN ST-212 in the bushing and past the crankshaft propeller oil tube (see figure 7-3).
compare parallelism of the wedge blocks with the
main When the plug is properly positioned in the rear of the
bearing journals. Bushing must be parallel with in .002 bore (flange forward) insert the oil plug drift (PIN 64770
inch. Support the crankshaft in vee blocks at the jour- for 1-3/4 inch plug) and seat the plug with several sharp
na1s adjacent to the bushing location. hammer blows on the drift.
7-8
Island Enterprises
and Aeciprocating Parts
751. Propeller Flange Bushings. If the propeller flange
bushings have been removed from the crankshaft, new
bushings must be installed. Use the crankshaft flange
bushing replacement tool (ST-115) to install new
bushings. Consult the applicable Parts Catalog for proper
location of the bushings.
WASHER "A" DIM. MINIMUM DISTANCE FROM

BOTTOM OF GROOVE TO OPPOSITE
EDGE OF CIRCLIP.
"B" DIM. MINIMUM GAP
ASSEMBLE CIRCLIP
WITH SHARP EDGE OF
CIRCLIP TOWARDS
OUTSIDE
Figure 7-10. Assembly of Washer and Retaining Ring in

Counterweight
752. Counterweight Assembly. (Figure 7-3). When

assembling the counterweights which have previously Figure 7-11. Location of Gap When Installing Retaining
been installed on the engine, use the identifying marks Rings
made on the various parts during the disassembly. To
enable matching each washer to the proper seat on the NOTE
counterweight from which it was removed. Install washer Do not take measurements rod
of connecting bearing
(19) with chamfered side toward the roller and retainer the parting of the
across rod and cap. Take all
ring (18) with the sharp edges toward the outside on one measurements at 600 from the parting of connecting rod
side of the counterweight. (See figure 7-11). Place the
and cap.
counterweight on the proper crankshaft lobe, insert the
proper roller and secure the assembly by installing the 7-54. Place the crankshaft on a suitable support on the
washer (19) and retaining ring (18) as stated above. After bench so that all crankpins are free for installation of con-
the installation of the retaining ring the gap muse be in necting rods. Disassemble connecting rods after checking
the position as shown in figure 7-11. Insert one end of the bearing ID, thoroughly coat both inserts and the crankpin
counterveight retaining ring gap gage PIN 64892-2, bet- journals with preservative oil and assemble rods on their
ween the ends of the ring, making sure the gage is resting respective crankpins. The order of assembly should be
in the bottom of the groove. The gage must pass betwen such that the numbers stamped on the caps and rods will
the ends of the retaining ring and must clear the inside be down (toward the sump).
edge at the top of the retaining ring. If the gage does not
NOTE
enter the gap of the retaining ring and clear the top of the
ring, the ring is not completely seated in the groove pro- Connecting rods are marked at manufacture with the part
perly. Make sure that all rings are seated in the proper number followed by a letter lA through El designating
position. Consult the latest edition of Service Instruction weight groups, It is recommended that replacement sets
No. 1012 for the correct location of each counterweight on of rods be of the same weight classification. Individual
the crankshaft. rods may be replaced by a service rod bearing the letter
"S’:
753. Connecting Rods. (Figure 5-2). Assemble two new 7-55. The connecting rod bolts are tightened to a specified
connecting rod bolts (4) in each connecting rod (5). Install
torque of 480 inch pounds (40 foot pounds).
new bearing inserts (3) in the connecting rod and cap (2),
making sure the tang of each bearing insert enters the 756. Camshaft. See figure 7-3. Secure the tachometer
locating slot, Assemble each connecting rod and cap, shaft (6) to the end of the camshaft with pin (13). Assem-
tighten the nuts (1) moderately. Measure the inside ble the camshaft gear (3) over stepped dowel(2) and secure
diameter of each bearing and check for clearance against gear to camshaft with lockplate (4) and hex head screws
the measurements taken previously on the diameter of the (5). On engine employing the propeller governor, install
crankpin journals. woodruff key (31) and governor drive gear (27) figure 7-3.
7-9
Island Enterprises
SeE1ion I OVERHAUL MANUAL AVCO LYCDMING SER IES AIRCRAFT ENGINES 76
CRn~Esn. Cranbhalt
and ReaiarrEsaing Partl
767. Cmn*ease. Place both crankease halves on a suitable 7-6~1. Prelubricato the main bearing inserts of the left half
support with the interior of each half facing upward Place of the erankease. Pick up the erankshaft assembly by the
new iwariny inserts in the crankcase making certain that odd number connecting rods and lower into the left half of
the lang of each insert is fitted into the recess provided in crankcase, being careful not to move the timing mark on
the eranheasc. the camshaft gear. The tirmng mark on the crankshaft
gear and camshaft gear must be in a plane with the par´•
tinE surface of the crankcase as shown in figure 1-12
NOTE
If the timing marks are not in the pmpe’ ph"’ after the
erankahalt is in place, rotote the cmnkshnp until the tim-
ing mark i in the correct position Raise the camshoft un´•
ril the enmshop gear is disengoged from the oil pump
dnue gear and rotate the eomsho(t until timing mor~ is
the correct pion a,ith the crankcosa parhngsurfoCe See
Fla
1´•66. See figure 7-L3. If either the crankcase or crankshaft

has been the erankshaft end clearance must be
replaced,
checked When crankshaft is located in the left erankcase
half push the crankshaft forward as far as possible. Check
the clearance. at the rear of the front main bearing sur-
face, between the crankcase and erankshaft shoulder
Figure 7´•12. Showing Timing Marks Position i~’oinl "A") It clearance exists between ersnkcase and
on Camshaft Oeor and Crankshalt aenr crankshaft thrust surface iPaint A) regrind the front face
of the crankshaft slinger iPoint to remove the
clearance. Ulind only that amount, from the face of the sl´•
7-56. I’lace the left crankcase half on a suitable support on ingrr, necessary to remove clearance Push the crankshaft
the bench with the cylinder pads down This support as far as possible to the rear of eran*ease. Check the
should be so constructed as to give approximately six in- clearance between the thrust surface of crankshaft and
ehea ebarance between the crankcase and bench crankcase.
7-59. I,sy the right erankcase half on the bench with the 7-66. Prelubricate the main bearing inserts of the right
cylinder pads down. Install the governor drive shaft gear crankcase half
where applicahle
1´•60. A eounterhored recess is provided for an oil seal ring 7-67 Apply a film of non-hardenmg gasket compound to
st each bolt and stud location install a new oil seal ring the outside mating surfaces of each crankcase half. The
ii. figure 7-2L at the base of each stud. compound must not he applied to any of the intenor
mating.surfeces such as the hearing support webs. Next
761. Oil and Vacuum Puml, Uriue. See figure 7-1.1nstall imbed a length of ’~m" silk thread in the gasket eom-
key iSL in keyway on vacuum pump shaft 161
the oil and pound slang outside edge of left crankcase half. Pun the
Install shaftin lefthalf of crankcase. Plaeeoilpumpdrive length of thread so that it is both sides of bolt hole
gear 131 on shaft and secure with lockplate 12L and nut ill. without touching each other An alternate method of seal-
Use service tool ST-416 to tighten pump nut. Torque to 55 ing is discussed in Service Instruction No. 1125.
foot pounds. Secure nut with lockplab
NOTE
7-62. Prelubricate the cemshaft lobes and bearings with
Lubi-Bond or equivalent. Place the eamshaft assembly in On engine silh gouamor. hold the governor drive geor
the left half of crankease. As the camshaft assembly is shaft is right half ofcrankcase with safety mir~ that con he
place in the crankcase. the breather baffle must be install- removed when cmnkcose to fasten together
ed at the same time. The baffel is marked on one side
rear of engine~’ and must be installed with the 7-68. Lower the right half of the crankcase so that the
net edge toward the sump. l’he timing merk on the cam- studs align properly with the left half. If necessary, tap
shaft gear must be in a plane with the parting surface of the right half gently with a soft hammer to facilitate
the era~ease. The mark must be located between the assemhly. However, no difficulty will be encountered if
eamshaft and the crankshaft gear as shown in figure 7-12. the two halves are kept parallel while the right is being
lowered onto the left. After the eases are together, tap the
NO?% right half with a soft hammer to seat it securely all
around.
Thl timing mark on the eomshnp gear and cmnkshor
gear may ~e a etched stmyht line, circle or a dot. NOTE
7-63. Install new oil seal in tachometer drive adapter When tapping emnbeose with soft hammer os stoted in
Slide adapter over tachometer shaft so the adapter will be paragraph 768 he careful that the comshoft gear is not
at the proper location on the dowel of crankesae, jored out of tm~e
1-10
Island Enterprises
Place "o" ring seal (7) in groove of pump body. Install oil
o pump body over pump shaft and impellers. Secure with
O plain washers, lockwashers, and attaching nuts. Tighten
a the attaching nuts in a random pattern and increasing
B! IE~l V I I I I steps until the final torque of 150 inch pounds is reached.
After each step rotate the crankshaft to insure that the
o impellers are free and not binding. If any binding occurs,
loosen the attaching nuts to free the impellers and retor-
que using a different tightening sequence until crankshaft
can be rotated and oil pump is free.
NOTE
When installing oil and vacuum pump body be careful not
o to damage the oil seal.

7-79 Oil Cooler Adapter and Oil Pressure Housing. See
figure 7-15. Assemble the oil cooler bypass plunger (3),
spring 14), gasket (5) and plug (6) in the oil cooler adapter
(2). Install adapter (2), oil cooler adapter gasket (1) along
with oil pressure screen housing (9), screen (8), and gasket
a
(7) on the crankcase assembly.
7-80. Oil Filter Adapter Assembly. See figure 7-16. Assem-

ble the oil filter adapter (4) with gasket (7) on crankcase.
Install temperature control valve (5) in adapter. Install
converter plate (3) and converter plate stud (2) to oil filter
1771
adapter assembly. Torque converter plate stud to 50 60
foot pounds.
Figure 7-13. Checking Crankshaft End Clearance
7-81. Assemble the crankshaft oil seal.
7-69. Install all crankcase fastenings. Consult the ap-
i. Remove spring from the new seal.
plicable Parts Catalog for correct attaching parts,
2. Apply a thin film of Lubriko M-6 grease on sealing
7-70. In order to insure uniform loading on the main bear- surface of seal, on crankshaft sealing surface and on
ings, it is necessary to tighten the studs and bolts in the edge of crankshaft propeller flange. Consult Service In-
following sequence, struction No. 1324 for information on crankshaft oil
seal.
7-71. Install torque hold down plate (ST-222 or equivalent)
3. Place seal over edge of propeller flange with open
at cylinder pads.
portion of seal toward the flange.
7-72. Install nuts on free ends of 1/2 inch thru-studs and to hold
4. Insert pin in crankshaft propeller bushing
using the sequence specified in figure 7-14, tighten to 300 both sides of seal.
inch pounds (25 foot pounds).
5. Use tool ST-383 overpropeller flange and under seal.
7-73. Using the same sequence as specified in paragraph Rotate tool around propeller flange until seal is on
7-72, tighten the nuts on the thru-studs to 600 inch punds crankshaft.
(50 foot pounds) torque. 3" TIGHTEN ON IST TIGHTEN ON 2ND TIGHTEN ON
front main bearing (4, figure IDE

7-74. Torque 3/8 inch nuts at
7-13) to 300 inch pounds (25 foot pounds). 10
9 8 a
7-75. Using the sequence specified (5 thru 10, figure 7-14), (n a
tighten 1/4 inch nuts at crankcase parting face to 98 108

inch pounds (8 to 9 foot pounds).
7-76. Using any sequence tighten the remaining 1/4 inch ~T 2 y( 4

nut at crankcase parting face 96 to 108 inch pounds (8 to 9
foot pounds). I
6
7-77. Tachometer Drive. See figure 7-3. Place "o" ring seal
(10) over the tachometer adapter (81. Install tachometer
drive seal retainer(ll) and external retaining ring (12) on
the adapter. L4TH TIGHTEN ON LEFT
7-78. Oil and ~acuum Pump. See figure 7-1. Install the oil 5-rH TIGHTEN CRANKCASE FASTENING 5 THRU 10
pump driving impeller (12) on the previously installed oil SEQUENCE AS INDICATED
pump shaft (6). Place the driven impeller (4) in the
Figure 7-14. Crankcase Tightening Sequence
crankcase. Install new oil seal (9) in the oil pump body.
(Four Cylinder)
7-11
Island Enterprises
Section
7Crankcase, MANUAL AVCO LYCOMING 76 SERIES AIRCRAFT ENGINES

6. Install spring over crankshaft and fasten 90 that 7-82.Generator or Alternator Drive Belt (Where Ap-
there is no twists and kinks. Force spring into the rear plicable) and Ring Gear Support Assembly. Place the
of the oil seal. drive belt in the pulley of the ring gear support and assem-
ble the ring gear support over the propeller flange
7. Clean all grease from the outside diameter of seal, bushings. Be sure the bushing hole in the ring gear sup-
propeller flange and the crankcase seal bore. port bearing the identification "O" is assembled over the
flange bushing also identified with "O" etched on
8. Apply a coat of adhesive Goodyear Pliobond No. 20 or crankshaft flange next to bushing. The starter ring gear
Dow Coming Silastic No. 140 to outside diameter of the must be located correctly to assure proper alignment of
seal. Insert seal into crankcase with firm pressure until the timing marks on the ring gear.
it is sealed in the crankcase bore.
6
(9
5-7 ~n;´•
8
4~
o
2
7’
32 i~r\
DC
I/i":
i. Gasket
2. Oil Cooler Adapter
3. Plunger
4. Spring
5. Gasket
6. Plug
7. Gasket
8. Screen
9. Screen Housing
10. Washer
11. Bolt
Figure 7-15. Oil Cooling Adapter and Oil Pressure Screen Assembly
7-12
Island Enterprises
6
5
7
d
E"´•e~;- i!
y
3 mb
iB
Ij
i. Oil Filter
2. Converter Plate Stud
3. Converter Plate
4. Oil Filter Adapter
5. Temp. Control Valve
6. Breather Fitting
7. Adapter Casket
8. Oil Cooler Fittings
Figure 7-16. Oil Filter Adapter Assembly
7-13
Island Enterprises
SECTION
TEST PROCEDURE
Island Enterprises
Test Procedure
SECTION 8
TEST PROCEDURE
8-1. At the completion of the engine after overhaul, it is 8-6. Any engine accessory drive which transmits oil
recommended that the engine be mounted upon a test pressure through oil passages in the engine and which is
stand for its initial or run-in operation. The run-in serves a not pressurized by normal operation on the test stand
two-fold purpose; first, to seat piston rings and burnish must be checked for leakage at normal oil pressure by
means of a special drive cover with oil transfer holes as re-
any new parts that may have been installed and second,
to
give the operator control over the first critical hours of quired. The oil passages involved shall be inspected for ex-
operation, during which time he can observe the function- ternal leaks at the completion of the test run.
ing of the engine by means of the test cell instruments.
can be corrected and oil 8-7. It is desirable to have some method of maintaining
Also, at this time any malfunction
leaks repaired. the oil temperatures within the specified limits during the
run-in. See Table 8-1. Engine should be idled until the oil
8-2. The test stand should be installed in a test cell that is temperature is approximately 1400F. (600C.) before star-
clean and free of any articles that could be moved by the ting the run-in schedule. See Table 8-2.
test club air blast.
8-8. Operate during the run-in with (MIL-L-6082 Grade
8-3. The instruments should be used, plus any 1100) lubricating oil if the engine is to be stored operate
following or
additional instruments that may be deemed necessary by with a mixture of 35’ MIL-C-6529, type 1 and 65’ MIL-
the operator. 00 to 6000F. temperature gage, counter L-6082.
tachometer, fuel flow meter, fuel pressure gage, manifold
and 8-9. Fuel should conform to specifications. See Table 8-1.
pressure gage, oil temperature gage, oil pressure gage
an oil flow measuring device.
8-10. Engines equipped with a fuel pump shall be tested
NOTE
with a test stand fuel system terminating in a float
Avco Lycoming recommends that a test cell be used for chamber vented to the atmosphere. The fuel level in this
run-inof engines after overhaul. Consult engine tes t eq uip- chamber shall be below the entrance to the fuel pump by
ment, SSP1169, for more detail list of cell equipment and at least one foot. The fuel pressure to the chamber shall be
schematic of oil supply system and fuel. In the event a maintained at 2 to 5 psi.
test cell is not available, it is permissible to mount the
8-11. Engines not equipped with fuel pump shall be
engine in the airframe for the run-in providing the follow- a
tested with remote fuel pump.

ing requirements are observed. a
1. Consult Table 8-4 for the correct configuration of test 8-12. Attach the instrument connections and connect oil
club adapter and bolts to be used during test. Do not and fuel lines. Connect throttle and mixture control levers
use a flight propeller during test. to the stand controls. Be sure the cables are free and not
binding and that the travel is sufficiently long enough to
2. A cooling shroud equivalent to a test cell cooling completely open and close throttle and move the mixture
shroud is installed. control from full rich to idle cut-off. Install the applicable
cooling shroud, test club (64802), adapter (64980) and
3. The airframe gages may not be used. All necessary bolts 164983). See Special Service Tool Catalog No.
calibrated gages shall be installed independent of the SSP2172. Be certain that the test club will turn up the
airframe, rated RPM 50. See Table 8-1.
8-13. It is desirable to keep log sheet and record the in-

pressure to engines which can
a
8-4. Test stand oil supply
be run simulated wet sump shall be held to 1.5 2.0 psi strument reading during each speed of the run-in
schedule.
throughout the run. Test stand oil supply pressure to
engines run simulated dry sump shall be held to 0.5 3.0
Personnel should consult Service 8-14. Before that the magneto switch is
starting be certain
psi at rated conditions.
Bulletin No. 113 when desiring to use dry sump test stand in the "off" position. Turn the engine over a few revolu-
installation for wet sump engines. tions to ascertain that no interference exists within the
are of the test club or within the engine itself. If it does
not turn freely, do not try to force it or attempt to start

8-5. Engines equipped with an integral full flow oil filter,
should be run-in with a slave filter and the regular filter in- until the cause has been determined and the fault cor-
stalled at the end of the run, rected.
TABLE 8-1
ENGINE RUN-IN TEST LIMITS
Fuel Press. Maximum Oil Oil Press. Max. Cyl.

Fuel-Minimum Consumption Operating- Head Temp. Full Throttle
psi-at inlet
Models to carb. or Octane Rating psi Oil Inlet Oil Outlet Bayonet Engine Speed
Aviation Grade Lbs.iHr.l Qt.lHr. Normal Idle Temp. OF. Temp OF. Location OF. RPM
injector
1001130 1.2 .67 75-85 35 165-230 190-210 500 2700
0-320-H 1-6
1001130 1.4 .78 75-85 35 165-230 190-210 500 2700

0-360-E 1-6
8-1
Island Enterprises
Test Procedure
TABLE 8-2
RECOMMENDED RUN-IN SCHEDULE
RPM LOAD TIME REMARKS
1200 Prop.load 10
1500 Prop.load 10
1800 Prop. load 10
2000 Prop. load 10
2200 Prop. load 10 Check magneto drop-off+.
2400 Prop. load 10
Normal Rated** Prop. load 15
Normal Rated** Prop. load 60 Oil consumption run.
Do not exceed 150 RPM drop on either magneto or 35 RPM difference between magneto.
&15. Run-in. Start the engine in accordance with the controlled by the addition of STD-425 washers under the
following procedure. cap as required (maximum of nine), to increase the
pressure. Particles of metal or other foreign matter bet-
a. Place mixture control in full-rich position. ween the ball and the seat can cause the oil pressure to
drop or fluctuate. Therefore, if a drop or excessive fluctua-

b. Turn fuel valve to on position. tion is noted it is advisable to disassemble, inspect and
clean the valve.
c. Set throttle at 1110 open position.
Speed Adjustment. With the engine thoroughly
8-21. lalle
d. Turn magneto switch to "left" and engage starter. warmed up, check magneto drop-off. If the magneto drop-
off is normal, proceed with the idle adjustment. Close the
(1) Turn combination magneto starter switch to start. throttle. Adjust the idle speed adjusting screw so as the
engine RPM is approximately 600 RPM. After the mix-
e. When engine fires move magneto switch to "Both". ture is adjusted it may be necessary to readjust the idle
RPM to the desired speed.
(1) Combination spring loaded switches will return to
"Both". 8-22. Mixture Adjustment. With the engine operating at
the idle speed as previously set, move the mixture control
CA UTION lever with a smooth steady pull into the idle cut-off posi-
tion and observe the tachometer for any change in RPM
If oil pressure is not observed Luith ten (10) seconds, stop during the leaning process. Caution must be exercised to
engine and determine cause. return the mixture control level to "Full Rich" before the
RPM can drop to a point where the engine cuts out. An in-
8-16.Operate engine at approximately 1000 RPM until a crease of more than 50 RPM while "leaning out" indicates
minimum oil in temperature of 1400F. is obtained. Check an excessively rich mixture. A decrease in RPM (if not
magneto drop-off and general operation of the engine. preceded by a momentary increase) indicates that the
Check the engine for oil leaks. Any malfunction or oil leak mixture is too lean.
should be remedied before continuing the run.
8-23. If it is indicated that the mixture is either too lean or
8-17. Complete the run in accordance with the schedule too rich, turn the idle mixture adjustment in the direction
listed in Table 8-2. required for correction. Check this setting by repeating
the procedure in paragraph 8-21. Each time the adjust-
8-18 Oil Consumption Run. An oil consumption run ment is changed, it is necessary to run the engine for a
should be made at the end of the run-in schedule. Oil con- short time at 2000 RPM to clear the engine out before pro-
sumption can be determined by the use of a scale tank ceeding with the idle speed check. The final adjustment of
through which the oil line pass and the scale reading the idle speed should be made with the throttle closed
taken at the beginning and end of the oil consumption against the idle stop.
run. Or it can be determined by draining and weighing the
oil supply before and after the oil consumption run. Oil 8-24 Preservation and Storage. In the event the engine is
temperature should be held as closely as possible to the to be stored at the completion of the run-in the engine
Limits shown in Table 8-1. Oil consumption should not ex- should be preserved in the following manner.
ceed the maximum as listed in Table 8-1.
8-25.Upon completion of the run-in, drain the oil. Refill
8-19 Oil Pressure Relief Valve. Subject engines are equip- the engine with a 1 to 1 mixture of MIL-C-6529, Type 1,
ped with a non-adjustable relief valve. A brief description and Bayol "D" or equivalent.
follows.
8-26. Remove top spark plugs, and with the crankcase full
Non-Adjustable Oil Pressure Relief Valve. Although
8-20. of oil, slowly turn the propeller through two (2) revolu-
the valve is not adjustable, the oil pressure can be tions.
8-2
Island Enterprises
Test Procedure
Let engine stand for ten (10) minutes after which the pro- 8-33. Exhaust ports and other openings should be closed
peller should be turned back and forth through 900 for with suitable covers.
twelve (12) cycles. Drain the preservative oil.

8-34. Allexposed cadmium plated and machined surfaces
8-27. Spray the exhaust port and valve of each cylinder should be liberally coated with soft-film, corrosion preven-
with the piston approximately 1/4 turn before top center titive compound, MIL-C-16173, Grade 2.
of the exhaust stroke using MIL-C-6529 oil, Type i.
8-35. Although the above procedure should prevent corro-
8-28. Spray each cylinder with an airless spray gun sion under favorable conditions it is recommended that
(Spraying System Company "Gunjet" model 24A-8395 or the engine be periodically inspected for evidence of corro-
equivalent) through the spark plug holes with MIL- sion. If corrosion should be present, the affected part
C-6529 oil, Type 1. Spray approximately two (2) ounces of should be cleaned and the engine represerved. Also,
oil into eachcylinder. engines preserved by the above procedures are not ade-
quately protected for extended periods of storage. If at
8-29. For all spraying the spray nozzle temperature shall the end of 60 days it is found that the engine must remain
be maintained between 2000F. and 2200F. in storage it must be represerved
NOTE 8-36. Represervation Run. The represervation run should

In the event airless spray gun is not available it is
an be accomplished under the same conditions as the run-in
recommended that a moisture trap be installed in the air after overhaul except that only the followin time schedule
line of the conventional spray gun and the oil shall be must be followed.
200"F. to 2200F, at the nozzle.
TABLE 8-3
8-30. Seal the breather openings with oil and moisture
resistant caps or dehydrator plug, P/N 40238 or RECOMMENDED REPRESERVATION SCHEDULE
AN4062-11.
RPM LOAD TIME(MI
8-31. All accessory drives for which oil seals are provided
shall be liberally coated with MIL-C-6529 oil, Type 1, 1200 Prop. Load 5
before applying the drive covers. 1800 Prop. Load 5
2400 Prop. Load 5
8-32. Engines shall have spark plugs installed in the bot- Normal Rated See Table 8-1 15
tom cylinder location and dehydrator plugs, PIN 40238 in-
stalled in the upper cylinder location. The ignition harness
shall be attached to the spark plugs in the bottom loca- 837 Preservation and Storage. Float Type Carburetors.
tions and have ignition cable protectors (AN-4060) on the Carburetor shall be emptied of all residual gasoline and
top locations. the throttle locked in the closed position.
TABLE 8-4
TEST PROPELLER CONFIGURATION
TEST TEST TEST

ENGINE PROPELLER PROPELLER PROPELLER
MODELS P/N ADAPTER PIN BOLTS PIN
0-320-H 64802 64980 64983
0-360-E 64803 64981 64984
LO-360-E ST-298 64981 64984
8-3
Island Enterprises
SECTION
TABLE OF LIMITS
Island Enterprises
SECTION 9
TABLE OF LIMITS
This section of the manual has been reserved for the

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

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

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

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

automatically be forwarded.
Island Enterprises
LYCOMING
SERVICE TABLE OF LIMITS
AND
TORDUE VALUE
RECOMMENDATIONS
NOTICE
The basic Table of Limits, SSP2070 (including SSP2070-1, SSP2070-2, SSP2070-3 and SSP2070-3A) has been completely
revised and reissued herewith as SSP1776. It is now made up of the following four parts, each part contains five sections.
PART I DIRECT DRIVE ENGINES (Including VO and IVO-360)

PART IZ INTEGRAL ACCESSORY DRIVE ENGINES
PART III GEARED ENGINES
PART IV VERTICAL ENGINES (Excluding VO and IVO-360)
SECTION I 500 SERIES CRANKCASE, CRANKSHAFT CAMSHAFT’
SECTION II 600 SERIES CYLINDERS
SECTION II1 700 SERIES GEAR TRAIN
SECTION IV 800 SERIES BACKLASH (GEAR TRAIN)

SECTION V 900 SERIES TORQUE AND SPRINGS
This publication supersedes replaces the previous publications SSP2070, SSP2070´•1, SSP2070-2, SSP2070-3 and
and
SSP2070-3A; it is not to be used in conjunction with them. To make sure that SSP1776 will receive the attention of
maintenance personnel, a complete set of pages for the book is sent to all registered owners of Overhaul Manuals. These
recipients should remove all previous Table of Limits material from the Overhaul Manual and discard.
Additional copies of this revised Table of Limits, bound in a plastic cover, are available as indicated in the latest edition of
Service Letter No. L114.
Reference numbers in the Table of Limits vary from previous Table of Limits therefore, the current as well as the old
numbers are listed. The shaded columns contain the old reference numbers.
SSP1776 April 30, 1979*
6 Indicates cut-off date for data retrieved prior to publication.
Island Enterprises
INTRODUCTION
This Table of Limits is provided to serve as a guide to all service and maintenance personnel engaged in the repair and
overhaul of Avco Lycoming Aircraft Engines. Much of the material herein contained is subject to revision; therefore, if any
doubt exists regarding a specific limit or the incorporation of limits shown, an inquiry should be addressed to the Avco
Lycoming factory for clarification.
DEFINITIONS:
Ref. (Ist column) The numbers in the first column headed "Ref." are shown as a reference number
to locate the area described in the "Nomenclature" column. This number will be
found in a diagram at the end of each section indicating a typical section where
the limit is applicable.
Ref. (2nd column) Indicates the old reference number. There are no diagrams in this manual for
these numbers. These numbers are only to be found in previous publications.
Chart (3rd column) The letter or letter and number in this column are used as symbols to designate
engine models to which the specific limits is applicable. A list of the letter or
letter and number and the engine to which they refer is shown below.
Nomenclature (4th column) This is a brief description of the parts or fits specified in the adjacent columns
and indicated in the diagram at end of each section.
Dimensions (501 601 columns) The dimensions shown in column 5 are the minimum and maximum dimensions
for the part as manufactured. The dimensions shown in column 6 indicate the
limit that must not be exceeded. Unless it can be restored to serviceable size, any
part that exceeds this dimension must not be rebuilt into an engine.
Clearance (7th 801 columns) Like the dimensions shown in the 5th and 6th columns, the clearance represents
the fit between the two mating surfaces as controlled during manufacture and as
a limit for permissible wear. Clearances may sometimes be found to disagree
with limits for mating parts; for example, maximum diameter of cylinder minus
minimum diameter of piston exceeds limit for piston and barrel clearance. In
such instances, the specified maximum clearance must not be exceeded.
In some instances, where a parts revision has caused a dimensional or tolerance change, the superseded dimenional data has
been deleted from the list; provided compliance with the change is not mandatory.
Letters alphabet and numbers am used as symbols throughout the Table of Limits to represent specific
of the
interpretations and to designate engine models, l[Rtters in parenthesis refer to dimensional characteristics; letters (or
combinations of letters and numbers) without parenthesis indicate engine models. They are listed below with their separate
definitions.
(A) These fits either shrink fits controlled by machining, fits that may readily be
are
adjusted, fits where wear does not normally occur. In each case, the fit must
or
be held to manufacturing tolerance.
(B) Side clearance on piston rings must be measured with face of ring flush with
piston
(D) The dimensions shown are measured at the bottom of the piston skirt at right
angles to the piston pin.
(E) Permissible wear of the crankshaft (rod and main bearing journals) to be minus
0.0015 on the diameter.
(L) Loose fit; wherein a definite clearance is mentioned between the mating
surfaces.
(T) Tight fit; shrink or interference fit.
(WD) Wide Deck Crankcase.
Island Enterprises
Introduction
The illustrations shown are typical of the referenced limit or fit described in the Table and in no instance are these
illustrations intended to represent a specif~e part or engine model unless specified. Also, the terms used to designate cylinder,
piston and ring materials such as "nitride, chrome, half-wedge" are more fully explained in the latest edition of Service
Instruction N~. 1037.
PART I DIRECT DRIVE ENGINES (Including VO and IVO-36O)

CHART MODELS CHART MODELS
A 0-235 S5 IO, LIO-360-A, -C (Angle Valve)

Al 0-235-F, -G, -K, -L S6 IO, LIO-360-A, -C With Gov. at Front
B 0-290 (IO, LIO-360-C1E6 IO-360-A1D6)
B1 0-290-D2 S7 HIO-360-D
D 0-435-A S8 HIO-36O-B
ED 0-320-H (76 Series) S9 HIO-360-C, -E
G O, IO, LIO, AEIO-32O S1O HIO-360-A
G1 O, 10-820 With Gov. at Front T O, IO, LIO, AEIO, TIG, LTIO-540
(0-320-E1F, -ELJ, -D1F IO-320-D1B) T1 0-540-G, -H IO-540-N, -R
G2 AIO-320 (Large Mains Parallel Valve)
J 0-340 T2 IO-540-A, -B, -E, -G, -P
Y VO, IVO-360 (Angle Valve)
S O, IO, LIO, HIO, LHIO, TO, TIG, AEIO-36O T3 IO-540-K, -M, -S; TIG, LTIO-540-A,
S1 TO-360 -F, J, -N, -R (Large Mains Angle
52 AIO-360 Valve)
S3 TIG-360 T4 TIO-540-C, -E, G, -H
S4 0-360-A With Gov. at Front AF 10-720
(0-360-A1H, -ALLD) BE O, LO-36O-E (76 Series)
NOTE: In "Chart" column, a number appearing after a letter shows exception to the basic model.
Island Enterprises
sERV ICE ~ABIE OF LIMITs
PART 1 DIRECT DRIVE ENGINES
SECTION I CRANKCASE, CRANKSHAFT, CAMSHAFT
Chart Nomenclatura Dimendons Cleuoncss

Rei. Ref.
Mfr. I I Mfr.
Min. Serv. I Min. Serv.
New Old
Max. a Max.
Max. Max.
All Main Bearings and .0025L

500 I’Fi~S:i4 A
Crankshaft .0060L
i:i:.:i:i:i:~:l B-D-G-J-S-T-Y-BD-BE -AF Main Bearings and Crankshaft

.0015L
(Thin Wall Bearing .09 .0060L
Wall Approx.) T0045L
B-G-J-S-T-Y-AF Main Bearings and Crankshaft

.0011L
(Thick Wall Bearing
10041L .0050L
.16 Wall Approx.)
A Diameter of Main Bearing 2.3735

Journal on Crankshaft (E)
B-D-G-J-S-T-Y-BD-BE Diameter of Main Bearing

Journal on Crankshaft 2.3745
(2-3/8 in. Main) (E)
T1-T3-AF Diameter of Main Bearing

Journal on Crankshaft 2.6245
(2-5/8 in. Main) -Z~GZF (E)
S8-S10 Diameter of Front Main

Bearing on Journal on Crank- 2.3750
shaft (2-3/8 in. Main) 2.3760 (E)
T1-TI-AF Diameter of Front Main

Bearing Journal on Crank- 2.6245
shaft (2-5/8 in. Main) 2.62155 (E)
500 A-B-B1-D-G"-BD-BE Crankcase Bearing Bore Dia-

meter (All) (Thin Wall Bear- 2.566
ing) (2;3/8 in. Main) 2.567 2.5685
G*aJ-S-T-Y Crankcase Bearing Bore Dia-

meter (All Except Front) (Thick 2.6865
Wall Bearing) (2;3/8 in. Main) 2.6875 2.6890
T1-T3-AF Crankcase Bearing Bore Dia-

meter (Front Only) (Thin Wall 2.816
Bearing) (2-5/8 in. Main) 2.817 2.8185
T1-TB-AF Crankcase Bearing Bore Dia-

meters (All Except Front)
(Thick Wall Bearing) (2-5/8 2.9365
in. Main) 2.9375 2.9390
S1-T-AF Crankcase Bearing Bore Dia-

meter (All) (Thin Wall Bear- 2.816
ing) (2-5/8 in. Main) 2.817 2.8185
G""-J-S-T-Y Crankcase Bearing Bore Dia-

meter (Front Only) (Thin Wall 2.566
Bearing) (2-3/8 in. Main) 2.567 2.5685
0-320-A, -E Narrow Deck.

0-320-A, -E Wide Deck.
ALL Connecting Rod Bearing and .0008L
’I5~%:
Crankshaft .0038L .0050L
A-B-D-G-J-S-T-Y-BD Diameter of Connecting Rod

Journal on Crankshaft 72-1/8 2.1235
in.) (E)
SSP1776 1-1
Island Enterprises
BERV ICE TABLE OF LIMITB
Ref. Ref. Chart NomencLatu~ Dlmenaiona Cleari´•nces

Mtr. Mfr.
New Old Min. lerv. Min. Serv.
a Max. a Max.
Max. Max.
S´•T-AF Diameter of Connecting Rod

on CrankshaPt i2-114
Ilnqjmal (E)
A-B-D-c-J-s-T-Y-BD-BE Connecting Rod Bearing
Bore Diameter (2-1/8 in.)
(Measured At Axis 300 on 2.2870
Each Side) 2.2875
S-T-AF Connecting Rod Bearing

(Measured At Axis 300 on 2.4205
Each Side) 1 2.4210
502 ALL Connecting Rod Side Clearance .004L
.010L .016L
ALL Connecting Rod Alignment .010 in 10 Inches
ALL Connecting Rod Twist .012 in 10 Inches
505 I Crankshaft Run-Out at Center
Main Bearing
4 CYLINDER Mounted on No. 1 and 4 Journals

Max. Run-Out No. 2 Journal .002 .002
Mounted on No. 1 and 4 Journals







Max. Run-Out No. 3,4 and 5
Journals I 1 .005 .0075
ALL Crankshaft and Crankcase Front 9e9L
End Clearance .016L .026L
~3isi:l ALL Clearance Front Face of
Crankshaft Oil Slinger to
Front Face of Recess in
CrankcaseThrust Face(Crankshaft Against (A)
SSP1776 1-2
Island Enterprises
BERV ICE TABLE OF LIMITS
Ref. Ref. Chart Nomenclature I Dimensions I Clearances

Mtr.
Nela Old Min. I Serv. Min. I Serv.
I Max. Q I Max.
Max. Max.
508 ALL Crankshaft Prop. Flange

Run-Out I 1 1.002 .005
ALL Starter Ring Gear and Support .014T

.022T (A)
A-B-D-C-J-S-T-Y-AF Crankshaft Timing Gear and .0005T

ED-BE Crankshaft .oolomr (A)
511 A-B-D-G-J-S-T-Y-AF Tappet Body and Crankcase
.0a33L .004L
ED-BE Tappet Body and Crankcase .0010L

.(1030L .004L
A-B O.D, of Tappet .6232

.6229
B1-D-G-J-S-T-Y-AF O.D. of Tappet .7169

.7177 .7166
ED-BE O.D. of Tappet .8740

.8745 .8737
A-B I.D. Tappet Bore in .6250

Crankcase .6263 .6266
B1-D-G-J-S-T-Y-AF LD. Tappet Bore in 1 .7187

ED-BE LD. Tappet Bore in 1 .8755

512 ~i:i5;ggi B1-D-G-J-S-T-Y Tappet Plunger Assembly .0010L

andBody -Chilled .0067L
,i S7-S1-AF Tappet Plunger Assembly

and Body Hyperbolic
.0010L
.0067L .0087L
513 B1-D-G-J-S-T-Y Tappet Socket and Body .002L

.005L .007L
S7-S1-AF Tappet Socket and Body .002L

(Hyperbolic) .007L~ .009L
514 ALL Camshaft and Crankease .002L

:15h37~ .004L .006L
515 ALL Camshaft -End Clearance .002L

r:Is;3;s .009L .015L
isps: ALL Camshaft Run-Out at Center .000

Bearing Journal .006
517 I..5i7iS.] All ModelsUsing Counterweight Bushing and .0013T

Counterweights Crankshaft -~0026T (A)
518 All ModelsUsing CounteMreight Roller End I .007L
Counterveigh ts Clearance .025L .038L
519 All ModelsUsing Counterweight and Crankshaft .003L

Countenveights Side Clearance" ~m3I; .017L
520 ~i:i69& All Models Using Counterveight Bore and Washer .0002L
Counterveights O.D. .0030L (A)
521 All ModelsUsing LD. of Count~nueight .7485
Counterweights Bushing .7505 .7512
Measure below roller next to flat.
SSP1776 1-3
Island Enterprises
EERV ICE TABLE OF LIMITB
Ref. Ref. Chart Nomenclature Dhmensions Clearances

M~. 1 I Mir.
New I Old Min. Serv. I Min. Serv.
a Max. I a Max.
Max. Max.
szz O.D. of CounteMreight Roller
521
I~ iiijiiiiiiij
~9i01:
~lo
(AS APPLICABLE) (See latest edition of Service
Instruction No. 1012)
Thrust
Shaft
Bearing and Propeller .0000
.0012L .002L
62a 1S019~
I.: Thrust Bearing
Cap Clamp Fit (Shim
and Thrust Bearing
to this Fit) I I (.005T
.003T
I (A)
Thrust Bearing Tilt .027 Tilt
526525 Crankshaft Run-Out Rear Cone
Location I I I 1 .003
527
li i5’96~1" Crankshaft Run-Out
Location
Front Cone
.007
528 lii:SiO~ Thrust Bearing and Thrust Bearing .0016L

Cage .0034L .0045L
´•~T‘´• o
8 o
8 8 8 8
O
8 Q Q O
O
‘o o
o
0\0 C) O
507--/ 1 i I 1~1
(CRANKSHAFT AGAINST g a
O O
THRUST FACE) I i O
THRUST FACE
501
Longitudinal Section Thru Engine

SSP1776 1-4
Island Enterprises
BERV lee TABLE OF LIMITB
~z
ii--i
´•----i
r 521
1If522
:-P
513
524
s~C \~To
517
526 523
525’ \O
0-435-A
Crankcase, Crankshaft, Camshaft and Related Parts
SSP1776 1-5
Island Enterprises
SECTION II CYLINDERS
Ref, Ref. Chart Nomenclature Dimensions Clearances

Mfr.
New Old Min. Serv. Min. Serv.
B Max. Q Max.
Max. Max.
Connecting
’ ’ ’ LLA Rod Bushi~ng
Rod and Connecting Bushing To Be
Burnis~Ted in Place
ALL Finished I.D. of Connecting

Rod Bushing
601 A-B-D-G-J-BD Length Betwe_en Connecting

RodBearing Centers
S-T-Y-AF-BE Length Between Connecting
ALL Rod
ConnPistonectingPin Bushing and
.0025L
603
’ ’ ’ ’ ’ ’ ’ LLA Piston Pin and Piston
.0018L
iii
ALL of Piston Pin Hole
in PistonDiameter
ALL Diameter of Piston
Pin1.124
604
’ ’‘ -DB-FA-T-S-J-G-ABE Piston and Piston Pin Plug
.002L
’’’’’’EB A-G-J-S-T-AF-BD- *Diameter of Piston Pin Plug
605 III~ESIIIIJ B-D-G-J-S-T-Y-AF Piston Pin and Pist6n Pin

´•88~- .005L
*Diameter of Piston Pin Rug
B-D Diameter of Piston Pin Plug
"See latest edition of Service Instruction No. 1267.
606 Piston Ring and Piston Side

Clearance (Top Ring Comp.) .000
(Plain) Full Wedge .004L .006L(B)
Piston Ring and Piston Side
Clearance TTop Ring Comp.) .0025L
(Chrome) Full Wedge .0065L .008L(B)
G-J-S-T-Y-AF-BD- Piston Ring and Piston Side
BE Clearance (Top Ring Comp.) .0025L
Half Wedge T0055L .008L(B)
sos Piston RinF! and Piston Side
Clearance (2nd Ring Comp.) .0025L
i
(Chrome) Full Wedge .0065L .008L(B)
A-B-D-G-J-S-T-Y-AF- Piston Ring and Piston Side
Clearance (2nd Ring Comp.) .000
Full or Half Wedge .004L .006L(B)
J Piston Ring and Piston Side
Clearance (3rd Ring Comp.) .000
Half Wedge .004L .006L(B)
ALL
606’’ ’~’ ’ ’ ’ Piston Ring and Piston Side
.006L(B)
SSP1776 1-6
Island Enterprises
Ref. net. Chart Nomenclature Dimensions Clearances

Mfr. Mtr.
a Max. 8 Max.
Max. Max.
A Piston Ring and Piston Side .003L

:´•:´•:´•:´•i
.Clearance (Bottom) .0055L .007L(B)
607 ;i:il ALL Piston Ring Gap (Compression)
Plain and Chrome Cylinders .020
(Straight Barrels) .047
ALL Piston Ring Gap (Compression)

Nitrided and Chrome Cylinders .045
(Choke Barrels) .067
ALL Piston Ring Cap (Oil Regulating) .015

(All Barrels) IC)30 .047
A-T2 Piston Ring Gap (Oil Scraper) .015

(All Barrels) .047
For Choke Barrels Ring gap is measured within 4 inches from bottom. Ring gap at top of travel must not be
less than .0075.
For all Other Barrels Ring gap is measured at top limit of ring travel.
Engine and Piston Application Min. Piston Diameter Cylinder Barrel

Max.
Clearance
Type of Maximum PistonSkirt
Letter Pinon Number Top Bottom TypeafPismn Surface Oiametar &Cyl.
608 A 61147, 73851 4.3470 4.3555 Cast-Round P 4.3795 .021L
608 E! 61333 4.3470 4.3555 Fo -Round P 4.3795 .021L
609 LW-11621+. LW-13623" 4.3290 4.3605 Cast-Cam N 4.3805 .018L
69841". 69958. 70396 4.8290 4.8620 Cast-Cam P-C 4.8805 .o18L
D 69958 4.8290 4.8620 Cast-Cam P 4.8805 .018L
G T 73196, 74059, 75413 5.0790 5.1090 Cast-Cam P-C-N 5.1305 .018L
69337 5.0790 5.1090 -Cam P-C 5.1305 .018L
J,S,Y,T 71594Y, 72967,, 74530+,
i
75089Y 5.0790 5.1090 Cast-Cam P-C-N 5.1305 .018L
ED LW-15357’ 5.0790 5.1090 Cast-Cam N 5.1305 .018L
S,T,AF 73264", 75617", 76966,
i8203,, LW-10207+,
LW-13358", LW-14610+,
LW-11487Y, LW-10545 5.0790 5.1090 -Cam N-C 5.1305 .018L
T LW-13396+ 5.0790 5.1090 Cast-Cam N 5.1305 .018L
NOTES:
To find the average diameter of cylinder in an area 4" above Maximum taper and out-of-round permitted for cylinder in
bottom of barrel: First, measure diameter at right angles service is.0045 inch.
from plane in which valves are located. Second, measure
liiililiili~ill diameter through the plane in which valves are located. Add See Service Instruction No. 1243 for identification of cast
both diameters; this sum, divided by 2, represents the average and forged pistons. The suffix "S" that will be found with
diameter of the cylinder. the part number on 76966, 78203, LW-10207, LW-10545,
LW-11487, LW-13358, LW-14610 pistons indicates the
+=High Compression. piston weight is within the limits specified for any group of
pistons and may be substituted for any like piston on a
Cylinder Barrel: P=plain steel, N=nitride hardened, C=chrome particular engine. Other pistons are manufactured within
plated. weight limits that do not require any weight controlled
piston for replacement.
To find the
average measurediameter of
cylinder in 4" above bottom of barrel: First, measure
an area Piston diameter at top is measured at top ring land (between
diameter at right angles from plane in which valves are top and second compression ring grooves) at right angle to
located. Second, measure diameter through the plane in piston pin hole; diameter at bottom of piston is measured at
which valves are located. Difference between diameters must the bottom of the piston skirt at right angles to the piston
not exceed .0045 inch. pin. See Service Instruction No. 1243 for illustration.
SSP1776 1-7
Island Enterprises
Ref. Her. Chart Nomenclature Dimensions Clearances

Mfr. Mir.
g, Max. Max.
Max. Max.
611 Exhaust Valve Seat and Cylinder .0065T

Head .010T (A)
B-D-G-J-S-T-Y-BD-BE Exhaust Valve Seat and C~linder .0045T

Head .008T (A)
S1-S2-S3-S5-S6-S7- Exhaust Valve Seat and Cylinder .0075T

S9-S10-T2-T3-AF Head .OllT (A)
A O.D. Exhaust Seat 2.0025

2.004
B-D-G-J-S-T-Y-BD- O.D. Exhaust Seat 1.7395

BE 1.741
S1-S2-S3-S5-S6-S7- O.D. Exhaust Seat 1.9355

S9-S10-T2-T3-AF 1.937
A I.D. Exhaust Seat Hole in 1.994

CLlinder Head 1.996
B-D-G-J-S-T-Y-BD-BE I.D. Exhaust Seat Hole in 1.733

Cylinder Head 1.735
all sl-sz-S3-ss-Ss-s7- Exhaust Seat Hole in 1.926

S9-S10-T2-T3-AF CylinderHead I~ZB
612 IIl~jtll A Intake Valve Seat and Cylinder .0070T

Head .0105T (A)
B-D-G-J-S-T-Y-AF-BD- Intake Valve Seat and Cylinder .0065T

BE Head .010T (A)
A O.D. Intake Seat 2.0965

2.0975
A1-B-D O.D. Intake Seat 1.9265

1.928
B1-C-J-S-T-Y-BD- O.D. Intake Seat 2.0815

BE 2.083
i
S1-S2-S3-S5-S6-S7- O.D. Intake Seat 2.2885
S9-S10-T2-T3-AF 2.290
A I.D. Intake Seat Hole in 2.087

Cylinder Head z.ol
Al-B-D J.D. Intake Seat Hole in 1.918

Cylinder Head 1.920
B1-G-J-S-T-Y-BD- I.D. Intake Seat Hole in 2.073_

BE Cylinder Head 2.075
81-82-83-85-86-87- I.D. Intake Seat Hole in 2.280

S9-S10-T2-T3-AF Cylinder Head 2.282
613 ALL Exhaust Valve Guide and .001T

Head
CS~linder .0025T (A)
.5938
iljljlilil
illilil:li
SSP1776 1-8
Island Enterprises
sERV ICE TABLE OF LIMITS
PART 1 DIRECT DRIVE ENGINE~S
Ref. Ref. Chart NomeneLature Dimensions Clearances

Max. Q Max.
Max. Max.
O.D. Exhaust Valve Guide .6267

.6272
G-J-S-T-AF-BD-BE O.D. Exhaust Valve Guide .6633

.6638
S1 O.D. Exhaust Valve Guide .6953

.6958
A-B-D-J I.D. Exhaust Valve Guide .5913

Hole in Cylinder Head .5923
j
613 I.D. Exhaust Valve Guide .6247
Hole in Cylinder Head ;6257
G-J-S-T-AF-BD I.D. Exhaust Valve Guide .6613

Hole in Cylinder Head
S1 I.D. Exhaust Valve Guide .6933

Hole in Cylinder Head
Cylinder Head .(lO25T

.Illllilll
ii~liijiii
ALL O.D. Intake Valve Guide .5933
ilililllil
.5938
lililj:iij
lillli.iii ALL I.D. Intake Valve Guide .5913
615 A-B-D Exhaust Valve Stem and Valve .0020L

Guide .0038G (A)
jr2~sil
A1-G-J-S-T-BD-BE Exhaust Valve Stem and Valve .0040L
Guide (Parallel Valve Heads) .0060L (A)
j Y Exhaust Valve Stem and Valve .0035L

Guide .0053L (A)
S1-S2-S3-S5-S6-T2- Exhaust Valve Stem and Valve .0037L

T3-AF Guide (Angle Valve Heads) .0050L (A)
87-89-810 Exhaust Valve Stem and Valve

Guide (Angle Valve Heads .0035L
Helicopter) .0055L (A)
A-B-D O.D. Exhaust Valve Stem .4012

.4020
Al O.D. Exhaust Valve Stem .4320

.4333
G-J-Y O.D. Exhaust Valve Stem .4332

.4340
G-J-S-T-BD-BE O.D. Exhaust Valve Stem .4935

(Parallel Valve Heads) T;m~ .4915
81-82-83-85-86-87- O.D. Exhaust Valve Stem .4955

S9-S10-T2-T3-AF (Angle Valve Heads) .4965 .4937
rvice allowable limits
f.4937 or .4915 is
licable only to inconel
nimonic valves.
8SP1776 1-9
Island Enterprises
IERV ICE TAILE OF LIMITS
net. Ref. Cbort Nomenclature Dimensions Clearances
New Old Min. Serv. Senr.

a Max. a Max.
Max. Max.
615 liitRZXi;l A-B-D Finished LD. Exhaust Valve .4040

Guide .4050
A1-GJ Finished I.D. Exhaust Valve 4370

Guide .43-8~-
Y Finished LD. Exhaust Valve .4375

Guide .4385
GJ-S-T-BD-BE Finished LD. Exhaust Valve .4985

Guide (Parallel Valve Heads)
81-82-83-85-86- Finished I.D. Exhaust Valve .4995

ii~iiiiiiii Tz.n.nF Guide (Angle Valve Heads) .50(15
87-89-810 Finished LD. Exhaust Valve

Guide (Angle Valve Heads .5000
Helicopter) .5010
1/2 inch diameter exhaust valves may have exhaust valve guides that are .003 in. over the maximum inside
diameter limit, anytime up to 300 hours of service. After 300 hours of service inside diameter of exhaust valve
guide may Increase .001 m. during each 100 hours of operation up to the recbmmended overhaul time for the
engine or not to exceed .015 inch over the basic I.D. See latest edition of Service Instruction No. 1009 for
recom;nended overhaul time.
ALL Intake Valve Stem and Valve .0010L

Guide .0028L .006L
ALL O.D. Intake Valve Stem .4022

.4030 .4010
61e ALL
jl: Finished I.D. Intake Valve
Guide
.4040
.4050
611 ALL
/~ij il j: : :
Intake and Exhaust Valve and
Valve Cap Clearance (Rotator .000
Type Small Dia. Head) .004L .005L
618 A-B Solid Tappet Clearance I I 1 .006

(After Engine in Run) I I 1 .012
G-D-J-S-T-Y-AF- Dry Tappet Clearance .028

ED-BE
619
Ij~:i A Valve Rocker Shaft and
Cylinder Head (No Bushing) .0025L
B-D-J-S-T-Y Valve Rocker Shaft and Valve

Rocker Bushing (Parallel I I I .0001L
Valve Heads) .0013L .0025L
81-82-83-85-86- Valve Rocker Shaft and Valve

S7-S9-S10-T2-T3- Rocker Bushing (Angle Valve .0001L
AF Heads) I I I .0013L I .0025L
Finished I.D. of Valve Rocker

Shaft Bores in Cylinder Head .6246
(No Bushings) .6261 .6270
619 B-D-G-J-S-T-Y Finished I.D. of Valve Rocker

Shaft (Bushing) in Cylinder
Head(Paralle ral .6270
SSP1776 1-10
Island Enterprises
QIRV ICE TAILE OF LIMITI
Ref. Ref. Chart Nomenclature I Dimensions Clearances

Mfr. Mir.
a Max. a Max.
Max. Max.
619 SI-S2-S3-S5-S6- Finished I.D. of Valve Rocker

iliiiifiijii S7-S9-S10-T2- Shaft (Bushing) in Cylinder .6246
ijiijiiijiijj T3-AF Head (Angle tralve Heads) .6261 .6270
620 ALL Valve Rocker Shaft and Valve .0007L

~ififilitj:jfl Rocker Bushing I I I .0017L .004L
Finished I.D. of Rocker Arm .6252

Bushing .6263 .6270
ALL O.D. Valve Rocker Shaft .6241

.6245 .6231
621 i] ALL Valve Rocker Bushing and Bushing Must Be

t Valve Rocker Burnished In Place
´•:´•:-:´•:´•I:
622 :)5121:ilALL Valve Rocker Shaft Bushing .0022T

and Cylinder Head 10038T (A)
ALL Valve Rocker Shaft Bushing 1 .7380
623 E:L3~31:3 A-B-D-G-J-Y´•S-T Valve Rocker and Cylinder

Head -Side Clearance .005L
(Parallel Valve Heads) .013L .016L
81-82-83-85-86- Valve Rocker and Cylinder

S7-S9-S10-T2- Head Side Clearance .002L
T3-AF (Angle Valve Heads) .020L .024L
624 A-BJ Push Rod and Ball End .0005T

.0025T (A)
A
""Ii9lrf~
Intake and Exhaust Valve .705
Guide Height .725
ALL Intake Valve Guide Height .705

(Parallel Valve Heads) .725
ALL EXCEPT Exhaust Valve Guide Height .765

0-235 (Parallel Valve Heads) .785
ALL Intake and Exhaust Valve

Guide Height (Angle Valve .914
Heads) .954
MEASURE VALVE GUIDE HEIGHT

FROM THE VALVE SPRING SEAT
COUNTERBORE IN THE CYLIND
HEAD TO THE TOP OF VALVE
GUIDE.
SSP1776 1-11
Island Enterprises
88RV ICE TABLE OF LIMITS
625
~´•’e 625
´•s
611
´•t´•´•:i: ::I´•´•:: i: ;´•i~´•/ 607

•´I, ~i;:•´ -
´• n-´•/:
601
608 ~OPTION
600(BUSHING
6)1
.lul~
Cylinder, Piston and Valve Components

1-12
SSP1776
Island Enterprises
619-7 r620 r623
0-235 TYPE
+~W i ~624
621
620
622-/ PARALLEL VALVE HEAD
623
620
619
ANGLE VALVE HEAD
SSP1776 1-13
Island Enterprises
8 ERV I CE TABLE OF LIMITS
SECTION III GEAR TRAIN SECTION OIL PUMP
Ref. Ref. Chart Nomenclature Dimensions Clearances

Mir. Mir.
Ns~v Old Min. Serv. Min. Serv.
Max. a Max.
Max. Max.
ALL Oil Pump Drive Shaft .0010L

700´•’´•’´•’´•’´• Pump Body or Cover
and Oil
.004L
701 :BO~E A-B-D-G-J-S-T-AF Oil Pump Drive Shaft and .0015L

and Accessory Housing .0030L .006L
Y OilPump Drive Shaft and .0015L

Accessory Case .0030L .006L
ED-BE Oil Pump Drive Shaft and .0010L

Crankcase .0025L .004L
702 S-T-AF Oil Pump Drive Shaft End .015L

(DUAL MAGNETO) Clearance .050L .065L
ED-BE Oil Pump Drive Shaft End .017L

Clearance .037L .047L
A-B-D-G-J-S-T-Y- Oil Pump Impellers- Diameter .002L
:~4B;I AF
ED-BE
Clearance
Oil Pump
Clearance
Impellers Diameter
.006L~
.0035L
.0075L
.008L
.009L
704 :gti5 ALL(ExceptBD-BE) Oil Pump Impeller Side .002L
jj
ED-BE Oil Pump Impeller Side .003L

AS APPLICABLE Width of Oil Pump Impellers .622

.624 .621

.749 .746

.997 .994
ED-BE Width of Oil Pump Impellers .622

.623 .620
S-T-AF Oil Pump Impeller and Idler .0010L

(DUAL MAGNETO) Shaft .0025L .004L
A-B-D-G-J-S-T-Y- Oil Pump Impeller and Idler .001T

AF Shaft .003T (A)
ED-BE Oil Pump Impeller and Idler .002T
Shaft .004T (A)
706 lili8g& A-B-D-G-J-S-T-Y- OilPump Idler Shaft and Oil .0005L
AF Pump Body .0020L .003L
ED-BE Oil Pump Idler Shaft and Oil .0010L

Pump Body .0025L .003L
S-T-AF OilPump Idler Shaft and Oil .0000

iii´•jj:iiiii (DUAL MAGNETO) Pump Body .0015T (A)
707 tilbia~ A-B-D-G-J-S-T-Y- OilPump Idler Shaft and .0010L
Accessory Housing .0025L .0035L
ED-BE Oil Pump Idler Shaft and .0010L

SSP1776 1-14
Island Enterprises
SERV ICE TABLE OF LIMITS
SECTION III GEAR TRAIN SECTION SCAVENGE PUMP
Ref. Ref. Chart Nomenolature Dimendon~ Clearancea

Mtr.
New Old Min. Serv. Min. Bsrv.
a Max. a Max.
Max. Max.
708 G2-S2 Scavenge Pump Drive Shaft and .0010L

Adapter .004L
G2-S2 Scavenge Pump End Clearance .000

.045L .060L
710 Scavenge Pump Impellers .007L

Diameter Clearance .014L
Scavenge Pump Impellers .009L

Side Clearance .005L .006L
1.498 1.495
712 G2-S2 Scavenge Pump Impellers and .0010L

IdlerShSPt 0016L .004L
713 C2-S2 Scavenge Pump Body and Idler 0000

iiliji’iiii: Shaft (A)
S3-T4-AF Turbocharger Scavenge Pump .0010L

Drive and Adapter .0025L .004L
gilgiili cwIDE DECK)
715 S3-T4-AF Turbocharger Scavenge Pump .0010L
(WIDE DECK) Shaft and Adapter .0035L
716 E:~B S3-T4-AF Gerotor Pump Rotor Side .0015L

(WIDE DECK) Clearance .003L .004L
717 S3-T4-AF Gerotor Pump Housing and .0005L

(WIDEDECK) Adapter .0020L (A)
718 S3-T4-AF Turbocharger Scavenge Pump .0055L

ONIDE DECK) End Clearance .0365L .0415L
T4 (DUAL MAGNETO) Turbocharger Scavenge Pump .0105L

End Clearance .039571 .0445L
SECTION III GEAR TRAIN SECTION FUEL PUMP
119 A-B-D-G-J-S-T AC Fuel Pump Plunger and .0015L

720 J-S-T-AF Crankshaft Idler Gear and .001L

Crankshaft Idler Gear Shaft .003L .005L
721 S-T-AF Crankshaft Idler Gear Shaft .0020L

and Accesso~y Housing .D035L .0065L
(DUAL MAGNETO)
S-T-AF Crankshaft Idler Gear Shaft .0020L
(DUAL MACNETO) and Crankcase .0035L .0065L
.001L
722
/i:’ S-T-AF AN Fuel Pump Idler Gear and
Shaft .003L .005L
723 :ga~ S-T-AF AN Fuel Pump Idler Gear Shaft

(DUAL MAGNETO) and Accessory Housing and .0020L
S-T-AF AN Fuel Pump Idler Shaft and .0020L

iliiiillllllltl (DUAL MAGNETO) Crankcase .0035L .0065L
8SP1776 1-15
Island Enterprises
8ERV ICE TABIE OF LIMITs
SECTION III GEAR TRAIN SECTION FUEL PUMP (CONT.)

Mfr. Mir.
New Old
Min. Serv. Min. Serv.
a Max. a Max.
Max. Max.
Crankshaft Idler Gear End .003L

Clearance I I I .043L I .058L
´•J-S-Y Crankshaft Idler Gear End .005L

T-AF Crankshaft Idler Gear End .007L

Clearance .037t .052L
S Crankshaft Idler Gear End .020L

(DUAL MAGNETO) Clearance .03 OL .040L
T Crankshaft Idler Gear End .015L

(DUAL MAGNETO) Clearance I I .038L .046L
725 AN Fuel Pump Idler Gear End .010L

T-AF AN Fuel Pump Idler Gear End .002L

Clearance I I .018L .024L
S-T-AF AN Fuel Pump Idler Gear End .015L

(DUALMAGNETO) Clearance .038L .045L
S-T-AF-Y Drive Shan Gelr .0010L

.0025L .004L
727 AN Fuel Pump Drive Shaft Gear .035L
T-AF AN Fuel Pump Drive Shaft Gear .044L

End Clearance .081G .091L
T-AF AN Fuel Pump Drive Shaft Gear .035L

(DUAL MAGNETO) End Clearance .073L .083L
Y AN Fuel Pump Drive Shaft Gear .000L
SECTION III GEAR TRAIN SECTION GOVERNOR HYDRAULIC PUMP
728 i Front Governor Drive Idler Shaft .0010L

(NARROW DECK) (Bath Ends) and Cn~nkesse .0025L .004L
729 G1-G2-S2-S4-S6- Front Governor Idler Gear and .0010L
ijiiiiiiiiijijj T-AF (WIDE; DECK) Shaft .0025L .004 L
730 ED-BE Front Governor Drive Gear .0010L

and Crankcase .0025L .004L
ED-BE Front Governor Drive Gear and .0005L

and Camshaft I I .0025L I .004L
731 G1-GS-S-T-AF Front Governor Gear and .0010L
Crankcase 10025L .004L
ED Front Governor Gear and .0010L

732 G1-GB-S-T-AF Front Governor Gear End .008L
ED-BE Front Governor Gear End .0045L
8SP1776 1-16
Island Enterprises
SECTION III GEAR TRAIN SECTION GOVERNOR HYDRAULIC PUMP (CONT.)
Ref. net. Chart Nomenclature Dimensions Clearances

Mir.
New Old Serv. Min. Serv.
Max. Q Max.
Max. Max.
c-J-s Rear Governor Gear and .0010L
’"/isPsj G-S
(DUALMAGNETO)
Adapter
Rear Governor Gear and Accesso

Housing
.0025L
.0010L
.005L
.005L
G-J-S Rear Governor Gear End .002L

G-S Rear Governor Gear End .002L

i:l:I:I:I:! Clearance .037L .044L
(DUAL MAGNETO)
735 Hydraulic Pump Gear and .0010L

Adapter ~TnTZSE- .004L
T-AF Hydraulic Pump Gear and .0010L

(DUAL MAGNETO) Accessory Housing TUUZ~G .004L
T-AF Hydraulic Pump Gear End.010L

liilililili T-AF Hydraulic Pump Gear End .007L

1’’’’’’’’’’’’
SECTION III GEAR TRAIN SECTION VACUUM TACHOMETER
737 A-B-C-J-S-T-Y- Vacuum Pump Gear and.0010L

AF Adapter .0030L .0045L
131/ ´•i-i´•B´•i:
S-T-AF Vacuum Pump Gear and .0010L
(DUAL MAGNETO) Accessory Housing .0025L .004L
7371:i:W89i D Vacuum Pump Gear and .0010L

A-B-G-J-S-T-AF Vacuum Pump Gear -End .010L

D Vacuum Pump Gear End .003L

Y Vacuum Pump Gear -End .000

S Vacuum Pump Gear -End .012L

T-AF Vacuum Pump Gear -End .017L

’"I
i6%51:1 A-B-Y Tachometer Drive Shaft and .0015L
Adapter .0035L .006L
ED-BE Tachometer Drive Shaft and .0010L

D-G-J-S-T-AF Tachometer Drive Shaft and .0015L

740 G-J-S Vacuum Pump Gear and .0010L

(DUAL DRIVE) Adapter .0025L .004L
us
lise´•
a´•´•´•´•P~,r.,a.a
(DUAL DRIVE) Clearance .017L .027L
SSP1776 1-17
Island Enterprises
BERV ICE TABLE OF Lll~nlT8
SECTION IIT GEAR TRAIN SECTION VACUUM TACHOMETER (CONT.)

Mtr. Mfr.
a Max. a Max.
Max. Max.
742 G-J-S Idler Gear and Shaft 10L
743ioil .il i’ ’ ’ ~ (DUAL DRIVE) .0030L .005L
G-J-S Idler Gear End Clearance .021L

(DUAL DRIVE) L .060L
744 i7BiQ: G-J-S Propeller Governor Gear and .0013L

G-J-S Hydraulic Pump Gear and .0013L

745 Propeller Governor or Hydraulic .000

j:i’’’’’
tiiiiiliti (DUAL DRIVE) Pump End Clearance .054L .074L
SECTION III GEAR TRAIN SECTION MAGNETO, GENERATOR, STARTER
7461~rX’ ’i~l T Magneto Bearing and Gear .0005T

1L .0005L
746
1’: ‘’ ´•~´•’´•’´•’´• Magneto Bearing and Gear .0008T
L .0005L
747 Magneto Bearing and Crankcase .0002T

ii"B (A)
747 i56i~i Magneto Drive Bearing and .0006T
~ii i-i Adapter .0008T (A)
748 87 Magneto Bearing and Gear .0001T
.0010T (A)
749 87 Magneto Bearing and Adapter .000
12L .0015L
160 S-T-AF Magneto Drive Gear and .0010L

ii: (DUAL MAGNETO) Crankcase L .003L
751 ´•’s~sstil S-T-AF Magneto Drive Gear End .005L

:!;;;II (DUALMAGNETO) Clearance .073L .083L
752’’ ’ ’ ’ ’ ’ li i i l’ AF Magneto Drive Gear and I I 1.001L

Shaft L .005L
753 ED-BE Magneto Drive Gear and .001L

Crankcase L .005L
154 Y Magneto Shaft Gear and .001L

Magneto Case L .005L
Magneto Shaft Gear and .001L

Support Assembly .003L .005L
756’ Y Magneto Shaft Gear and

Accessory Drive Shaft Gear .0075
End Play .015
757 Y
1:’~’ : : : : :’ ’ i´•I Accessory Drive Shaft Gear
andSupport Assembly
.001L
L .005L
758 S Magneto Gear and Bushing .0005L

(S4LN-21 and S4LN-1227) .0020-~ .0035L
T Magneto Gear and Bushing .0015L

(S6LN-21 and S6LN´•1227) L .0055L
88P1776 1-18
Island Enterprises
EIERV ICE TABLE OF LIMITS
PART I DIRECT DRIVE ENGINES
SECTION III GEAR TRAIN SECTION MAGNETO, GENERATOR, STARTER (CONT.)
Ref. I Ref. I Chart Nomenclature I Dimensions Clearances

Mfr. Mir.
Ne~a I Old Min. Serv. Min. Serv.
a Max. I Q Max.
Max. Max.
758 :i:i:i:i:~i:ilT-AF Magneto Gear and Bushing .0015L

(DUAL MAGNETO) I I I I .0035L .0055L
70951tili~iliiiliiiiI ED, BE Bushing -Magneto Drive .0025T

and Crankcase .0045T (A)
759 Generator Gear Bushing and .0020T

Generator Gear .0035T (A)
Generator Gear Bushing and .001L

Generator Drive Coupling Adapter .0028L .005L
.0005T
761
:::/o Bendix Drive Gear Bushing and
Crankcase .0025T (A)
762 Bendix Drive Gear and Bendix .0010L

Drive Gear Bushing .0025L .005L
Bendix Drive Shaft and Bendix .003L

Drive Housing .005L .010L
764 Bendix Drive Shaft End .000

i" Clearance .0059L .080L
702
700 r703
d*S~
lul~
jY I
6 CYL-DUAL MAG 4 CYL-DUAL MAG
~i i~h rJ _
m7~.,
706
700
70)
7m
0-320-H,O,LO-360-E
STANDARD TYPE
Oil Pumps
SSP1776 1-19
Island Enterprises
EIERV ICE TABIE OF LIMITS
SECTION III GEAR TRAIN
718
717
711
715
716
TURBO SCAVENGE PUMP 8 HYD PUMP (TIO-540-C)

TURBO SCAVENGE PUMP 8~ GOV. (TIO-360)
715 lr717 716
715
DUAL MAG: TURBO SCAVENGE PUMP 8 HYD. PUMP
712-7 /-716 ~-713
709 r-768
711
712 "713
SCAVENGE PUMP AIO 320 8~ AIO-36O
Scavenge Pumps
SSP1776 1-20
Island Enterprises
BERVIOE TABLE OF LIMITS
SECTION IIIGEAR TRAIN
720
721 7~a r721
723
721 1
719
AC FUEL PUMP o
(DUAL MAG) I 8-
AC FUEL PUMP
(4 CYL)
724
AN FUEL PUMP (DUAL MAG)
125
AC FUEL PUMP(GCYL)
726
AN FUEL PUMP(68r8 CYL) AN FUEL PUMP (4CYL)
Fuel Pumps
SSP1776 1-21
Island Enterprises
729
no
732
731
731
4 8~ 8 (WIDE DECK)
0-520-H 0LO-360-E
728
732
732
731
NARROW DECK (6 8 CYL.
Front Governor
SSP1776 1-22
Island Enterprises
723
725
723
735
HYDRAULIC PUMP-DUAL MAG

HYDRAULIC PUMP
720
723~ r725 724
723
‘h i
133
734
734
732
PROP GOV (4 CYL~ REAR PROP GOV (4 GYL.I

REAR
(DUAL MAG.) (STANDARD)
Rear Governor and Hydraulic Pumps
SSP1776 1-23
Island Enterprises
8ERV ICE TABLE OF LIMITs
739 1
f L739
TACHOMETER DRIVE
737
738
VACUUM PUMP 8( TACHOMETER

740
741
742
743
738
737
743
744
DUAL DRIVE (VACUUM PUMP 8 PROP GOV

VACUUM. PUMP
OR (VACUUM PUMP 8 HYD. PUMP)
Tachometer Drives, Vacuum and Hydraulic Pumps

SSP1776 1-24
Island Enterprises
747
747
0-4354
nccEssoRu
6 CYLINDER
HIO-360-DTYPE
8 CYLINDER
0-320-H,0,LO-360-E
r!
4 CYL.(S4LN-21 a S4LN-1227)
151
DUAL Mnc. (662 CYL)
4 CYL. DUAL MAG.
Accessory Drives: Magnetos, Generators and Starters
SSP1776 1-25
Island Enterprises
757
VO. IVO-360
Accessory Drives: Magnetos

SSP1776 1-26
Island Enterprises
8ERV ICE TABLE OF LIMITB
700
759
760
GENERATOR DRIVE
0-435-A
761
763
BENDIX DRIVE
0-435-A
I~
Generator and Bendix Drive
SSP1776 1-27
Island Enterprises
sERV ICE TABIE OF LIMITs
SECTION IV BACKLASH

Mfr. Mir.
B Max. Max.
Max. Max.
800 i62L:I A-B-G-J-S-T-Y-AF Camshaft and Vacuum Pump .004

dni Backlash .015 .020
Camshaft and Vacuum and Oil .006

801
I´•~ii iji i i ED-BE
Pump Drive Backlash .014 .020
802 Camshaft and Fuel Pump .004

Backlash .015 .020
Camshaft and Crankshaft Idler .004

803
’´•’´•’´•’´•’´•’:i h~i:/ *´•B´•G´•J´•S-T-Y´•AF
Backlash .015 .020
804 A-B-GJ-S-T-Y-AF Crankshaft and Crankshaft .004

i~na:l: Idler- Backlash ;015 .020
805 tsr:a: A-B-G-J-S-T-AF Magneto Drive and Crankshaft .004

Idler- Backlash .015 .020
806 3~ ED-BE Magneto Drive and Crankshaft .006

Gear Backlash .014 .020
807 ED-BE Crankshaft Gear and Vacuum .006

and Oil Pump Drive Backlash .014 .020
808 A-B-D-G-J-S-T- OilPump Impellers .008

Y-AF Backlash .015 .020
ED-BE Oil Pump Impellers .008

ijijliijiji Backlash TmZ .ozo
sosir~i6i S-T-AF Oil Pump Drive and Crank- .004

(DUAL MAGNETO) shaft Idler- Backlash .015 .020
810’ Y Magneto and Magneto Shaft .004
Blji:rsX’
Gear- Backlash .015 .020
rf8iR Y Accessory Drive Shaft Gear .003

and Magneto Driven Shaft .005 .012
Gear-Backlash
812 ~SS;: Y Crankshaft Gear and Accessory

Drive Shaft Gear Spline .002
Backlash 7005 .015
813 G-J-S Camshaft and Propeller Governor .004

(DUAL DRIVE) or Hydraulic Pump Backlash .015 .020
al~ G-J-S Governor or Hydraulic Pump
I iiiiliirilil (DUAL DRIVE) Drive and Drive Gear Spline

Backlash
.0013
.0073 .010
815 89i211 G-J-S Governor or Hydraulic Pump .004

iiiiiijiiiiil (DUAL DRIVE) and Idler Backlash .015 .020
816 GJ-S Vacuum Pump and Idler .004

iililjljlilj (DUAL DRIVE) Backlash .015 .020
817 S-T-AF AN Fuel Pump Idler and.004

I Crankshaft Idler Backlash .015 .020
818 S-T-AF AN Fuel Pump Idler and Fuel .004

Pump Drive -BacMash .015 .020
SSP1776 1-28
Island Enterprises
BERV ICE TABLE OF LIIVIITB
SECTION IV BACKLASH
net. net. Chart Nomenelature Dimensions Clearances

B Max. Q I Max.
Max. I I Max.
819 S-T-AF Crankshaft Gear and AN Fuel .004

Pump Idler Backlash .020
(DUAL MAGNETO)
T-AF Hydraulic Pump and Crankshaft .004
Idler- Backlash Tb15 .020
821 G-J-S Propeller Governor Drive and

Crankshaft Idler- Backlash .004
(Rear Governor) ~UTE;- .020
822 G1-G2-S2-S4-S6- Governor Idler and

Propeller
T-AF Camshaft -Backlash (Front .004
Governor) ~ms´• .020
823 G1-G2-S2-S4-S6- Propeller Governor Drive and

T-AF Idler- Backlash (Bevel .004
Gears) (Front Governor) ~iXTS .015
ED-BE Governor Drive and

Propeller
Camshaft -Backlash (Bevel .003
Gears) (Front Governor) ~C)11 .015
Crankshaft Timing Gear and .004

Camshaft Gear Backlash .015 .020
826 II:iS~SI:il D Camshaft Gear and Generator .004

Gear- Backlash ~ms .020
Crankshaft Gear and Generator .004

827
1:1:g8%1" Gear Backlash ,015 .020
Magneto Coupling Spline .001

828ilS6i~1" Backlash .0075
829 D Vacuum Pump Gear and Vacuum .004

Pump Drive Gear Backlash .020
830 :6~851 D Starter Drive and Bendix Drive .004

Gear- Backlash .015 .020
831 t:.836:.1 D Bendix Drive Shaft Spline and

Bendix Drive Gear Spline .001
Backlash .006 .015
832 S Injector Pump Idler Gear and

Injector Pump Drive Shaft .004
Gear- Backlash .020
SSP1776 1-29
Island Enterprises
SECTION IV BACKLASH
VACUUM PUMP
CRANKSHAFT IDLER1
PROP GOVERNOR OIL PUMP
ECCENTRIC805
CRANKSHAFT
823 IDLER
TACHOMETER MAGNETO
AC FUEL
j´•ii
IDLER
jVACUUM PUMPCRANKSHAFT
C~ i~ PROP GOV.
0-360 DUAL MAG.

CAMSHAFT AT FRONT
FRONT GOVERNOR
TACHOMETER
CAMSHAFT
CRANKSHAFT IDLER
--r VACUUM PUMP
CRANKSHAFT
ECCENTRIC
MAGNETO
MAGNETO
AC FUEL PUMP
IDLER
OIL PUMP
r--PROP GOVERNOR
VACUUM PUMP
IDLER 814
CRANKSHAFT IDLER
~I CRANKSHAFT
~--FUEL PUMP IDLER
FUEL PUMP DRIVE

j GOVERNOR OR
HYDRAULIC PUMP
~I CAMSHAFT
AN FUEL PUMP OPTION
DUAL DRIVE OPTION
0-235 0-320 0-340 8( 0-360

ALL VIEWS~ SHOWN FROM REAR OF ENGINE
Backlash (Accessory Drives)

SSP1776 1-30
Island Enterprises
SECTION IV BACKLASH
CAMSHAFT
FUEL PUMP
VACUUM PUMP7
CRANKSHAFT
llo
~800 ui,
CRANKSHAFT
ACCESSORY DRIVESHAFT
GEAR
j
OIL PUMP IMPELLERSj 811

MAGNETO DRIVEN
ET
VO, IVO-36O
CAMSHAFT GEAR
AT FRONT
c~
CAMSHAFT PROP GOVERNOR
TACHOM ETER
CAMSHAFT
VACUUM OIL PUMP
CRANKSHAFT
808
j
OIL PUMP IMPELLERS
-r"MAGNETO
0-320-H, O, LO-360-E
ALL VIEWS SHOWN FROM REAR OF ENGINE

SSP1776 1-31
Island Enterprises
SECTION TV BACKLASH
PROP GOVERNOR
CAMSHAFT (FRONT)
CAMSHAFT (REAR)
TACHOMETER
IDLER
VACUUM PUMP
CRANKSHAFT IDLEA~
CRANKSHAFT
EGCENTRIC OIL PUMP
i
1
WIAGNETO CRANKSHAFT IDLER
AC FUEL PUMP
AN FUEL PUMP kHYDRAULIC PUMP
FUEL PUMP IDLER
0-540 8 10-720 DUAL MAG.
PROP GOVERNOR
CAMSHAFT (FRONT)
823
TACHOMETER
CAMSHAFT (REAR)
IDLER
VACUUM PUMP
CRANKSHAFT IDLER
ECCENTRIC
MAGNETO
_~_
-aw ~-CRANKSHAFT IDLER

AN FUEL PUMP IDLER--~ j j
AC FUEL PUMP
bN FUEL PUMP
~HYDR*ULC PUMP
OIL PUMP IMPELLERS
0-540 8( 10-720
ALL VIEWS FROM REAR OF ENGINE
Backlash (Accessory Dri\ies)
SSP1776 1-32
Island Enterprises
sERV ICE TABLE OF LIMITB
SECTION IV BACKLASH
825
C
i´•I-$
830
831
STARTER DRIVE
0-435-A
ACCESSORY HOUSING
0-435-A
~O O
O
MAGNETO DRIVE
0-435-A
SECTION THRU REAR

OF ENGINE

SSP1776 1-33
Island Enterprises
BERVICE TABLE OF LIMITB
SE;CTION’ V SPECIAL TORBUE RE$UIREMENTS
Ref. Ref.
Thread
Chart Size Nomenclature Torque Limits
New Old
900 liWI:I;l A-B-D-G-Y-S-T-BD-BE 3/8-24 Connecting Rod Nuts 480 in.lbs.
sBi J
S1-S3-S5-S6-S7-S9-
T3-AF
3/8-24
3/8-24
Connecting
Connecting
Tighten to
Rod Nuts
Rod Bolts
Length
360 in. Ibs.
2.255 2.256
901 ItiSr~lil ED-BE 9116-18 Oil Pump Shaft Nut 660 in. Lbs.
sat BD-BE 5118-24 Rocker Stud Nut 150 in.lbs.
903 ALL(AS APPLICABLE) 3/8-24 Magneto Nut (To attach drive

(EXCEPT 57) member to magneto) Bendix
Sintered Bushing Gray 120 -150 in. Ibs.
Magneto Nut (To attach drive

member to magneto) Bendix
Steel Bushing 170 300 in. Ibs.

member to magneto) Slick 120 300 in. Ibs.
S7 1/2-20 Magneto Nut (To attach drive

j:I::::::::, member to magneto) 170 300 in.lbs.
904 ALL 10-32 Magneto Plate Screws (To

attach ignition cable outlet
plate tomagneto) 15 in. Ibs.
905 ALL 1/4-20 Rocker Box Screws 50 in.lbs.
908 ALL 5/16-18 Exhaust Port Studs 40 in.lbs. min.
907 ALL 18MM Spark Rugs 420 in.lbs.
908 Fi8li~:i:l ALL 1/8-27 NPT Fuel Pump Vent Fitting (Approx-
‘[ii imately
tight)
two turns beyond finger
96 in. Ibs.
909
lii~Bijil ALL 5/8-32 Alternator Pulley Nut 450 in.lbs.
910 ~jlWXii ALL 114-28 Alternator Output Terminal Nut 85 in.lbs.
911
:I~jrjii ALL 10-32 Alternator Auxiliary Terminal Nut 30 in.lbs.
912 ALL 5/16-24 Starter Terminal Nut 24 in. Ibs.
’’’)ELALL
BACIL(AS
PPA 1/16-27 NPT Piston Cooling Nozzle in Crankcase
100 in. Ibs.
914 Y-S-T-AF 118-27 NPI~ Injector Nozzle in Cylinder

Head 60 in. Ibs.
915 liji8fi~iil ALL (AS APPLICABLE) 3/4-16 Oil Filter Bolt (AC Can and
Element 300 in. Ibs.
ALL (AS APPLICABLE) 13/16-16 Oil Filter (Throw Away ’I~pe) 240 in. Ibs.
i8n~i ALL (AS APPLICABLE) 3/4-16 Converter Stud 720 in. Ibs.
916 ALL (AS APPLICABLE) 3/4-18 NPT Carburetor Drain Plug 144 in. Ibs.
917 jiI´•iji.i:i´• (AS APPLICABLE) 1.00-14 Oil Cooler Bypass Valve 300 in. Ibs.
918 ALL (AS APPLICABLE) 1 1/4-12 Oil Pressure Relief Valve 300 in. Ibs.
SSP1776
1-34
Island Enterprises
SECTION V SPECIAL TORQUE REQUIREMENTS (CONT.)
Ref. Ref.
Thread

Ncur Old
’ ’ ’ LLA 1/4 Hex Head Hose Clamps (Worm 5pe)

and Below 20 in. Ibs.
5/16 Hex Head Hose Clamps (Worm Type)

and Above 45 in. Ibs.
920 ALL Cylinder Head Drain Back

Hose Clamps 10 in. Ibs.
921 Exhaust V-Band Coupling Torque Data
I’
T-Bolt Split 1/4 In. Drilled Hex Nut
CouplingSize Avco Lycoming Vendor Type Locknut With Safety Wire
Tube OD Part No. Part No. Torque In. Lbs. Torque In. Lbs.
1.75 in. LW-12093-4 MVT69183-175 65 7

2.00 in. LW-12093-5 MVT69183-200 85 75
2.25 in. LW-12093-6 MVT69183-225 85 75
2.25 in. LW-12125-3 MVT69197-225
3.69 in. LW-13464 U4 204-55-369M 70
3.69 in. LW-14 985 ANH1000902-10 70
922 ALL Turbocharger V-Band Torque Data
Turbocharger Model No. V-Clamp Part No. V-Clamp Diameter Torque In.
T0-473" 400500-600 6.00 in. 40-80

400500-685 6.85in.
THO8A60" 400500-775 7.75 in. 40-60
THO8A69" 400500-775 in.
301E10-2** TC-6-15 6.50 in. 15-20
AiResearch turbocharger.
Rajay turbocharger.
See latest edition of Service Instruction No. 1238 for assembly procedure.
Thread
927 ~a ALL DUAL MAGNETO 1/2-20 Crankshaft Gear Bolt

MODELS 660 in. Ibs.
iii;jlill
li~gjl ED 1/4 Crankshaft Gear Bolts 96 120 in.lbs.
928 ALL 3/8-16 Cylinder Hold Down Studs
ij
(Crankcase Driving Torque) 100 in. Ibs.
7/16-14 Cylinder Hold Down Studs


929 I.itla~:ilj A-B-D-BD-BE-J-G-Y- 3/8 Cylinder Hold Down Nuts

S-T-AF 300 in. Ibs.
Al 7/16 Cylinder Hold Down Nuts 420 in. Ibs.
B-D-BD-BE-J-G-Y- 1/2 Cylinder Hold Down Nuts

S-T-AF 600 in. Ibs.
Cylinder Hold Down and Crankcase Parting Flange Nuts’ Tightening Procedures See latest edition of Service
Instruction No. 1029.
SSP1776 1-35
Island Enterprises
SECTION V SPECIAL TORQUE REQUIREMENTS (CONT.)
Ref. I Ref.
Thread
New Old Chart Size Nomenclature Torpue Limits
930 ALL 3/8 Alien Head Screw (Diaphragm

Fuel Pump) 225 250 in. Ibs.
931 A 9/16 Locking Nut (Valve Adjusting

Screw) 450 in. Ibs.
932 ALL 5/16-18 Exhaust Transitions Studs

(Driving Torque) 100 in. Ibs.
ALL 3/8-16 Exhaust Transitions Studs

SECTION V SPRINGS
Length COMP. LOAD

AvcoLyc.l Wire At Comp. Mfr. 1 Mfr. Senr.
Chart Nomenclattlre Part No. Dia. Length Min. I Max. Max.
950 li,~Otlil A-B-D-G-J-S-T-Y- Outer Valve Springs 76994

ED-BE (Parallel) LW-11800 1.177 1.30 in. 112 Ib. 122 Ib. 1109 Ib. min.
A-B-D-G-J-S-T-Y- Outer Valve Springs

ED-BE (Parallel) 65427 .162 1.30 in. 82 Ib. 89 Ib. 79 Ib. min.
81-82-83-85-86- Outer Valve Springs

S7-S9-S10-T2-T3 (Angle) 68326 .177 1.46 in. 103 Ib. Illlb. 1100 Ib. min.
81-82-83-85-86- Outer Valve Springs

S7-S9-S10-T2-T3 (Angle) LW-11796 1.182 1.43 in. 116 Ib. 124 Ib. 1113 Ib. min.
A-B-D-G-J-S-T-Y- Auxilliary Valve 65567

ED-BE Spring (Parallel) LW-11795 .135 1.17 in. 611b. 67 Ib. 58 Ib. min.
81-82-83-85-86-87- IAuxilliary Valve 68328

S9-S10-T2-T3-AF Spring (Angle) LW-11797 1.142 1.33 in. 75 Ib. 83 Ib. 72 Ib. min.
952 i8a~ ALL Oil Pressure Relief

is~a (AS APPLICABLE)I Valve Spring
Avco Lycoming n
Part Numbers Dye Free Length
61084 None 2.18 .054 1.30 in. 8.5 Ib. 9.5 Ib. 8.3 Ib. min
65703 None 2.16 .063 1.47 in. 17.8 Ib. 19.4 Ib. 18.0 Ib.
2.04 .054 1.30 in. 7.11b. 7.81b. 6.9 Ib.
67 Yellow 1.90 1.054 1.30 in. 6.4 Ib. 7.11b. 6.2 Ib. min
LW-11713 White 2.12 1.059 1.44 in. 10.79 Ib. 11.92 Ib. 110.5 Ib, min
953 A-B-G-J-S-T-Y-AF Oil Cooler Bypass

Spring .0465 1.94 in. 6.50 Ib. 7.25 Ib. 16.411b; min
954 li:i:i:i:i:i:i:ili ED-BE Oil Filter Bypass

Spring .047 1.00 in. 3.05 Ib. 3.55 Ib. 3.0 Ib. min
Isro~i Magneto Coupling

Spring .091 .603 in. 201b. 221b. 19 Ib. min.
SSP1776 1-36
Island Enterprises
BERV ICE TABLE OF LIMITs
STANDARD TORQUE
UNLESS OTHERWISE LISTED
Torque limits for propeller attaching bolts to be supplied by propeller or airframe manufacturer.
TABLE II
TABLEI
PIPE PLUGS
BOLTS, SCREWS AND NUTS
Torque
Toraue Torque Thread In. Lbs.
Th read In.Lb. Ft.Lb. Thread In.Lb. Ft.Lb.
1116-27 NPT 40
10 49 1/2 900 75
1/8-27 NPT 40
1/4 96 9116 1320 110
1/4-18NPT 85
5116 204 17 5/8 1800 150
3/8-18 NPT 110
3/8 360 30 3/4 3240 270
1/2-14 NPT 160
7116 600 50
3/4-14 NPT 230
1-11 1/2 NPT 315
THIN NUTS (1/2 DIA OF BOLT) 1/2 LISTED TORQUE
TABLE IV
TABLE III
FLEXIBLE HOSE
OR TUBE FITTINGS
CRUSH TYPE ASBESTOS GASKETS
ANGLE OF TU RN
Torque
Thd. Pitch On Part
Tube Size Th read In. Lbs.
To Be Ti te ned Aluminum pper
rea er Inch Asbestos Asbestos
(-3) 3/16 3/8-24 30
8 1350 670 (-4) 1/4 7/16-20 30
10 1350 670 (-5) 5/16 1/2-20 35

12 1800 900 (-6) 3/8 9/16-18 35
14 1 -8 1/2 3/4-16 60
16 2700 1350
-10 5/8 7/8-14 70
18 2700 1350
20 2700 135
24 3 1
28 3600 1800
NOTE TABLE V
STUDS
Install all crushtype gaskets except the self centering
MIN. DRIVING TORQUE
type, with the unbroken surface against the flange of
the plug or part being tightened against the seal. Turn Torque
the part until the sealing surfaces are in contact and Threads In. L~b s.
then tighten to the angle of turn listed for the
1/4-20 15
appropriate thread size.
5116-18 25
NOTE: Lubricate Threads Unless Otherwise Specified. 3/8-16 50
SSP1776 1-37
Island Enterprises
SECTION V SPECIAL TORQUE REQUIREMENTS
931
ADJUSTABLE OIL RELIEF VALVE
907
905
929
Engine Accessories and Hardware
1-38
SSP1776
Island Enterprises
BERV ICE TABLE OF LI.MITB
PART 1 DIRE~T DRIVE ENGINES
921
II I
L[
SSP1776 1-39
Island Enterprises
r-----1
SSP1776 1-40
Island Enterprises
BERVIOE TAbLE OF LIMITI
PART 1 DIREC~T DRIVE ENGINES
SECTION V SPECIAL $ORQUE REQUIREMENTS
955
951
Engine Spri~gs and Hardware
SSP1776 ii-41
Island Enterprises
8ERV ICE TAj8LE OP LIMIT8
PART II INTEGRAL AICCESSORY DRIVE ENGINES
CHART MODELS
AQ TIG-541
AZ TIGO-541
SECTION E 500 SERIES CRANKCASE, CRANKSHAFT CAMSHAFT
SECTION III 700 SERIES GEAR TRAIN
(A) These fits ar~ either shrink fits controlled by machining, fits that may readily be
adjusted, or fits where wear does not normally occur. In each case, the fit must
be held to m$nufacturinn tolerance.
(B) Side piston rings must be measured with face of ring flush with
clearanc/e on
piston
(D) The dimensidns shown are measured at the bottom of the piston skirt at right
angles to the t,iston pin.
(E) Permissible Hiear of the crankshaft (rod and main bearing journals) to be minus
0.0015 on th~ diameter.
(L) Loose fit; a definite clearance is mentioned between the mating

surfaces.
(T) Tight fit; shri~k or interference fit.
(WD) Wide Deck Ciankcase.
SSP1776 July 31, 1979*
Indicates cut-off date for data retrieved prior to public$tion.
Island Enterprises
BERVICE
TnleLe of
PART II INTEGRAL A~CESSORY DRIVE ENGINES
SECTION I CRANKCASF, CRANKSHAFT, CAMSHAFT
Ref. Ref. Chart Nomenclature DimsnaLona Cbulncel

Mfr. Mtr,
Ne~ Old Min. Ssrv. Min. BaN,
Max. a Max,
Max. Max.
500 AQ Main Bearings and Crankshaft .0011L

(Except Fron .00411, .00501,
Main Bearings and CrankshaPt 11L

.0a41L .0050L
AQ front Main B~arings and .0021L

Crankshaft .00461, .0050L
AQ-AZ Diameter of Bearing

Journal on 2.6245
(2-5/8 Main) -Z~6Z6 (E)
’’‘I’’’’’’’’
A& Diameter of t Main

Bearing J on Crankshaft 2.6240
(2-5/8 Main) 2.6250 (E)
A9-Az Crankcase Bore 2.9365
Diameter 2.9375 2.9390
~coa AQ-AZ
"I
Connecting Rgd Bearing and .00081,
.........j Crankshaft .00381, .00501,
AZ Diameter of nnecting Rod 2.1235

Journal on tkshaft i~2-1/8) 2.125 (E)
iiiiijijijj As Diameterof nnectin~Rod 2.2485

Journal on Ikshaft ~2-1/4) 2.250 (E)
Connecting
E
I" Bearing Bore
Diameter(2-1A8 (Measure at
ilitiliiili Axis 300 on side)
Connecting Bearing Bore
Diameter (2-1 (Measure at 2.4205
Illillll I- Am:is 300 on side)
502 a~-nz Connecting Side Clearance .004L
.010L .0161,
503 jBi6~:ij AQ-AZ Connecting -Alignment .010 in 10 Inches
504 iS~ibiil AQ-Az Connecting -Twist .012 in 10 Inches
Crankshatt
Ru~-Out At Center
i;
i
MainBearings
ilililiiii
Mounted on Nb, 1 and 4 Journals
Illflllill Max. Run-OutlNo. 2 and 3
jiiiifiiii Journals .005 .0075
tltiiiiiii
tifiiiiili Mounted on 1 and 3 Journals
iiiftlliii Max, Run 2 Journal .003 .0045
iiiiiiiiii
Mounted on 2 and 4 Journals
Max. Run 3 Journal .003 .0045
AQ Mounted on .2 and 5 Journals

Max. Run-Ou 1 Journal .002 .002
Mounted on .2 and 5 Journals

Max, Run-Out ,3 Journal .005 .0075
Mounted on Nb. 2 and 4 Journals

SSP1776
2-1
Island Enterprises
PART II INTEGRAL ACCESSORY DRIVE ENGINES
Ref. Ref. Cbart Nomenclature Dimensions Clearances

Mfr. Mtr.
Ne~a Old Min. Serv. Min. Serv.
8 Max. a Max.
Max. Max.
506 A& (Cont.) Mounted on No. 3 and 5 Journals

506 AQ´•AZ Crankshaft and Crankcase .005L

:::::.:::j Front End Clearance .0I6L .026L
507 AQ Clearance Front Face of

Crankshaft Oil Slinger to
Front Face of Recess in
Crankcase (Crankshaft .002
iiiiili~iii Against Thrust Face) Tdbi- (A)
Crankshaft Propeller Flange
Run-Out .005
Gear and .014T

509
1’: AQ Starter Ring
Support 71TZZT (A)
.002L
sla
I: iaEl~iil’ ’ZA-QA Crankshaft Timing Gear
and Crankshaft .0005L (A)
Tappet Body and Crankcase .0010L

’ ZA-QA T6im6~ .004L
AQ-AZ O.D. of Tappet .9990

.9987
AQ-AZ I.D. Tappet Bore in 1.0005

Crankcase 1.0018 1.002
514
E:iB1~%´•’ ’ ’ ’ ~’ ’ ’ ’i AQ-AZ Camshaft and Crankcase .002L
.004L .006L
515 fiii~8isiil AQ-AZ Camshaft End Clearance .002L

.009L .015L
AQ-AZ Camshaft Run-Out At Center .000

B~uiqlaum´•l ~UUf .m6
AQ-AZ Counterweight Bushing and.0013T

Crankshaft .0026T (A)
518 A&-AZ Countenveight Roller End .003L

I:’ Clearance ,025L .038L
AQ-AZ Counterweight and Crankshaft

Side Clearance (Measure Below .003L
Ijliiilili Roller Next To Flat) ;013L .017L
520 :L9~6: A&-AZ Countennreight Bore and .0002L

liii~iiiltl Washer O.D. (A)
AQ-AZ LD. Counterweight Bushing .7485

Ijli;ilili .7505 .7512
AZ I´•D´•
Counterweight Bushing 1.030
(2nd Order) 1.032 1.0327
A~-AZ O.D. of Countenn~eight Roller
´•i:
Ig~il Az Thrust Bearing and Propeller .0001L
6291’’ ’ Shaft .0012L .002L
SSP1776
2-2
Island Enterprises
EERV ICE TABLE OF LIMITIB
PART II INTEGRAL AaCESSORY DRIVE ENGINES
SECTION I CRANKCAS~, CRANKSHAFT, CAMSHAFT
net. Ref. Chart Nomenclature I Dimendbnl Cleuances

Mfr. Mfr.
New Old I I I Min. Serv. Min. I Serv.
a I Max. Q Max.
Max. Max.
524 AZ Propeller Shaft and Rear .0015L

I :iSfil~1:/ Bearing ,0030L .0040L
524 Propeller Shaft Bearing Bore 2.1865

Diameter a11875 2.1885
Thrust Bearin~ and Crank- .0006L

case .oolOT (A)
Thrust Bearin~ and Thrust Bear-

""i’ li~fiiiiiif
ing Cap ClamPFit (Shim
this Fit)
to .003T
.005T (A)
527 Thrust Beari~ Tilt At 4 Foot .027 Tilt
528 Thrust Bearingf End Play .006

.008 .010
529 AZ Crankshaft and Crankshaft I I I .0002T

Front Bearing .0015T (A)
lir:i
o:I
500
Section Thru Prop. S,haft, Crankshaft and Front Bearings
8SP1776
2-3
Island Enterprises
BERV ICE TABLE OF LI~IITE)
522
,501
Connecting Rod, Counterweights and Related Parts
SSP1776
2-4
Island Enterprises
sERV ICE TA~LE OF LIMIT8
PART II INTEGRAL AC~ESSORY DRIVE ENGINES
-I
3;2~ j ii I
i17 i
i
´•"´•I~´•,
d f
:11.- i
o o
--;-I Fi
ol tqi
Longitudinal $ction Thru Engine
SSP1776
2-5
Island Enterprises
501
O
_4
Connecting Rod Bearing, Tappet Body and Crankcase
SSP1776
2-6
Island Enterprises
sERV ICE TL~BLE OF LIMIT8
SECTIO~ II CYLINDERS
net. Ref. Chart I Nomenclature Dimeneiona Clearmes~
Mfr.
New Old I I I Min. Serv. Min. Serv.
O I Max. a I Max.
Max. I I Max.
600 AQ-AZ Connecting ROd and Connecting Bushing To Be

Rod Bushing I Burnished In Place
AQ-AZ Finished I.D. ~f Connecting 1.1254

Rod Bushing 1 1.1262
601 AQ-AZ Length Between Connecting 6.7485

Rod Bearing 6.7515
602 li:g~ti: AQ-AZ Connecting Rbd Bushing and I I I .0008L

Piston Pin I I I .0021L .0025L
603 lli8~:Zlill AQ-AZ Piston Pin anci Piston .0003L

.0014L .0018L
AQ-AZ Diameter of Piston Pin 1.1249

Hole in Piston 1.1254
AQ-AZ Diameter of Piston Pin

1.12461.1241
604 11;~3 AQ-AZ Piston and Piston Pin Plug I I I .0002L
.0010L .002L
AQ-AZ +Diameter of ~iston Pin Plug 1

1.12421.1247
605 AQ-AZ Piston Pin and, Piston Pin
Nitride(l and Chrome .0005L
CylindersPlug .0025L .005L
AQ-AZ *Diameter of Piston Pin Plug 1

.5655.5665
See latest edition of Service Instruction No. 1267.
606 AQ-AZ Piston Ring a~Sd Piston Side I I I .0025L
Clearance
(Toi, Ring Comp.) .0055L .008L(B)
606 AQ-AZ Piston Ring arjd Piston Side I I I .000L

Clearance Ring Comp.) .004L .006L(B)
606 AQ´•AZ PistonRingar Piston-Side .002L

Clearance(Oil Regulating) .004L .006L(B)
607 AQ-AZ Piston Ring GCp (Compression)

Chrome C~lin(lers I 1 .020
(Straight Barr4ls) I 1 .030 1 .047
AQ-AZ Piston Ring GSp (Compression)

liiflifi~li (Choke Barrel~) .055 .067
AQ-AZ Piston Ring GCp (Oil Regulating) I I 1 .015

(All Barrels) I I 1 .030 .047
For Cholre Barrels Ring gap is measured wit~in 4 inches from bottom. Ring gap at top of travel must not be
less than .0075.
SSP1776
2-7
Island Enterprises
Rei. net. Chart Nomenclature Dimensions Clearances

Mfr. Mir.
Max. a Max.
Max. Max.
and Piston Aoolication Min. Piston Diameter Cylinder Barrel

ax.
Clearance
ifiiii:liiiiiil Engine Chartj I I I I Type of Maximum PistonSkirt
Code Letter Piston Number Top Bottom Type of Piston Su rf ace Diameter Si Cyl.
sos ~!siiliilAa,AZ 76966, LW-1o545 5.0790 5.1090 Forged-Cam N-C 5.1305 .018L
609608610:5~22i:i:
NOTES:
To find the average diameter of cylinder in an area 4" above service is.0o45 inch.
bottom of barrel: First, measure diameter at right angles
from plane in which valves are located. Second, measure See Service Instruction No. 1243 for identification of forged
diameter through the plane in which valves are located. Add pistons. The suffix "S" that will be found with the part
both diameters; this sum, divided by 2, represents the average number on 76966 and LW-1o545 pistons indicates the piston
diameter of the cylinder. weight is within the limits specified for any group of pistons
and may be substituted for any like piston on a particular
Cylinder Barrel: N=nitride hardened, C=Chrome plated. engine. Other pistons are manufactured within weight limits
that do not require any weight controlled piston for
To find the out-of-round, measure diameter of
average replacement.
cylinder in 4" above bottom of barrel: First, measure
an area
diameter at right angles from plane in which valves are Piston diameter at top is measured at top ring land (between
located. Second, measure diameter through the plane in top and second compression ring grooves) at right anles to
which valves are located. Difference between diameters must piston pin hole; diameter at bottom of piston is measured at
not exceed .0045 inch. the bottom of the piston skirt at right angles of the piston
pin. See Service Instruction No. 1243 for illustration.
Maximum taper and out-of-round permitted for cylinder in
Chart Nomenclature I Dimensions Clearances

Mfr. I i Mfr.
Max. Max.
Max. Max.
611 A&-AZ Exhaust Valve Seat and .0075T

CylinderHead .OllT (A)
AQ-AZ O.D. Exhaust Seat 1.9355

1.937
AQ-AZ I.D. Exhaust Seat Hole 1.926

in Cylinder Head 1.928
612 i5;2;4~:iAQ-AZ Intake Valve Seat and .0065T

iljljljljljl CLlinder Head .010T (A)
AQ-AZ O.D. Intake Seat 2.2885

2.290
iiirilitililitl AQ-AZ LD. Intake Seat Hole 2.280

618 Exhaust Valve Guide and .0011T

Cylinder Head .0030T (A)
618 AQ-AZ O.D. Exhaust Valve Guide
AQ-AZ I.D. Exhaust Valve Guide .6933

Hole in C~linder Head .6943
SSP1776
2-8
Island Enterprises
BERVICE TACLE OF LIMITI
PARTIIINTEGRALACCESSORYDRIVEENGINES
SECTION! II CYLINDERS

Mfr. Mir.
B Max. P Max.
Max. Malt.
614 Intake Valve duide and .0010T

Cylinder Head .0025T
AQ-AZ O.D. Intake V/llve Guide

.5938
AQ-AZ I.D. Intake V ve Guide Hole .5913

in Cylinder .5923
615 A&-AZ Exhaust Valve Sbm and .0037L

Valve Guide .0050L (A)
AQ-AZ O.D.Exhaust alveStem .4955

.4965 .4937
615 AQ-AZ Finished I.D. aust Valve .4995

jiiiiij iii Guide .5005
:i:i:i:i:i:i:il 1/2 inch diameter exhaust valves may have etrhaust valve guides that are .003 in. over the maximum inside
~Illil´•.tllii:ldiameter limit, anytime up to 300 hours of serviice. After 300 hours of service, inside diameter of exhaust valve
guide may Increase .001 In. during each 100 hburs of operation up to the recommended overhaul time for the
_.’."" engine,
iiiiiiiiiliiill or not to exceed .015 inch
recommended overhaul time.
over the
b~sic I.D. See latest edition of Service Instruction No. 1009 for
616 A&-AZ Intake Valve and .0010L

Valve Guide .0028L .006L
AQ-AZ O.D. Intake Vglve Stem .4022

.4030 .4010
616 AQ-AZ Finished I.D. take Valve .4040

Guide .4050
""1igs~i’~i‘ : : ZA-Q
Intake and Exhaust Valve and
Valve Cap (Rotator .000
5pe With Diameter Head) .005L
AQ-AZ Dry Tappet Cl$arance .040

.105
6191:~iliRiI A&-AZ Valve Rocker and Valve .0001L

i-i ii Rocker .0013L .0025L
AQ-AZ Finished I.D. Valve Rocker

Shaft in Cylinder .6246
Hsaa .szsl .sz?o
620 AQ-AZ Valve Rocker and Valve .0007L

Valve Rocker .0017L .004L
Bushing .6265 .6270
AQ-AZ O.D. Valve kel Sha~t .6241

.6245 .6231
621 832: Valve Rocker ~ushing and Bushing Must Be

Valve Rocker Burnished In Place
AQ-AZ Valve Rocker aft Bushing .0022T

and Cylinder .0038T (A)
.7380
623 tlilff~3lil AQ-AZ Valve Rocker gnd Cylinder Head .D02L

Side Clearan~e .020L .024L
SSP1776
2-9
Island Enterprises
sERV ICE TABLE OF LIMITI
INTAKE VALVE CAP CLEARANCE-

ROTATOR TYPE
623
617 ~1 (n\ $i
614
613\\’’~’
622
CHOKE
-607
OPTIONAL
605
601
609
TAPER
SSP1716
2-10
Island Enterprises
sERVICE
tLIBLE OC LIMITB
SECTION TII GEAR TRAIN
net. Ref. Chart Nomenclature Dimendon~ I

Mtr. Mfr.
New Old I I I Min. Secv. I Min. I Serv.
a Max. a I Max.
Max. Max.
700 ng´•nz Oil Pump Shaft and .0010L

iiiilii~ili Oil Pump .0030L .004L
701 AQ-AZ Oil Pump Shaft and .0035L

Oil Pump r 0050L .0065L
7a3 AQ-AZ Oil Pump Im -Diameter .002L

Clearance .008L
Impellers
18~1 Oil Pump
Clearance
Side .002L
.0045L .005L
Width of Oil Pbmp Impellers 1.372

1.374 1.371
705 Oil Pump privenImpeners and .0005L

Idler Shaft IU02L .004L
722 AQ-AZ Fuel Pump Idl Gear and .001L

Shaft 1003L .005L
725 I:i:1:i:i:i:i:1:l A&-AZ Fuel Pump Idler Gear End .002L

Clearance I I I .028L .038L
726 lifiii~9;iiil AQ-AZ Fuel Pump Drilve Shaft Gear .0010L

and Crankcase .0025L .004 L
727 AQ-AZ Fuel Pump Drive Shaft Gear .0015L

Front Governdr Drive Idler Shaft .0010L

i’l aq (Both Ends) a d Crankcase .004L
731 Aq´•AZ Governor Driven Gear and .0010L

732~1III AQ-AZ Propeller Governor Drive Gear .008L

I:´•s~q:1:1:1: :i D~ive Shalt and

.0035L.0015L .006L
759 AQ-AZ Vacuum and draulic Pump .0010L

Drive Shaft Gear and Crankcase .0025L .006L
760 i6~ai AQ-AZ Vacuum and draulic Pump

Drive Shaft Gelar End I I I .018L
761 AQ-AZ Magneto Coupling and Crankcase .0010L

.D030L .004L
762 AQ-AZ Magneto Drivel Shaft Gear and .0010L

763 AQ-AZ Accessory DriJe Gear

Intermediate ahd Crank- .0010L
case (2 Places) I I I .0030L .005L
764 A&-AZ Accessory Dri~e Gear End I I I .016L

AQ-AZ Accessory Dri~e Gear and .0010L

Crankcase I I I .0030L .005L
:I(
SSP1776
2-11
Island Enterprises
Ref. her. Chart Nomenclature Dimensions Clearances

Mfr. Mtr.
NePrr Old Min. Serv. I Min. Serv.
g, I Max. I Max.
Max. Max.
766
1::%~´•) AQ-AZ Compressor Drive Shaft
and Compressor Drive Adapter
.0010L
.0030L .005L
761 A&-AZ Compressor Drive Shaft End .0005

Play .0295 .040
AQ-AZ Breather Slinger Gear and .0021L

ShaPt I .005L
169/: i81Q~iil AQ-Az Breather

Play
Slinger Gear End .008
.017 .025
770
li iE)S~ii Propeller Shaft Drive Gear
and Bearings
.0025L
.0050L .0060L
771 li’i AZ Propeller Shaft Drive Gear .005

End Play .015 .022
172 Propeller Shaft and Rear .0015L

Bearing .0030L .0040L
AZ Alternator Driven Gear and .0025L

Adapter Bushing .0045L .0065L
774 AZ Starter Drive and Alternator .004

Drive Gear End Play .008 .011
176
/d
Starter Driven Gear and .0015L
ifiitiilif Adapter Bushing I I I .0030L I .005L
starter Drive Shaft (Slip .0015L

Coupling) and Crankcase .0040L .007L
Starter Idler Gear and Idler .0005L

iiiiijijii Gear Bearing I I I .0020L I .005L
SSP1776
2-12
Island Enterprises
IE#VICE TAglE OF IIMITI
PART II INTEGRAL ACiCESSORY DRIVE ENGINES
SECTION ITI GEAR TRAIN
-x‘I~
-:I
711
770
Prop. Shidt Drive Gear
SSP1776
2-13
Island Enterprises
BERV ICE TABLE OP LIMITB
CCc~
ALTERNATOR
ij
773ii
774
;i ;´•c:;
~1
774 jJ
i~
776
’´•CX:
STARTER~r I I I L775
772
Alternator, Starter and Propeller Shaft
SSP1776
2-14
Island Enterprises
sERV lee TAleLE of LIMITEI
SECTION qI GEAR TRAIN
Lj
CZ
761 762
_j
7631
--I
;r f
1_1_17
Fuel Pump, Magneto, Vacuum and Hydraulic Pump

SSP1776
2-15
Island Enterprises
731
’131
732
TIGO-541 TIGO-541
PROP GOVERNOR PRO~ GOVERNOR
71(
BREATHER GEAR FUEL PUMP IDLER GEAR
TIG-541 ONLY
Gov., Fuel Pump and Breather Gear
SSP1776
2-16
Island Enterprises
sERV ICE TAIBLE OF LIMITI
SECTION II/I GEAR TRAIN
~7(7
766
165
-COMPRESSOR
DRIVE
O
a
O Il
7051 r703
704
739
700
701
Oil Pump, Tachometer and Compressor
SSP1776
2-17
Island Enterprises
BERV ICE TABLE OF LIMITE
SECTION IV BACKLASH
Rei. I Ref. Chart Nomenclature Dimensions Clearances

Mfr. Mir.
New Old Min. Serv. Min. 1 Serv.
B Max. Q Max.
Max. Max.
808 AZ Oil Pump Impellers- Backlash I I 1 .008

.013 .020
822 Propeller Governor Idler and .005

Camshaft- Backlash .015 .020
823 AZ Propeller Governor Drive and .004

Idler Backlash .008 .015
825 AZ Crankshaft Timing Gear and .005

Camshaft Backlash .015 .020
~stitilA&-Az Accessory Drive and Accessory .004 L

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

mediate and Idler Spline .002
Backlash .005 .007
828 AZ Accessory Idler and Vacuum

and Hydraulic Pump Gear .004
Backlash .011 .016
829 PropellerShaft Reduction

Gear Total Backlash At 4 Foot .38
Radius .75 .90
830 I~l:fi:i:ilAZ Starter (Bendix Slip Coupling)

and Starter Drive Gear .016
Backlash .031 .045
831 :10~8 AQ-AZ Accessory Idler and Magneto .005

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

and Alternator Drive Shaft Gear .004
-Backlash .008 .015
833 AZ Alternator Drive Gear and
j
ilili~iiii Starter and Alternator Drive
Shaft Gear Backlash
.003
.008 .012
AQ-AZ Fuel Pump Idler Gear and

Vacuum and Hydraulic Pump .002
Drive Gear Backlash .015 .020
835 irb~iiij AQ-AZ Fuel Pump Idler Gear and .0006

Fuel Pump Drive Backlash .0160 .021
836 AQ-AZ Mag;neto Drive Shaft Gear

andMagneto Coupling .0010
Spline ]Jacklash 10045 .0075
837 :nss:i: AQ-AZ Accessory Drive Gear and

Compressor Drive Shaft .0040
Spline Backlash .0076 .014
838 t7ss~rtrl AQ-AZ Crankshaft Gear and Accessory

Drive Shaft Gear Spline .0040
Backlash I I 1 .0076 .014
839 AQ BreatherSlinger Gear and
I8:i Accessory Idler- Backlash .015 .020
SSP1776
2-18
Island Enterprises
BERVICE TABLE OP LIMITB
SECTION ~V BACKLASH
net. I Ref. Chart Nomenclature Dimensions I Clearances

Mh´•. Mh´•.
Ne~R Old I I I Min. Serv. Min. I Serv.
a Max. a I Max.
Max. I I Max.
840 Front Cranksh~ft Spline Bushing

and AltRmator gnd Starter Shaft .001
Gear Spline B~cklash 1 1.005 .006
&11 Propeller Shaft Gear and

Alternator and Starter Shaft .001
Gear Spline B~cklash .004 .006
842 AZ Propeller Shaft Gear and .008

Driven Gear .014 .016
843 AZ Starter Slip Gear and .0002

Starter Idler .0045 .0075
844 I:98~91:.:IAZ Bendix Starter Motor Shaft Gear .0002

and Idler .0045 .0075
845 tiSf~:1:ilAZ Propeller Shaft line and

Propeller Shaft n Gear .008
Spline Backl .011 .015
(When At O.D. Of
Propeller Gear) .020
.028 .036
IDLER
ACC. DRIVE INTERMEDIATE
ACCESSO~Y DRIVE
BREATHER SLINGER~ ~-MAGWETO DRIVE
CRANKSHAFT
COMPRESSOR DRIVE SHAFT
CRANKSHAFT
IDLER
GOV: DRIVE~ rr BS1~/ CAMSHAFT
HYD. a VAc.
FUEL
.U\Mpjl OIL PUMP DRIVE
OIL PUMP
PROP. GOV. IDLER
PROP GOV DRIVE
T10-541
(Access~ory Drives)
SSP1776
2-19
Island Enterprises
BERVIOE TABLE OF LIMITI
SECTION IV BACKLASH
827
GOV. DRIVEN rACC. IDLER
823
MAG DRIVESHAFTGEAR r i ~-ncc. DRIVE GEAR INTER.
MAG COUPLING
SECTION D-D
GOV. DRIVE
ACC. DRIVE
TOTAL BACKLASH 829
SECTION B-B SECTION C-C
I SHAFT DRIVEN
DRIVE
DRIVENKSHAFT
)i! O
MAG. DR. SHAFT GEAR
B B
O
COMPRESSOR SHAFT
1C1-I
0.
ACC. IDLER
&VACUUM
STARTER DRIVE
PROP SHAFT DRIVE G

ALTERNATOR
DR.STARTERIDLER 538-’iPMUP
FUEL
OIL PUMP
CRANKSHAFT
i-:
ALTERNATOR a STARTER
832 KSHAFT
STARTER DRIVE SHAFT GEAR
STARTER COUPLING
STARTER
DRIVECAMSHAFT ~I
830
844
OIL PUMP DRIVE
STARTER MOTOR-/~ OIL PUMP DRIVEN

SECTION A-A VIEW~-TJLD
(Accessory DriveJ)
SSP1716
2-20
Island Enterprises
BERVIC´• TABL6 OP LIMITB

SECTION V SPECIAL ITORQUE REQUIREMENTS
Rel. Ref.
Thread
New Old Chart Size Nomenclature Torque LMte
900 nQ-nz 3/8-2~ Rod Nuts Tighten

oLe 2.255 -2.256
AQ-AZ 3/8-2c~ to Nut (To attach drive

member to magneto) 300 in. Ibs.
904 AQ-Az 10-32 to ´•mate Screws 15 in. Ibs.
905 AQ-AZ 1/4-20 rBox Screws 50 in. Ibs.
907 AQ-AZ 18MM Plugs 420 in. Ibs.
909 As Alternator Pulley Nut 450 in. Ibs.
AZ Alternator Quill Shaft Nut 474 in. Ibs.
910 iE16aI AQ-AZ 1/4-28 Alternator Output Terminal

Nut 85 in. Ibs.
911 liriss;sitil AQ-AZ 10-32 Alternator Auxiliary Nut 30 in. Ibs.
912 jililjili A$-AZ 5/16-24 Starter Terminal Nut 2 in. Ibs.
913tEIFjrt: A&-AZ 1/16-27 NPT I Piston Cooling Nozzle in Crankcase 100 in. Ibs.
9151:i:868 AQ-AZ 3/4-16 Oil Filter Bolt (AC Can

Element 300 in. Ibs.
AQ-AZ 13/16-16 Oil Filter (Throw Away Type) 240 in. Ibs.
AQ-AZ 3/4-16 Converter Stud 720 in. Ibs.
917 AQ-AZ 1.00-14 Oil Cooler Bypass Valve 300 in. Lbs.
918 AQ-AZ 1 1/4-12 Oil Pressure Relief Valve 300 in. Ibs.
919 Jij’’’"’ AQ-AZ Hose Clamps 45 in. Ibs.
921 AQ-AZ Exhaust V-Band Torque Data
T-Bolt Split 1/4In. Drilled Hex Nut

CouplingSize Avco Lycoming Vendor Type Locknut With Safety Wire
Tube OD Part No. Part No. Torque In. Lbs. Torque In. Lbs.
2.00 in. LW-12093-5

In. 1 85 75
2.25 in. LW-12125-3 197-225
922 AZ Turbocharger V- Torque Data
Turbocharger Model No. V Part No. V´•Clamp Diameter Torque In. Lbs
T18A21* 925 9.25 in. 40-60
AiResearch turbocharger.
See latest edition of Service Instruction No. 1 for assembly procedure.
923 AZ 2 1/16-12 Propeller Shaft Lock Nut 1000 FT. LBS.
924 AQ-AZ 7/16-20 Fuel Injector Nozzles (In

Induction Housing) 210 in. Ibs.
240 in. Ibs.

925
:~:I 3/4-16 Compressor Drive Pulley Nut
SSP1776
2-21
Island Enterprises
8 ERV I OE TABLI OF L I nn I ´•rs
PART II INTEGRAL ACCESSORY DRIVE ENGINES~
Ref. Ref.
Thread
Chart Size I Nomenclature Torque Limits
New Old
926 AZ 5/8-18 Starter Drive Shaft Gear Nut 900 in.lbs.
927 AQ-AZ 1/4 Bolts Crankshaft Gear 96 -120 in. Ibs.
928 I.iifiii:iiiiiiil AQ-AZ 3/8-16 Cylinder Hold Down Studs


929 AQ-Az 3/8 Cylinder Hold Down Nuts 300 in. Ibs.
1/2 Cylinder Hold Down Nuts 600 in. Ibs.
Cylinder Hold Down Nut Tightening Procedure See latest edition of Service Instruction No. 1029.
re
932 AQ-AZ 5/16-18 Exhaust Transitions Studs
3/8-16 Exhaust Transitions Studs

SECTION V SPRINGS
Length COMP. LOAD

Avco Lye. Wire At Comp. Mfr. M~. Serv.
Chart Nomenclature Part No. Dia. Length Min. Max. Max.
950 Outer Valve Spring LW-11798 1 .192 1.610 in. 136 Ib. 144 Ib. 133 Ib. min.
76351
ii_´•ii .177 1.610 in. 136 Ib. 144 Ib. 133 Ib. min.
951 AQ-AZ Auxiliary Valve Spring LW-117991.148 1.48 in. 86 Ib. 94 Ib. 83 ib. min.
76352 .142 1.48 in. 86 Ib. 94 Ib. 83 Ib. min.
952 AQ-AZ Oil Pressure Relief

Valve
Avco Lycoming
Part Numbers I
68668 Purple 2.04 .054 1.30 in. 7.11b. 7.8 Ib. 7.11b. min.
LW-11713 White 2.12 .059 1.44 in. 10.79 Ib. 11.92 Ib. 10.5 Ib. min.
LW-11138 None 2.64 .051 1.44 in. 8.55 Ib. 9.45 Ib. 8.3 ib. min.
AQ-AZ Fuel Drain Check

Valve Spring .047 .75 in. 5.50 Ib. 6.50 Ib. 5.35 Ib. min.
956 AQ-AZ Oil Filter Relief

Valve Spring .054 1.93 in. 3.05 Ib. 3.55 Ib. 3.00 Ib. min.
Shroud Tube Spring .105 2.09 in. 14 Ib. 16 Ib. 13 Ib. min.
95a AQ-AZ Pressurizing Valve Spring .032 .455-.485 .65 Ib. .75 Ib. .63 Ib. min.
959 Spring Between Crankshaft

and Starter and Alternator
Drive Gear .13 1.40 in. 48 Ib. 52 Ib. 46 Ib. min.
960 LI:I:I:I:I:f:I:l AZ Alternator Drive

Coupling Spring .047 .83 in. 10 Ib. Illb. 9 Ib. min.
SSP1776
2-22
Island Enterprises
sERV ICE TABLE OF LIMITs
STANC)ARD TORQUE
UNLESS OtHERWISE LISTED
TABLE Il
TABLEI
PIPE PLUGS
Torque
Toraue Torque Th read In. Lbs.
1116-27 NPT 40
10 49 1/2 900 75
118-27 NPT 40
1/4 96 9116 1320 110
1/4-18 NPT 85
5/16 204 17 5 1800 150
3/8-18 NPT 110
3 360 30 3 3240 270
1/2-14 NPT 160
7116 600 50
3/4-14 NPT 230
1-111 NPT 315
TABLE IV
TABLE III
FLEXIBLE HOSE
OR TUBE FITTINGS
Thd. Pitch On Part ANGLE OF TU RN Torque

To Be Ti tened Aluminum pper
res er nc Asbestos Asbestos
(-3) 3/16 3/8-24 30
8 1350 670 (-4) 1/4 7/16-20 30

10 1350 670 (-5) 5/16 1/2-20 35
12 1800 (-6) 3/8 9/16-18 35
1 -8 1/2 3/4-16 60
16 2700 1350
-10 5/8 7/8-14 70
18 2700 1350
20 27 135
24 3 1
28 3600 1
NOTE TABLE V
Install all crushtype gaskets except the self centerillg STUDS

MIN. DRIVING TORQUE
type, with the unbroken surface against the flange Of
the plug or part being tightened against the seal. Tu~tn Torque
the part until the sealing surfaces are in contact anid Threads In. L~b s.
appropriate thread size. 1/4-20 15
5/16-18 25
SSP1776 2~23
Island Enterprises
BERV ICE TABLE OF LIMIT8
905
:10
!I)-sao
I;I "g57
2-24
Island Enterprises
sERV ICE TAJBLE OF LIMITs
903
,j
904
2-25
Island Enterprises
921
’’II
I
COMPRESSOR DR.
i‘
I i
PISTON COOLING NOZZLE
-r~
E=~
L.-i
911
910
2-26
Island Enterprises
OERVICE TA~LE OF LIMITI
PART II INTEGRAL ACqESSORY DRIVE ENGINES
SECTION V SPECIAL TbRQUE REQUIREMENTS
ALTERNATER
~irl II 999
i
960
´•;~:I
:~t)
i4j":I:
~I
~´•´•S;
STARTER
912
2-27
Island Enterprises
sERV ICE TABLE OF LIMITs
2-28
Island Enterprises
IERVIOE
TAI~LE OF LIMITI

SECTION V SPECIAL ~ORQUE REQUIREMENTS
FUEL INJECTION NOZZLE ASSEMBLY
Engine Acces~ories and Hardware
229
Island Enterprises
951
951 ~-950
950
VALVE SPRINGS
955
OIL RELIEF VALVE
FUEL DRAIN CHECK VALVE
952
OIL PRESSURE RELIEF VALVE
Engine Springs and Hardware
2-30
Island Enterprises
O BRV I OE TAP)La OF LlnnlT8
CHART MODELS
E 35 ALL
El -435-C2B -C2B2-6
H IGO-480 ALL
H1 -480-0
H2 -Q80-F1A6 -F2A6 -F4A6 -G2D6 -G2F6
H3 -480-G1H6 -G1D6
H4 -480-D1A (Crosswise Accesso H
H5 -480-G1B6 (Crosswise Accesso
P -480 IGSO´•480
P1 IG -480
AB IG -540
AC -540
NOTE
In "Chart" column, a number appearing after a letter shows exception to basic model.
SECTION I 500 SERIES CRANKCASE, CRANKSHAFT CAMSHAFT
SECTION III 700 7000 SERIES GEAR TRAIN
SECTION V 900 SERIES TORQUE SPRINGS
(A) These fits either shrink fits controlled by machining, fits that may
are
readily be or fits where wear does not normally occur. In each

adjusted,
case, the fit must be held to manufacturing tolerance.
(B) Side alearance on piston rings must be measured with face of ring nush
with piston.
(C) ReplaFements to correct these items must be made to give uniform

backli~sh within 0.001 between the stationary gear and pinions, and
withig 0.001 between the pinions and the ring gear.
(D) These dimensions shown are measured at bottom of piston skirt at right
angles to piston pin.
(E) PermiSsible wear of the crankshaft (rod and main bearing journals) to
be milius 0.0015 on the diameter.
(L) Loos$ fit; wherein a definite clearance is mentioned between the mating
surfa8es.
SSP1776 January 31, 1980*
Indicates cut-off date for data retrieved prior to publication.
Island Enterprises
EERVICE TABLE OF LIMITE
PART IIIGEIARED ENGINES
SECTIONICRANKCASEICRANKSHAFT,CAMSHAFT
Ref. Chart Nomenclature Dimensions Clearances

Ret.
I I I Min. Serv. Min. Serv.

New Old
a I Max. I a Max.
Max. Max.
500 All Main Bearings and .0015L

iilfifiiiiiiil I Crankshaft .0045L .0060L
H3-H5-P-AB-AC Main Bearings and Crankshaft .0011L

iiliil:lti (Except Front) I I I .0041L .0050L
H3-H5-P-AB-AC Front Main Berjrings and .0011L

Crankshaft I I .0041L .0050L
ifilililii
E-H-P Diameter of M~in Bearing 2.3745
Journal on Cra~ikshaft 2.376 (E)
500 E-H1-H2-H4 Crankcase Bearing Bore 2.566

Diameters (All) 2.567 2.5685
H3-H5-P-AB-AC Crankcase Bearing Bore 2.6865

Diameters (All) 2.6875 2.6890
501 ALL Gonnectlng RoB Bearings aOOBL

~ri and Crankshaft .0038L .0050L
: : : 1,: ALL Diameter of Cdnnecting Rod

Journal on Crai~kshaft (2-1/8 in.)
1 2.1235
2.125 (E)
501 Connecting R~d Bearing Bore
E
Diameter(MeaSured at axis 2.2870
300 on each si~e) 2.2875
502 ALL Connecting Rod Side Clearance .004L

.010L .016L
503 Connecting Roa Alignment .010 in 10 Inches
504 Connecting Rod Twist .012 in 10 Inches
505 Crankshaft Rub-Out At Center

Main Bearings

Max. Run-Out No. 2 and 3 Journals .005 .0075
Mounted on Nb. 1 and 3 Journals

Max. Run-Out ~o. 2 Journal .003 .0045
Mounted on N~. 2 and 4 Journals

Max. Run-Out f~o. 3 Journal .003 .0045
506 ALL Crankshaft and Crankcase Front .006L

510 H1-H2-H3 Crankshaft Timing Gear and .0015L

-HS-P-AB-AC Crankshaft Timing Gear and .0000

511 Tappet Body ahd Crankcase .0010L

.0033L .004L
SSP1776 3-1
Island Enterprises
ReT. Ref. Chart Nomenclature Dimensions Clearances

Mir. Mfr.
Now Old I I I Min. Serv. Min. Serv.
Max. a Max.
Max. Max.
511 O.D. of Tappet .7169

"3~’’’ .7177 .7166
I.D. Tappet Bore in .7187

ALL Tappet Plunger Assembly .0010L

iiii and Body (Hyperbolic) .0067L .0087L
513 Tapper Socket and .002L

Body (Hyperbolic) .007L .009L
514 Camshaft and Crankcase .002L

Illlil.lilllll( I I I I .004L I .006L
515 Camshaft End Clearance .002L

.009L .015L
516~9i:I:I ALL Camshafr Run-Out At Center .000

Bearing Journal .001 .006
ALL
518517 :;871LA
Counterveight Bushing and .0013T
:B~1:I:I CounteMeight Roller End .007L
519 Counterweight and Crankshaft .003L

Side Clearance" .013L .017L
Measure below roller next to flat.
sao Counterveight Bore and .0002L

Washer O.D. .0030L (A)
521 I.D. ofCounterweight .7485
Bushing .7505 .7512
522 O.D. of Counterweight Roller

(P/N 69433) (See latest edition .5045
of Service Instruction No. 1012) .5050
AC I O.D. of Countenveight Roller

ALL O.D. of Counterweight Roller

523
I Thrust Bearing and Propeller .0000
Shaft .0012L .002L
526 Thrust
~vu:´•:´•: Bearing and Thrust Bearing .003T
Cap Clamp Fit (Shim to This Fit) .005T (A)
527 Thrust Bearing Tilt .027 Tilt
SSY1776 3-2
Island Enterprises
88RV ICE T~BLE OF LIMIT8
SECTIONICRANKCAQE,CRANKSHAFT,CAMSHAFT
Ref. Ref. Chart I Nomenclature Dimensions Clearances
Mfr.
Bt Max. Q Max.
Max. Max.
528 I’i~6i:i,l ALL Thrust Bearing End Play .006

iifililtili .008 .010
530 ALL Propeller Sha~tRun-Out

(Rear Cone Li3cation) .003
531 ALL Propeller Shaft Run-Out

(Front Cone ~ocation)
(Propeller Shrift Installed) I I I 1 .007
532:Tj~7 E-H1-H2-H3 Starter Jaw a~d Crankshaft .0005L

.0040L (A)
533 I:iSi08: ALL Thrust Beari~g and Reduction .0006L

Gear Housing .0024L .0035L
534 :~89i:llALL Crankshaft add Crankcase .0010T

Front
Bushing~ .0025T (A)
535 81iu: ALL Pinion -End earance .011

.016 .030
536 ALL I Pinion Shaft rind Cage (See

latest edition ~f
Service .0001T
Instruction Nb. 1236) .0005T
ard
""Yis~it:i il
ALL Pinion Shaft Cage (See
latest edition pf Service Select for Hand
Instruction Nb. 1114) Push Fit (C) .002
5311 :~OX ALL Propeller Shaft

Bushing
and Crankshaft
I I i
.0020L
.0035L .005L
1; Isl~iiil ALL I.D. Propeller Shaft Bushing 1.251

In Cranksh 1.2525 1.253
This Diameter must be concentric

with Front Main Bearing within
.003 in. TIR.
538 ALL Stationary Gdar and Plate .000

j End ClearanCd .004 .007
539 Ring Gear and Drive Plate .000

EndClearanc~ .004 .007
540 P-AB-AC Reduction Gear Governor and

Magneto HouSing and Reduction .004T
Gear Housing Sleeve .006T (A)
541 H4-H5-P-AB-AC Rear CrankshCft Spline Bushing .0002T

and Crankshaft .0015T (A)
SSY1776 3-3
Island Enterprises
BERV ICE TABLE OF LIMITI
504
522
521
520
537
515
i a
Crankcase, Crankshaft, Bearings, Camshaft,

Tappets and Con nterweights
SSP1776 3-4
Island Enterprises
8ERV ICE TL~BLE OF LIMIT8
SECTION I CRANKCASe, CRANKSHAFT, CAMSHAFT
o a 8 o a
O
516
B B
53 is sl (8) is sl
Longitudinal Section Thru Engine,Camshaft,

Tappet Bo;dy and Crankshaft
SSP1776 3-5
Island Enterprises
535
527
5237 528
530
a 8______
531
526
538 ’535
Reduction Gear and Related Parts
SSP1776 3´•6
Island Enterprises
IERVICE TA~LI OF LIMITI
PART IIIGEARED ENGINES
532
Starter) aw and Crankshaft
SSP1776 3-7
Island Enterprises
SERV ICE TABLE OF LIMITE

Mfr. Mrr.
Now Old Min. Serv. Min. Serv.
a Max. Q Max.
Max. Max.
600 ALL Connecting Rod and Connecting Bushing To Be Burnished

Rod Bushing In Place
Finished I.D. of Connecting 1.1254

Rod Bushing 1.1262
601 Length Between Connecting
602
’a ~4li~tP-lHE Length Between Connecting
Rod Bearing Centers
Connecting Rod Bushing and

6.4785
6.7515
.0008L
Piston Pin .0021L .0025L
603 82~:i:IALL Piston Pin and Piston .0003L
´•i’~’
.0014L .0018L
ALL Diameter of Piston Pin Hole 1.1249

in Piston 1.1254
ALL Diameter of Piston Pin 1.1241

1.1246
604RiliBiiiil H-P-AB-AC Piston and Piston Pin Plug .0002L

.0010L .002L
H-P-AB-AC "Diameter of Piston Pin Plug 1.1242

1.1247
605 :983::1:IALL Piston Pin and Piston Pin .0005L
ii
Plug (Optional) .0025L .005L
H-P-AB-AC *Diameter of Piston Pin Plug .5655
E Diameter of Piston Pin

(Thin Wall Pin)
Plug .8415.56 5
.8405
See latest edition of Service Instruction No. 1267.
606 :B~Q:I:I1ALL Piston Ring and Piston Side

Clearance (Top Ring Comp.) .0025L
sos F25;i:i:IALL Piston Ring and Piston Side
Clearance (2nd Ring Comp.) .000
Full or Half Wedge .004L .0o6L(B)
Piston Ring and Piston Side
(AS APPLICABLE) Clearance (3rd Ring Comp.) .000
606’’’’’’ ALL Piston Ring and Piston Side

Clearance (Oil Regulating)
.002L
.004L .006L(B)
ALL Piston Ring and Piston Side .003L
AS APPLICABLE) Clearance (Oil Scraper) .0055L .007L(B)
SSP1776 3-8
Island Enterprises
sBRVleE TAiBLh OF LIMITI
Ref. RsT. Chart Nomenclature Dimensions Clearances

Mfr. Mir.
a Max. a Max.
Max. Max.
607 lil~lilfijlli;l ALL Piston Ring Gap (Compression)

Plain and Chrome C~linders .020
(Straight Barrels) .030 .047
ALL Piston Ring C~p (Compression)

Nitrided and Chrome CSrlinders .045
(Choke Barrel~) .055 .067
ALL Piston Ring Gslp (Oil Regulating) .015

(All Barrels) .030 .047
ALL Piston Ring Gap (Oil Scraper) .015

(AS APPLICABLE) (All Barrels) .030 .047
For Choke Barrels Ring gap is measured withih 4 inches from bottom. Ring gap at top of travel must not be less
than .0075.
Engine and Piston Application Min.Piston Diameter Cylinder Barrel

Max.
Clearance
Engine ´•Ch Type of Maximum Piston Skirt
Code Letter Piston Number Top Bottom Type of Piston Surface Diameter Cyl.
!jjl)ili
608 E 67266.71553 4.8395 4.8540 F -Round P 4.8805 .018L
608 isf~i:i E 20. 73628 4 95 4.8540 F -Round N 4.8805 .018L
609 67266, 71 ,73620,
610 liiSi~ii:it 73628. 73932 4.8395 4.8540 F -Round C 4.8805 .0225L
E 75984 4.8395 4.8590 F -Cam C-N 4.8805 .018L
69236 5.0905 5.1040 Fo -Round P-C 5.1305 .0225L
H-P 71545. 71 608* 5.0905 5.1025 F ound C 5.1305 .024 L
H-P-AB-AC 71940,72249",72578,
73947". 73976 5.0905 5.1040 F -Round C 5.1305 .0225L
H-AC 71940, 72249*, 73947",
73976 5.0905 5.1040 F -Round N 5.1305 .023 L
H-P-AB 7424 75617" 5.0790 5.1090 F C 5.1305 .018L
H-P-AB-AC 7424 76258" 5.0790 5.1090 F N 5.1305 .018L
AC 75617". 76258W 5.0790 5.1090 F C-N 5.1305 .018L
H-P-AB-AC 73264"75961,76956,
78203; ,78762,
LW-10207", LW-10208,
LW-10545 5.0790 5.1090 Forged-Cam C-N 5.1305 .018L
NOTES:
To find the average diameter of cylinder in an area 4r’ above Maximum !appr and out-of-round permitted for cylinder in
bottom of barrel: First, measure diameter at right angles from service is.0045 inch.
plane in which valves are located. Second, measure diameter
through the plane in which valves are located. Add both See Service Instruction No. 1243 for identification of cast and
iiiiiililiijljf diameters; this sum, divided by 2, represents the average forged pistons. The suffix "S" that will be found with the part
diameterof the cylinder. number on 73947, 74242, 75984, 75961, 76966, 78203,
787 62, LW-10207, LW-10208, LW-10545 pistons indicates the
"=High Compression. pjston weight is within the limits specified for any group of
pistons and may be substituted for any like piston on a
Cylinder Barrel: P=Plain steel, N=nitride hardened, C=chrome particular engine. Other pistons are manufactured within
plated. vveightlimits that do not require any weight controlled piston
for replace ment.
To find the out-of-round, measure diameter of
average
4" above bottom of barrel: First, ri~easure Piston diameter at top is measured at top ring land (between
cylinder in an area
diameter at right angles from plane in which vali~es are top and second compression ring grooves) at right angle to
located. Second, measure diameter through the plane in piston pin hole;diameter at bottom of piston is measured at the
i:i:i:j:j:i:j:lwhich valves are located. Oifference between diameters must boftom of the piston skirt at right angles to the piston pin. See
not exceed .0045 inch. Service Instruction No. 1243 for illustration.
SSP1776 3-9
Island Enterprises
Ret. Ref. Chart Nomenclature Dimensioncl Clearance~

M~. Mtr.
a Max. a Max.
Max. Max.
611 li:62~i9 ALL Exhaust Valve Seat and .0075T

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

1.937
ALL LD. Exhaust Seat Hole 1.926

612 I:i5~:i:] ALL Intake Valve Seat and .0065T

E-H-P O.D. Intake Seat 2.1675

2.169
AB-AC O.D. Intake Seat 2.2885

2.290
E-H-P I.D. Intake Seat Hole 2.159

in C~linder Head 2.161
AB-AC I.D. Intake Seat Hole 2.280

613 lifz6ilitl ALL Exhaust Valve Guide and .001T

C~linderHead .0025T (A)
:68:i:il ALL O.D. Exhaust Valve Guide .6633
.6638
ALL LD. Exhaust Valve Guide .6613

iiiiiiiiiliii( I Hole in Cylinder Head .6623
614 i’9;2P:i:il ALL Intake Valve Guide and .001T

ALL O.D. Intake Valve Guide .5933
.5938
ALL I.D. Intake Valve Guide Hole .5913

in Cylinder Head .5923
615 ALL Exhaust Valve Stem and Valve .0037L

Guide .0050L
ALL O.D. Exhaust Valve Stem .4957

.4965 .4937
Service allowable limits of

.4937 is applicable only to
inconel or nimonic valves.
ALL Finished I.D. Exhaust .4995

Valve Guide .5005
1/2 inch diameter exhaust valves may have exhaust valve guides that are .003 inch over the maximum inside
diameter limit, anytime up to 300 hours of service. After 31)0 hours of service, inside diameter of exhaust valve
guide may increase .001 inch during each 100 hours of operation up to the recommended overhaul time for
the engine, or not to exceed .015 inch over the basic I.D. See latest edition of Service Instruction No. 1009 for
recommended overhaul time.
SSP1776 3-10
Island Enterprises
BERVICE TABLE OF LIMITE
PART III G$ARED ENGINES
Ref. Ref. Chart Nomenclature Dimenaonni CbPrPnee~

Mir. Mir.
a Max. a Max.
Max. Max.
616 ALL Intake Valve Stem and .0010L

Valve Guide .0028L .006L
ALL O.D. Intake VBlve Stem .4022

.4030 .4010
ALL Finished LD. Iptake Valve .4040

Guide .4050
617 ALL Valve and ValJe Cap .000

618 Dry Tappet Clearance .028

.080
619 ALL Valve Rocker and .0001L

Valve Rocker .0013L .0025L
ALL Finished I.D. df Valve Rocker .6246

.6261 .6270
Shaft
(Bushing~) in Cylinder Head
620 lilSiarifl~lALL Valve Rocker and Valve .0007L

Rocker Bushidg .0017L .004L
ALL O.D. Valve Ro~ker Shaft .6241

.6246 .6231
ALL Finished LD. Rocker .6252

Arm Bushing .6263 .6270
621 Valve Rocker Bushing and Bushing Must Be Burnished

Valve Rocker In Place
Rocker Bushing
622~IALL
i and CylinderValve .0022T
.0038T (A)
1IIII1I ALL Valve Rocker $haft Bushing .7380

Hole in Head .7388
623 iW~Siii ALL Valve Rocker ~nd C~linder .002L

iiiiri .:i Head Side agarance .020L .024L
625 Intake and Exhaust Valve .414

Guide Height
MEASURE VqLVE GUIDE HEIGHT

FROM THE VIALVE SPRING SEAT
COUNTERBOPE IN THE CYLINDER
HEAD TO THe TOP OF VALVE
GUIDE.
SSP1776 3-11
Island Enterprises
8eRV lee sAB~E op LINIITI
PART II1 GEARED ENGINES
622
623
620
618
17 1 r617
951
950
614
613
616
615
611
612 625
CHOKE
606 601
OPTIONAL
604
608
605
616
601
609
TAPER
Cylinder, Piston, Connecting Rod and Valve Components
SSP1776 3-12
Island Enterprises
IERVICE TABLE OF LIMITI
PART III GE(ARED ENGINES

SECTION III GEAR TRAIN SECTION OIL SCAVENGE PUMP
Ref. Chart SJomencLature Dimensions Clearances

Ref.
Mfr. Mir.

a Max. Q Max.
Max. Max.
15118i:l;l Oil Pump Drive Gear and 0010L

700
’ ‘3H-2 1H-E Oil Pump Body .004L
701:4;4~: E-H1-H2-H3 OilPump Drive Gear and .0015L

Accessory Hous/ing 10030L .006L
702 Oil Pump Drive Gear End .008L

i ´•1 H4-H5-P-AB-AC Oil Pump and

Gear End Cleslrance
qcavenge Pump .007L
.030L .045L
703’’’’’’
ia~ E-H 1-H2-H3 Oil Pump Impeiler- .002L
Diameter Clearilnce .005L .008L
703 H4-HB-P-AB-AC Oil Pump and Slcavenge Pump .007L

Impellers Diari~eter Clearance .OllL .014L
704 E-H1-H2-H3 OilPump Impe -Side .002L

i:´•:::::::´•
704 (ilea311111 H4-H5-P-AB-AC Oil Pump andSjcavenge Pump .003L
Impellers Side Clearance .0055L .006L
Width of Oil Pymp Impellers .747

I~"’ E-H1-H2-H3
.749 .746
704 f
i5Bi3.li., Width of Oil Primp Impellers .995
’ ’CA-B P-SH-4 .997 .994
904 H4-H5-P-AB-AC Width of Oil nge Pump 1.496

Impellers 1.498 1.495
705 E-H1-H2-H3 Oil Pump Driven Impellers .0010L

ilililllil and Idler Shaft .0025L .004L
705 II4-H5-P-AB-AC OilPump and Oil Scavenge

Pump Driven Impellers and .0010L
Idler Shaft .0025L .004L
E-H l-H 2-H3 Oil Pump Idler Shaft and .0000

Oil Pump Body .0025T (A)
706 IS~i:i H4-H5-P-AB-AC Oil Pump IdlerlShaft and .0000

%5~’ Oil Pump Body .0015T (A)
707 16~5.:. E-H1-H2-H3 OilPump Idler Shaft and .0005L

713 H4-H5-P-AB-AC Oil Pump Idler/Shaft and .0000

iii iiiiii Scavenge Pumd Body .0015T (A)
777498:i: H4-H5-P-AB-AC Oil Pump Drive/ Shaft Bushing .001T

and Scavenge P/ump Body .003T (A)
778 H4-H5-P-AB-AC Oil Pump Drive~ Shaft Bushing .001T

and Oil Pump Body .003T (A)
779 :i:ilH4-H5-P-AB-AC Oil Pump Drive Shaft Bushing

Oil Pressure and Scavenge
andOil .0015L
Pump Gear .0035L .005L
780 IMT:l: -H6-P-AB-AC Oil Pump Drive Shaft Bushing .0015L

and Oil Pump Shaft .0035L .005L
I
SSY1776 3-13
Island Enterprises
SECTION III GEAR TRAIN SECTION FUEL PUMP
net. Ref. Chart Nomenclature Dimensions Clearances

Mfr. Mtr.
a Max. Q Max.
Max. Max.
727 ~8"tiII E-H1-H2-H3 Fuel Pump Drive Gear- .016L

iii iiiiiii End Clearance .045L .065L
781 i586 E-H1-H2-H3 Fuel Pump Drive Gear and .0010L

782 H4-HB-P-AB-AC Fuel Pump Drive Gear Bushing .001T

and Accessory Housing .004T (A)
783 Fuel Pump Drive Shaft Gear .006L
784
785
786
f’~ ’ ’
ililili:jl Ij
87~’
ar9~11
H4-H5-P
P1
Fuel Pump Drive Shaft Gear
and Bushing
Injector Drive Gear and Accessory

Housing Cover Bushing
.001L
.004L
.0036L
.0048L
.006L
.006L
Injector Drive Gear End .002L

i:iiiiii:i Clearance .020L .030L
Idler Gear and

Idler BallrotcejnIg iraeB Magneto .0005T
.0004L (A)
788 :718’:I:IP1 Injector Idler Shaft and Magneto .0001T
.jj Idler Ball Bearing .0005L (A)
789’ AB Injector Drive Shaftgear and .001L
Accessory Housing Bushing .003L .005L
790 FuelPump Drive Shaft~ear and .001L
iiii Accessory Housing Bushing .003L .005L
791
Injector Drive Shaftgear .006
i End Clean~nce .048
AC Fuel Pump Drive Shaftgear .006

End Clearance .036 .048
SECTION III GEAR TRAIN SECTION VACUUM TACHOMETER

737 IB~:lilE-H1-H2-H3 Vacuum Pump Gear and Accessory .0010L
Housing .0025L .006L
...1
793 Cl~iliiillH4-H5-P
Vacuum Pump Gear
New Reference No. 739 to follow New Reference No. 7000.

End Clearance .016L
.045L .065L
Vacuum Pump Shaftgear Bushing and .0015T

:ijj Aeeessory Housing Cover 7nm5~ (a)
794 -H5-P Vacuum Pump Shaftgear Bushing
Pump .002L
.006L
795 ?-a3´•~´• ´• ´• ´• ´• ´• ´• H5-P Vacuum Pump Shaftgear Bushing .0015T
796 H5-P Vacuum Pump Shaftgear Bushing
I (At Accessory Housing) and Vacuum
Pump Shaftgear .0045L .006L
SSP1776 3-14
Island Enterprises
sERVICE TA~LE OF LIMITI
PART IIIGE~RED ENGINES
SECTION III GEAR TRAIN SECTIOP~ VACUUM TACHOMETER (CONT.)
Ref. Ref. Chart ~omenclature Dimensions Clearances

Mfr. Mhr.
Nelm Old Min. Serv. Min. Serv.
8 Max. Q Max.
Max. Max.
797 -H5-P Vacuum Pump Sfiaftgear End .008
~i_ilii Clearance .030 .050
AC Vacuum Pump Gear and
I’’’’ End Clear nceVacu m Pump S~line Coupling .045.008 .065
799 igi31$i AC Vacuum Pump Gear Bushing .001T

and Accessory H~using .003T (A)
AC Vacuum Pump qrive Gear Bushing .002L
and Vacuum Puipp Drive Gear .004L .006L
?ss
I´•:~iiiiiiiji 1-H2-H3 Tachometer Dride Gear and
Accessory Housi~g
.0010L
.0025L .006L
70011!:F41BI:IIE-H 1-H2-H3 Tachometer Driv/e Gear End .000

7002
ijiiiiijlj :’/E-H1 Tachometer
Adapter
Driv;en Gear and .0015L
.0035L .005L
7003 Tachometer Cover and Adapter .001T

i~ifiiiiifi .003T (A)
70041:ie~l H1 Tachometer Gest End Clearance .001L
.040L .060L
70051::1&3 -H2-H3 Electric Tachometer Idler Gear .005L

7006 -H2-H3 Electric T ter Driven Gear .005L

7006 lii6i~l:j H4 -H5-P-AB-AC Electric Tachometer Driven Gear .007L

-H2-H3 Electric Tachom Idler Gear .001L

Shaft and Idler ar Bushing .0025L .004L
-H2-H3 Electric Tach ter Driven Gear .0015L

and Adapter .0035L .006L
~c:
7009 AC Tachometer Drive Idler Gear
Bushing and TacHometer Drive Bushing To Be Burnished
Idler Gear In Place
?olo ~17’09:1: AC Tachometer Idler Gear

Bushing and ometer Drive .001L
Idler Shaft .004L
?oll !~Ui’ AC Tachometer Drive Idler Gear .005L

ijiiiiiiiiii End CleatanEe .~hL .02~L
70121iIr~"I -H6-P-AB-AC
i j ijiE Electric Tachomeiter Driven Gear
and Accessory H Cover
.001L
.003L .004L
SECTION III GEAR TRAIN SECTION VERNOR HYDRAULIC PUMP
7013 L Governor Drive erGearBushing .000L

and Governor Idler Shaft .002L .004L
7014 Governor Driven and Governor .001L
SSP1776 3-15
Island Enterprises
PART I Ii GEARED ENG IN ES
SECTION III GEAR TRAIN SECTION GOVERNOR HYDRAULIC PUMP (CONT.)
ReT. Ref. Chart Nomenclature Dimensions Clearances

Mfr. Mlr.
New I Old Min. Serv. Min. Serv.
8 Max. Max.
Max. Max.
I Reduction Gear Governor and

Magneto Housing and Magneto .002T
and Governor Drive Bushing .004T (A)
7016I:1SIOZi:IALL Governor Drive Idler Gear

and Governor Drive Idler .001T
Gear Bushing .003T (A)
7017I1:BOld:ilALL Governor Adapter and Governor .001T

Drive Adapter Bushing .003T (A)
SECTION III GEAR TRAIN SECTION MAGNETO, GENERATOR, STARTER
7018 Magneto Drive Idler Gear .001T

I and Magneto Drive Idler Bushing .003T (A)
7019 Magneto Drive Idler Shaft and .001L
Magneto Drive Idler Bushings .003L .005L
7020 Reduction Gear Housing Magneto

Drive Bushings and Magneto Drive .000
Idler Shaft I I I .002L .004L
Magneto Drive Adapter and .001T

Magneto Adapter Bushings .003T (A)
7022 Magneto Drive Gear and Magneto .001L
li~iliiif Adapter Bushings I I I .003L .005L
7023 li:GRlii:ilE-H1-H2-H3 Magneto Drive Bearing and .001T

Magneto Gear I I I .0005L .001L
7024 Magneto Drive Bearing and .0001T

Support .0007L (A)
7025 -H5-P Magneto Drive Idler Gear Hub
Bushing and Magneto Drive Idler Bushing Must Be Burnished
Gear Hub In Place
7026 H80BI: -H5-P Magneto Drive Idler Gear Hub

Bushing and Magneto Drive Idler .001L
Shaft .003L .004L
7027 "1:06. -H5-P Magneto Drive Idler Gear Hub .005L

iiiiiiiiiii End Clearanc~ .014L .024L
4-H5-P Magneto Drive Shaft and Accessory .0020L

Housing Cover Bushing .0045L .006L
7029 -H5-P Magneto Drive Shaft and Accessory .0025L

Housing Bushing .0045L .006L
-H5-P Magneto Drive Shaft Sleeve and .001T

Magneto Drive Shaft .004T (A)
-H5-P Magneto Drive Shaft Sleeve and .001T
Magneto Drive Coupling .004T (A)
7032 Magneto Drive Shaft Gear .002L
7033 I´•::683:i:ilE-H1-H2-H3 Generator Driven Gear Bushing .001T

and Accessory Housing I I I .003T (A)
SSP1776 3-16
Island Enterprises
sERV ICE TA9LE OF LIMITO
~ART
IIIGEqRED ENGINES
SECTION III GEAR TRAIN SECTION MAGNETO, GENERATOR, STARTER (CONT.)
Ref. Rei. Chut ljomenclature I Dimendonl Cls´•raseea

Mh´•. Mh´•.
Naw I Old I I I Min. Ssru. I Min. I 8e~.
a I Max. a I Max.
Max. Max.
7034 E-H1-H2-H3 Generator Driveli Gear and .002L

Bushing T666G .006L
7035 If 1-H2-H3 Generator Driveli Gear .005L

7036 li~aiiilal I Generator Drive tdler Gear Bushing Must Be

and Bushing (Hi-Speed) Burnished In Place
7037 H1 Finished I. D. of Idler Gear 1.000

´•il´•il´•i´• Bushing 1.001 1.002
I Generator Drive %ountershaft .0015L

and Bushing I I I .0035L .005L
I Generator Drive tdler Gear .004 L

End Clearance I I 1 .010L .020L
Driven Gear Bushing and Generator .001T

Housing I I I .a65T (A)
E1-H1´•H3 Angle GeneratorlDrive Generator .002L
Driven Gear and Bushing .004L .006L
7042 li:IQ2~:i$l-H1-H3 Angle Generator/Drive -Generator

Housing and Gederator Drive .001L
Gear I I 1 1 .004L
704 3 -P-AB-AC Generator Drive Clear Bushing

and Accessory Cover (A)
7044 li:P~i:ilH4-HS ´•P-AB-AC Generator Drive Gear Bushing
(At Cover) and generator I I I .002L
Drive Gear I I I .004L .006L
7 04 5 -P-AB-AC Generator Drive Gear Bushing .002T

and Accessory Hbusing .004T (A)
7046 R:E28i:~H4 -H5-P-AB-AC Generator DriveGear Bushing
(At Accessory H~using) and .0025L
Generator Drive Gear I I I .0045L~ .006L
70471:.988 HB-P-AB-AC Generator Drive Gear End .010

Clearance .038 .050
7048 rjiZiZ H4-H5-P´•AB-AC Starter Drive Bushings .002T

and Adapter .004T (A)
7049
fBI~13::ilH4 -H5-P-AB-AC Starter Drive
and Starter
Bushings
Gear
.002L
.004L .006L
7050 Starter Drive and .0005L

Accessory HoushCg Cover (A)
7051 Oil and Oil
ReliefRelief Valve .001
.005L
7051 OilReliefValve unger .001L

and Sleeve .003f, .005L
7053 Accessory Idler Bearing .0001L

and Accessory Djive Gear .0007T (A)
8881776 3-17
Island Enterprises
PART I1I GEARED ENGINES
SECTION III GEAR TRAIN SECTION ACCESSORY DRIVE
Rei. Rsf. Chut Nomenclature Dimenaicna OIearaneea

Mtr. Mfr.
a Max. a Max.
Max. Max.
7053 Accessory Drive Gear Bearing .0001L

and Accessary Drive Shaft .0007T (A)
Accessory Idler Gear Bearing

7053’’ ’ ’ ’ ’
iiiiilii and Supercharger and Accessory
Drive Gear
.0001L
.0007T (A)
-AB Supercharger and Accessory .001T
Drive Gear and Bushing .003T (A)
70SS(iiji~iai -H6-P-AB-AC Accessory Idler Gear Bearing
Accessory Drive Shaft .0005T
i i ifti iIf’ and
Adapter .0005L (A)
7056 -AB Supercharger and Accessory Drive
:::::::::f Gear Bushing and Accessory Drive - .0005L
Shaft .0017L .004L
7056 I:ts~al Finished I.D. of Supercharger

and Accessory Drive Gear 1.3295
Bushing 1.3305 1.3312
-AB Supercharger and Accessory Drive .004L

Gear End Clearance .012L .017L
7058 Accessory Drive Shaft and

Bushing (A)
Finished I.D, of Accessory Drive .750
Shaft Bushing .7515 .752
-AB Supercharger Drive Shaft Gear .002L

and Accessory Drive Shaft Bushing .004L .006L
7060
lirRi~’ ’ : ’ ’ ’ ’ i -AB Supercharger Drive Shaft Gear.0038L
and Supercharger Shaft Bearing .0050L .008L
7061t95‘5i:jj -AB Supercharger Drive Shaftgear .OllL

(Use 1 Spacer If Necessary to
Maintain Fit)
’1062 r:s;aili -AB Impeller and Supercharger Air

1:i InlP~adapter´•clsu´•afe
.MOL
WUt
7063 Intermediate Supercharger Drive.0040L

ji~i Shaft Gear and Bushing .0055L .0075L
7064 Liigllil~t -AB Accessory Housingand Inter-

mediate Supercharger Drive .001T
Shaft Gear Bushing .003T (A)
-AB Intermediate Supercharger Drive .002L
Gear and Bushing .004L .006L
7066 !:Z~ii Intermediate Supercharger Drive .OllL

~ii iii. Gear- End Clearance .026L .030L
7066 Intermediate Supercharger Drive .OD9L

Accessory Housing Adapter .0006L

and Bearing .0006T .0016L
88P1776 3-18
Island Enterprises
BERV ICE TABLE OF LINIITB
SECTION III GEAR TRAIN SECTION ACCESSORY DRIVE (CONT.)
Ref. Ref. Chart I Nomenclature Dimensions Clearance(l

Mir. Mfr.
a Max. a Max.
Max. I I Max.
7068 lii~aii Supercharger and Accessory .0002T

Drive Gear SuElport and Bearing .0013T (A)
7069 (iii~i Supercharger ai~d Accessory .001T

Drive Gear Sudport and Bushing .003T (A)
70701illBiC16.iilP´•AB Supercharger Bearing .0005L

and Superch Housing .002L (A)
Supercharger and Accessory

Drive Gear an~ Accessory Drive .001L
Shaft End Cl~arance .015L .020L
70721ii’921i~ AC Oil Pressure and Scavenge Pump

and fuel
Idler Gear
Busf~ing
ip~ Injector or Fu~l Pump Drive
Shaftgear (As Applicable)
.001L
.003L .005L
Oil Pressure add Scavenge Pump .001T

Idler Gear and Bushing .003T (A)
7074 liii8Si9: Throttle Shaft and Supercharger .001L

Air Inlet Housing Bushing .003L .005L
7074 I:f~f39: Throttle Shaft and Supercharger .0005L

Air Inlet Housing Bushing .0025L .005L
7075 I.:E)~3’’ H3 Propeller Flange Two Locator .5000

Holes .5008
SSP1776 3-19
Island Enterprises
EERVICE TABLE OF LINIITs
SECTION III GEAR TRAIN SECTION
7036
7039
8
i 703
704
702
700
701
a
~-707
706~ 705
REAR MOUNTED ACCESSORY HSG.
7037 ~703
706--, IA 1 /-705 /-713
704~ ~704
760-/ ’779
777
C~
706’ 713
CROSSWISE ACCESSORY HSG.
Oil Pumps
SSP1776 3-20
Island Enterprises
IERV lee ´•rAieLe of IIMirs
PART IIIG~ARED ENGINES
SECTION III G~AR TRAIN SECTION
786
785
Simmonds Injector
737
781
738~ ’-727
Vacuum and Fuel Pump Drives
SSP1776 3-21
Island Enterprises
794--\11 11 L /-797
/~66
793
784 \--796
782
783
SSP1776 3-22
Island Enterprises
I~RVICE TALLI OF LIMITS
PART III GE(ARED ENGINES
SECTION III GE~R TRAIN SECTION
787
788
IGSO-480
Fuel Injector and Magneto Idler Bearing
792
791
i-
789
L
7000 790
’799
798
IGO, IGSO-540
Fuel Injector and/or Fuel Pump, Vacuum Pump Drives
SSP1776 3-23
Island Enterprises
IERV ICE TABIE OF LIMIT8
~Clr-
7012~- \t~3 ~7006
GO-480-D, GSO, IGSO-480 8~ IGO, IGSO-540
7001
M037 ~7002
7006
7007
7004
739
7005
7008
7001
GO-480-B, F a cio~ GO-435-C 8( GO-480-B
Tachometer Drives
SSP1776 3-24
Island Enterprises
8ERV ICE TA9LB OF LIMIT8
SECTION III GEIAR TRAIN SECTION
7022
7023
7020
7018
7019
7020
7021
7024
IGO, IGSO-540 G0-435 a GO-480-B
7028 7029
7031 -J 7032 L
7030
GO-480-D, GSO, IG~O-480
Magn~to Drives
SSP1776 8-25
Island Enterprises
8LRV ICE TABLI OF LIMITs
7000
7011
7010
IGO, IGSO-540-A 8 8
Tachometer Drives
7027
GO-480-B, GIB6, GSO, IGSO-480
Magneto and Tachometer idler Gear
SSP1776 3-26
Island Enterprises
EERV ICE TABLE OF LIMIT8
7047
7045
7043
7044
7049
7046
7050
GO-480-B, GSO, IGSO-480 8r IGO, IGSO-540
Generator and Starter Drives
SSP1776 3-27
Island Enterprises
7013
7014
7016
7015 7017
ili_ 7075
GO-48O-F, GID6
GOVERNOR DRIVE PROP FLANGE
8
7035
7033
7040
7034
7042
7074
7041
IGSO-480, 540 GO-435, GO-480-B, GID6

THROTTLE LEVER DUAL GENERATOR 8 VACUUM PUMP DRIVE
Governor Drive, Prop. Flange, Throttle Lever,

Dual Generator and Vacuum Pump Drive
SSP1776 3-28
Island Enterprises
sERV ICE TACLE OF LIMITs
PART IIIGEIARED ENGINES
7051
7051
li--
t-
Oil R~lief Valves
SSP1776 3-29
Island Enterprises
7054
7064
7063~ /o
0 7/ii i /-7053
7065
s~_ ~’70
7062
7061
7056
7060
O
7057 7058
7059
7055
Supercharger and Components
SSP1776 3-30
Island Enterprises
sERV ICE TACLE OF LIMITS
70731 r7072
4 n Ba
Oil Scavengel Pump and Drives
SSP1776 3-31
Island Enterprises
7070
7067
7068
7069
7071
Supercharger Housing
SSP1776 3-32
Island Enterprises
BERV lee TABLE OF LIMITB
SECTION IV BACKLASH
Ref. Ref. Chart Nomenclature Dimendons Clearcmce~

Mh´•. Mtr.
New Old Min. Serv. Min. Setv.
a Mp~´• a Max.
Max. Max.
807 E-H1-H2-H3 Oil Pump Drive Gear and .004

Crankshaft Timing Gear .020
sos E-H1-H2-H3 Oil Pump Impellers .008

.015 .020
808 E-H1-H2-H3 Oil Pump and Scavenge Pump .ooS

BDB Impellers .015 .020
825 Crankshaft Timing Gear and .004

Camshaft Gear .015 .020
829 Propeller Shaft Reduction

Gear -Total Backlash (At
iiiliiIiiii 4 ft. Radius) .50
846 i5S:~lii E-H1-H2-H3 Camshaft Gear and Magneto .004

Gear .015 .020
ii iiii´•i
847 E-H1-H2-H3 Tachometer Drive Gear and .004
´•i iiii. Crankshaft Timing Gear .015 .020
848 E-H1 Tachometer Driven Gear and .004

Tachometer Drive Gear .015 .020
&19 ALL Stationary Gear and Stationary .002

Gear Drive Plate .005 .010
850~:E5R6. ALL Ring Gear and Ring Gear .001

Drive Plate .004 .010
851
1: ~8ejilij
’3H-2H-E
iiiliiiii
Generator Drive Gear and
Generator Driven Gear
.004
.015 .020
j ’ 3H-2 1H-E
OilPump Drive Gear and
Accessory (Fuel Pump) Drive .004
iiiiiijii Gear .015 .020
853 ~Q1:i:il E-H 1-H2-H3

1 riiiiiiii Oil Pump Drive Gear and
Vacuum Pump Drive Gear
.004
.015 .020
854 ALL Pinion Gear and Stationary .004

%ii: Gear .0077 .012(C)
855 Pinion Gear and Ring Gear .003
.0065 .012(C)
856 Governor and Magneto Drive
Gear and Governor Drive Idler .004
Gear .015 .020
857 AB-AC Governor and Magneto Drive

Gear and Magneto Drive Idler .004
Gear .015 .020
858 Governor Drive Idler Gear

(Bevel Gear End) and Governor
iii Driven Gear
.004
.008 .015
Camshaft Gear and Generator
860859’
.004
Drive Idler Gear .015 .020
H1 Generator Drive Idler Gear and .004

Generator Driven Gear .015 .020
88P1776 3-33
Island Enterprises
EIERV ICE TABLE e)F IIMITs
SECTION IV BACKLASH
Ref. Ref. Chut Nomenclature Dimendons Clearances

Mil. Mh´•.
a I Max. a M´•´•.
Mac. MP~I.
861 E1-H1´•H2-H3 Electric Tachometer Idler Gear

: : : : 8 R:I and Driven Gear
.004
.015 .020
862 E1-H1-H2´•H3 Electric Tachometer Idler Gear

i618:ZB: and Tachometer Drive Gear
.004
.015 .020
863 AngleGenerator Drive Gear and .002

fllilif:fil~l Generator Driven Gear .004 .010
864
)ii ij9~ii
i~-i
.003
.007 .009
iO~OS:
I’’H~ Generator Drive Gear and
Drive Idler Gear
Magneto .004
.015 .020
865 i~3 H4´•H5´•P-AB´•AC Generator Drive Gear and Tach- .004

meter Drive Idler Gear .015 .020
866 Electric Tachometer Drive Gear

(Magneto Idler Hub) and Tachometer .004
Driven Gear .015 .020
866 H4-H5-P-AB-AC Tachometer Drive Idler Gear and .004

filififitilil Tachometer Driven Gear .015 .020
se7
l,i i:i i jZi H4-H5-P Tachometer Drive Idler Gear and
MagnetoDrive Shaftgear
.004
.015 .020
868 H4-H5-P Magneto Drive Shaft (Spline) and .001

Magneto Drive Shaft Gear (Spline) .005 .008
869 I:i83;1:i:I H4-H5-P Magneto Drive Shaft Gear (Spline)

and Magneto Drive Coupling .001
(Spline) .005 .008
H4-H5-AC Rear Crankshaft (Spline Bushing) .002

and Accessory Drive Gear (Spline) .0073 .018
870 l~m:B: P-AB Rear Crankshaft (Spline Bushing) .002

and Accessory Drive Shaft (Spline) .0073 .018
H4-H5-AC
8711 Accessory
Drive Gear
Idler Gear and Starter .004
.015
871 P-AB Supercharger and Accessory Drive

Gear and Starter and Accessory .004
Drive Gear .008 .015
872 H4-H5-P-AB-AC Accessory Drive Gear and 004

Generator Drive Gear
j .015 .020
873 ~5iiiil H4-H5-P Accessory Drive Gear and .004

iiiiiiiiiiil I VacuumPump Shaftgear .015 .020
H4-H5-P Vacuum Pump Shaftgear and Oil .004

iiili~iiii Pressure and Scavenge Pump Gear .015 .020
875 ~rililE Scavenge Pump Driven Gear and .004

Accessory Drive Gear .015 .020
876 E Scavenge Pump Impellers .008

.015 .020
Supercharger and Accessory Drive
"’I Gear and Intermediate Supercharger

Drive Shaftgear
.006
.015 .020
SSP1176 3-34
Island Enterprises
SECTION IV -BACKLASH
Ref. Ref. Chut Dlmendons ClePrPnceo

Mtr. Mh´•.
New Old Min. aerv. Min. Serv.
a Mix. a Mu.
M´•x. I I M´•r.
878 P-AB Supercharger Drive Shaftgear

and Intermediate Supercharger .006
Drive Gear .015 .020
879 Intermediate Supercharger Drive

Shaftgear (Spline) and Intermediate .000
Supercharger Drive Gear (Spline) .002 .005
880 P1 Fuel Injector Idler Gear and

´•i´•iiiij Magneto Drive Shaftgear .020
881 liiBiti~j Fuel Injector Drive Idler Gear .004

and Fuel Injector Idler Gear .015 .020
882 Injector Drive Shaft(Spline) .0005

E:a8~0:ii" and Fuel Injector Pump (Spline) .008
883 Magneto Drive Shaftgear (Spline)

and Fuel Injector Drive Shaft .002
(Spline) .006 .008
884
I:i9i08i:/ AB-AC Magneto Drive Idler Gear (Bevel
End) and Magneto Driven Gear
.004
.008 .015
885 :E~ AB-AC Magneto Driven Gear (Spline)

(Spline) .004 .007
886 AB-AC Magneto Drive Coupling (Spline) .001

and Magneto Coupling (Spline) .004 .007
887 H4´•H5-P-AB-AC Starter Jaw (Spline)and .002

Starter Drive Gear (Spline) .005 .010
888 ~.:l:1:I:I:i:i:il AB-AC Accessory and Starter Drive

and Oil Pressure and Scavenge .004
Pump Idler Gear .015 .020
889 t:i:i:l:l:i:i:it AB-AC Oil Pressure and Scavenge

Pump Idler and Oil Pressure .004
and Scavenge Pump Gear .015 .020
890 Fuel Injector Drive Shaftgear

(Spline) and Fuel Injector .003
Drive Coupling (Spline) .007 .012
891 Fuel Injector Drive Coupling

i~iiiiiiili (Spline) and Fuel Injector I I 1 .002
Pump (Spline) .005 .010
i-i~
11AB-AC Oil Pressure and Scavenge Pump
I’/ Gear (Spline) and Vacuum Pump

Coupling (Spline)
.003
.0065 .010
893 FiisgOiti] AB-AC Vacuum Pump Drive Gear

(Spline) and Vacuum Pump .003
Coupling (Spline) .0065 .010
894 AB Vacuum Pump Drive Gear and .004

Fuel Injector Drive Shaftgear .015 .020
895 H4-HS-P-AC Vacuum Pump Shaftgear and .004

Fuel Pump Drive Shaf$ear .015 .020
1:g
S8P1776 3-35
Island Enterprises
SERVIOE TABLE OF LIMITS
SECTION IV-BACKLASH
CAMSHAFT
860~ ~GENERATOR DRIVEN rlllTRI
GENERATOR
t
TOR DRIVE
GENERATOR DUAL DRIVE
tI~DRIVE
DRIVE IDLER GENERATOR DRIVE
HIGH SPEED
DUAL DRIVE
MAGNETO MAGNETO
ERATOR DRIVEN
GENERATOR DRIVE
DUAL DRIVE
CAMSHAFT
CRANKSHAFT
807
OIL PUMP
OIL PUMP
~iLTACHOMETER MAGNETOI;;;?
DRIVE GENERATOR
LOW TACH. IDLER
SPEEDCRANKSHAFTX
-t -t
VP~UUM OR
HYOR~I FUEL PUMP
TACH.
DRIVEN
PUMP
TACHOMETER DRIVE
OPTIONAL ACCESSORY DRIVE
GO-480-B, G IGO-480-A SERIES 0 0 -4 35 0281 G0-480-02E6, G I H6
ERATOR DRIVEN
CAMSHAFT
ERATOR DRIVE
LOW SPEED
MAGN
CRAN
KSHAFT6
f
-t
MAGNETO
TACHOMETER DRIVEN
OIL PUMP DR
OIL PUMP IMPELLERS

+:TACHOMETER DRIVE
FUEL PUMP
hS
(GO-435-C2A
YRSUMP
D)YLNO
G0-435-C2A 028 SERIES
G0-480-F,G SERIES
Accessory Drives
SSP1776 3-36
Island Enterprises
EERV ICE TABLE OF LIMITE
SECTION IV-BACKLASH
MAGNETO DRIVE SHAFTGEAR
li-(TACH.
DRIVE IDLER GEAR
CAMSHAFT
GEAR
TACH.
DRIVEN
GEAR
ENERATOR DRIVE
SHAFTGEAR
873
CRANKSHAFT
STARTER
GEAR
ACCESSORY
DRIVE GEAR
ACCESSORY DRIVE GEAR´•
OIL 8 SCAVENGE
’-VACUUM PUMP
PUMP GEAR SHAFTGEAR
BQI
OIL 8 SCAVENGE PUMP

IMPELLERS
FUEL PUMP
DRIVE SHAFTGEAR
GO-480-D
VIEWING LEFT SIDE OF ENGINE
Accessory Drives
SSP1776 3-37
Island Enterprises
SECTION IV-BACKLASH
-t
TACH. DRIVE IDLER GEAR
CAMSHAFT
GEAR
DRIVEN
867
~--i INTERMEDIATEDRIVE GEARSUPERCHARGER
GEAR
INTERMED.
SU PER.
.-t\
DRIVE
.~XT-/
j;
ERATOR
825
DRIVE
SHAFTGEAR
871
873
SUPER. DRIVE
CRANKSHAF
GEAR
TARTER a Ace.
DRIVE GEAR
SUPER. a ACCESSORY
DRIVE GEAR
OIL8r SCAVENGE ~-VACUUM PUMP
PUMP GEAR /1C´•/ 874-f SHAFTGEAR
OIL& SCAVENGE PUMP

IMPELLERS
FUEL PUMP DRIVE
SHAFTGEAR
Accessory Drives
SSP1776 3-38
Island Enterprises
SECTION IV BACKLASH
MAGNETO DRIVE-7 888-\ ~MAGNETO DRIVE

cOU PLI NG I SHAFTGEAR
MAGNETO DRIVE SHAFT
GENERATOR DRIVE
TACH. DRIVE IDLER GEAR SHAFTGEAR
STARTER JAW
887
STARTER ACCESSORY
VACUUM PUMP SHAFTGEAR
DRIVE GEAR
OIL PRESS. SCAVENGE

\LFUEL PUMP DRIVE
SHAFTGEAR
PUMP GEAR
GO-480-D. GSO-480-B
Accessory Drives
SSP1776 3-39
Island Enterprises
SECTION IV BACKLASH
FUEL INJECTOR IDLER GEAR
MAGNETO DRIVE SHAFT GEAR
FUEL INJECTOR DRIVE

IDLER GEAR
MAGNETO DRIVE
SHAFT GEAR
CAMSHAFT GEAR
TACH. DRIVE GEAR
-i (MAG. IDLER HUB)
INTERMED. SUPER.
DRIVE GEAR
MAGNETO DRIVE
IDLER GEAR
881
TACH. DRIVEN GEAR
GENERATOR DRIVE
SHAFTGEAR INTERMED.
SUPER DRIVE
,1t- SHAFT GEAR
ess,
i
825
877
i..~4",2 879
878 7
r- I
871
i
CAMSHAFT GEAR
i
DRIVE SHAFTGEAR
REPUSRAEGTFAHS
SUPER B,ACCESSORY
DRIVE GEAR ~si
STARTER 8r ACCESSORY
DRIVE GEAR
874VACL)UM PUMP
OIL a SCAVENGE PUMP GEAR
OIL SCAVENGE PUMP IMPELLERS FUEL PUMP DRIVE

SHAFTGEAR
IGSO-480-A
Accessory Drives
3-40
SSP1776
Island Enterprises
BERVIOE TABLE OF LIMITEI
SECTION IV-BACKLASH
MAGNETO DRIVE MAGNETO DRIVE

868
COUPLING SHAFT GEAR
MAGNETO DRIVE SHAFT
FUEL INJECTOR IDLER GEAR
MAGNETO DRIVE IDLER GEAR
MAGNETO DRIVE IDLER

GEAR HUB
--‘I
FUEL INJECTOR DRIVE GENERATOR DRIVE

IDLER GEAR t SHAFTGEAR
i
STARTER JAW
887
STARTER ACCESSORY
DRIVE GEAR ~--VACUUM PUMP SHAFTGEAR
PRESSURE 8 CI
I
PUMP GEAR SHAFTGEAR
IGSO-480-A SERIES
Accessory Drives
SSP1776 3-41
Island Enterprises
SECTION IV-BACKLASH
DRIVE IDLER
CAMSHAFT
ACHOMETERTACHOMETER
DRIVEN
INTERMEDIATE
SUPERCHARGER
DRIVE
SHAFTGEAR
DRIVE
879
825 DRIVE
SHAFTGEAR
878
871
SUPER. DR
SHAFTGEAR
CRANKSHAFT
SSORY 8r 888
TIMING ARTER
OIL PRESS. 8~ SCAVENGE

SUPERCHARGER
PUMP IDLER
ACCESSORY DRIVE
889
OIL 8r SCAVENGE PUMP
895-/ Tppr~ I VLL 1 VIYII VI\ IIYUECTOR

DRIVE SHAFTGEAR
13´•cY VACUUM PUMP DRIVE

IMPELLERS
IGSO-540
Accessory Drives
SSP1776 3-42
Island Enterprises
IERV ICE TABLE OF LIMITs
SECTION IV-BACKLASH
DRIVE IDLER GEAR

CAMSHAFT
GEAR
TACH.TACH.
DRI
GEAR
_ii
866
G12 GENERATOR DRIVE

SHAFTGEAR
870
CRANKSHAFT
STARTER a
GEAR
ACCESSORY
DRIVE GEAR
ACCESSORY DRIVE GEAR

889
~VACUUM PUMP
OIL 8 SCAVENGE
PUMP GEAR X´•/ aor;~ SHAFTGEAR
OIL a SCAVENGE PUMP

IMPELLERS
FUEL PUMP
DRIVE SHAFTGEAR
IGO-540
Accessory Drives
SSP1776 3-43
Island Enterprises
8ERV ICE TABLE OF LIMITs
SECTION IV-BACKLASH
TACHOMETER DRIVE IDLER
I GENERATOR DRIVE SHAFTGEAR
STARTER JAW
887
I I FUEL PUMP DRIVE

STARTER a ACCESSORY
I I I SHAFTGEAR
DRIVE GEAR
INJECTOR DRIVE
COUPLING
890
OIL PRESSURE a SCAVENGE
PUMP IDLER
892
891
FUEL INJECTOR
FUEL INJECTOR
DRIVE SHAFTGEAR
PUMP
OIL PRESS. a SCAVENGE PUMP
IGSO-540-B ONLY
VACUUM PUMP--’
SPLINE COUPLING DRIVE
100-540 IGSO-540-A I B
Accessory Drives
SSP1776 3-44
Island Enterprises
EERV ICE TABLE OF LlnnlTE
SECTION IV BACKLASH
/-i GOVERNOR DRIVEN
858
GOVERNOR DRIVE IDLER
c, PROPELLER GOVERNOR
i AND MAGNETO DRIVE
VIEWING FRONT OF ENGINE
PROP SHAFT
MAGNETO DRIVEN 857--/
MAGNETO DRIVEN 1 i~
884---~7 1 I I P~h--B84 MAG. DRIVE IDLER
MAG. DRIVE COUPLING

SECTION 8B
ETO DRIVE
COUPLING
MAG. DRIVE IDLER
SECTION CG
IGO, IGSO-54O
Accessory Drives
SSP1776 3-45
Island Enterprises
~ERVICE TABLE or
SECTION IV BACKLASH
883
MAGNETO DRIVE
SHAFT GEAR FUEL INJECTOR
IDLER GEAR
882
INJECTOR DRIVE SHAFT
FUEL INJECTOR PUMP
IGSO-480-B
GOVERNOR
DRIVEN GEAR
GOVERNOR DRIVE
IDLER GEAR GOVERNOR DRIVE
IDLER GEAR
GOVERNOR A
DRIVE GEAR
GOVERNOR
DRIVEN GEAR
A
GOVERNOR
DRIVE GEAR
858
VIEWING-FRONT OF ENGINE
856
SECTION A-A
G0-435, GO, GSO 8~ IGSO-480-A
Accessory Drives
SSP1776 3-46
Island Enterprises
IERV ICE TABIE OF LIMIT8
SECTION IV-BACKLASH
CRANKCASE
8547 8557 i I 850
CRANKSHAFT
829
SECTION THRU REDUCTION GEAR
Accessory Drives
SSP1776 3-47
Island Enterprises
BERVIOE TABLE OF LIMITI
Ret. Ref.
Thread
Ne~a Old Chart Size Nomenclature Torque Limits
900 -P 3/8-24 Connecting Rod Nuts 480 in. Ibs.
’ ’ li li i AC 3/8-24 Connecting Rod Bolts Tighten

To Length 2.255 -2.256
901 HB-P-AB-AC 112-20 Oil Pump Shaft Nut 360 -480 in. Ibs.
3/8-24
903’ ’i
ij’ member to magneto) Steel Bushing 300 in. Ibs.
904 P1 10-32 Screw mate Nuts (To attach ignition

cable outlet plate to magneto) 15 in. Ibs.
905 114-20 Rocker Box Screws 50 in. Lbs.
906 ::::IALL 5/16-18 Exhaust Port Studs

(Driving Torque) 40 in. Ibs. min.
To Cylinder Head 160 180 in. Ibs.
907 ALL 18MM Spark Plugs 420 in.lbs.
909 :IALL 5/8-32 Alternator Pulley Nut 450 in. Ibs.
ALL 5/8-32 Alternator Nut (Quill Shaft) 474 in. Ibs.
910 1/4-28 Alternator Output Terminal Nut 85 in.lbs.
10-32 Alternator Auxiliary Tenninal Nut 30 in.lbs.
913 HB-HS-P-AB-AC 1/16-27 NPT Piston Cooling Nozzle in Crankcase 100 in.lbs.
~P
Head 60 in. Ibs.
91s 1/4 Hex Head Hose Clamps

and Below
(Worm’I~pe)
20 in. Ibs.
ALL 5/16 Hex Head Hose Clamps (Worm Type)

919- ALL "T" Bolt Hose Clamps

1 Initial Torque 35 in. Ibs.
Retorque After Engine Test 25 in. Ibs.
920 818:i:IALL Cylinder Head Drain Back Hose

Clamp 10 in. Ibs.
928 ALL 318-16 Cylinder Hold Down Studs

ALL
929 ALL 3/8 Cylinder Hold Down Nuts 300 in. Ibs.
ALL 1/2 Cylinder Hold Down Nuts 600 in. Ibs.
ijii
’.Cylinder
9201
iiiiiiiil Instruction
Hold Down and Crankcase
No.
Parting Flange Nuts’ Tight~ning Procedures See latest edition of Service
931 ~lila’jllllALL 2.000-16 Pinion Cage Retaining Nut 400 FT. LBS.
SSP1776 3-48
Island Enterprises
Ref. Ref.
Thread
Chart Nomenclature Torque Linifts
Size
New Old
932’’’’’ E-H1-H4-H5-P- Propeller Retaining Nut

AB-AC 450 500 FT. LBS.
933 Accessory Drive Shaft Nut 75 -125 FT. LBS.
934
liijIitji~ij H4-HS-P-AB-AC CrankshaPt Gear Retaining Nut 150 FT. LBS.
936 P-AB Sugercharger- Intermediate

iiiiiiiiiii Dr~ve ShaftNut 75 FT. LBS.
937 P-AB Supercharger Impeller Locknut (600 in. Ibs. Plus Torque
’’’’’i
itiili~iii Req’d. to Reach Next
Locking Slot)
938 RQ-H5-P-AB-AC 1/4-28 Thin Slotted Nut 38 in. Ibs. Plus Torque
Req’d. to Reach Next
Locking Slot)
940 lii8B;5iifil ALL Ring Gear Assembly
iiliiiliiii Attaching Nuts 360 in. Ibs.
Reduction Gear kssembly

Attaching Nuts 300 in. Ibs.
942 lilffdj~iiil E1-H1 1/4-18 NPT Carburetor Drain Plug 120 144 in. Lhs.
E-H-P 1/8-27 NPT Carburetor Drain Plug 50 60 in. Ibs.
943 P 10-32 Screws (To attach Accessory

Drive Coupling Plate) 25 30 in. Ibs.
SECTION V -SPRINGS
Length COMP. LOAD
Mfr. Mir. Serv.

Part No. Die. Length Min. Malt. Max.
Outer Valve Springs

(Angle) 68326 .171 1.46 in. 103 Ib. Illlb. 100 Ib. min.
ALL Outer Valve Springs

(Angle) LW-11796 .182 1.43 in. 114 Ib. 124 Ib. Illlb. min.
ssl ALL Auxilliary Valve 68328 .142 1.33 in. 75 Ib. 83 Lb. 72 Ib, min.
iiiiiii: i springs (Angle) LW-11797 .142 1.33 in. 73 Ib. 831b. 70 Ib. min.
~Rgilil H4-H5-P-AB-AC I Check Valve Springs
Avco Lycoming
Free Length
Part Numbers
654-B .031 1.03 in. .74 Ib. .94 Ib. .69 Ib. min.
73761 2.065 .041 1.03 in. 3.15 Ib. 3.35 Ib. 3.10 Ib. min.
Valve Spring
Avco Lycoming Identification

Part ~jumbers Free
Dye Length
:i:i:i:i:i:i:IH4-H5-P-AB-AC 68542 None 2.38 .067 1.66 in. 15 Ib. 17 Ib. 14 Ib. min.
H4-H5-P-AB-AC LW-14029 White 2.28 .072 1.66 in. 20 Ib. 22 Ib. 17 Ib. min.
E1-H1-H2-H3 60476 None 2.38 .047 1.44 in. 7.15 Ib. 7.65 Ib. 7.00 Ib. min.
E1-H1-H2-H3 66920 None 2.54 .047 1.44 in. 8.35 Ib. 8.85 Ib. 8.20 Ib. min.
74596 None 2.96 .047 1.44 in. 11.65 Ib. 12.15 Ib. 11.50 Ib. min.
8SP1776 3-49
Island Enterprises
OERV ICE TABIE OF LIMITs
Rei. Ref.
Thread
New Old Chart Size Nomenclature Torque Limits
SECTION V SPRINGS (CONT.)
Length COMP. LOAD

Avco Lye. Wire At. Comp. Mir. Mfr. Serv.
Chart Nomenclature PartNo. I Dia. Length Min. Max. Max.
954
Supercharger Drive
Coupling Spring
Avco Lycoming
Part Numbers Free Length
P 68830 1.25 .148 1.10 in. 168 Ib. 184 Ib. 165 Ib. min.
P LW-12303 1.28 1 .148 1.13 in. 168 Ib. 1 184 Ib. 165 Ib. min.
AB 74 1 1.23 1,11_71 l.lOin. 1 249113.1 2751b. 1 2441b.min.
AB I LW-12301 1 1.26 .177 1 1.13in. 255 Ib. 270 Ib. 250 Ib. min.
SSP1776 3-50
Island Enterprises
STANDARD TORQUE
TABLE II
TABLEI
PIPE PLUGS
Torque
Toraue Torque Thread In. Lbs.
1/16-27 NPT 40
10 49 1/2 900 75
1/8-27 NPT 40
114 96 9116 1320 110
1/4-18 NPT 85
5/16 204 17 5 1800 150
3/8-18 NPT 110
3/8 360 30 3/4 3240 270
1/2-14 NPT 160
7/16 600 50
4-14 NPT 0
1-111 NPT 315
TABLE IV
TABLE III
FLEXIBLE HOSE
OR TUBE FITTINGS
Thd. Pitch On Part ANGLE OF TU RN Torque

To Be tened Aluminum
er nch Asbestos Asbestos
(-3) 3/16 3/8-24 30
8 1350 670 -4 1/4 7/16-20 30

10 1350 670 -5 5/16 1/2-20 35
12 180" (6) 3/8 9/16-18 35
14 1 -8 1 3/4-16 60
16 2700 1350
18 2700
-10) 5/8 7/8-14 70
20 27 135
24 3 1
28 3 1
NOTE TABLE V
Install all crush STUDS

type gaskets except the self centering
type, with the unbroken surface against the flange of MIN. DRIVING TORQUE
the part until the sealing surfaces are in contact and Threads In. Cb s.

appropriate thread size. 1/4-20 15
5116-18 25
SSP1776
3-51
Island Enterprises
BERVIOE TABLE OF LIMITE)
SECTION V SPECIAL TORQUE; REQUIREMENTS
907
*J
r,
i-
_r~ZfJ
z
950 z
U
i
i
i
a
905
Ml\l 900 900
951 r
906
920
SSP1776 3-52
Island Enterprises
sERV ICE TABLE OF LlnnlT8
911
*vr‘
Y 4
jS Q
9’0
Fl
1
P:.x
FZ
911~ ’-911
ALTERNATOR ALTERNATOR DRIVE
903
f
U1
f 1:1
901
OIL PUMP MAGNETO
SSP1776 3-53
Island Enterprises
BERV ICE TABLE OF LINIITB
CRANKCASE
910
932
CRANKSHAFT
SECTION THRU REDUCTION GEAR
SSP1716
3-54
Island Enterprises
8ERVICE TABLE BF= IIMITEI
954 ~-936
i sa
I~
934
\o
933
SECTION THRU ACCESSORY HSG. 8r SUPERCHARGER
SSP1776 3-55
Island Enterprises
sERV ICE TABLI OF LIMITI
952
919 /-91911
920
914
953
Engine Springs and Hardware
SSP1776
3-56
Island Enterprises
PART IV VERTICAL DRIVE ENGINES EXCLUDING VO AND IVO-360
CHART MODELS
L vO, TVO-435 (ALL)

L1 VO-435-B, TV0~35-F
L2 TVO-435-A
V VO, IVO, TVO, TIVO-540
V1 TVO, TIVO-540
NOTE
In "chart" column, a number appearing after a letter shows exceptions to the basic model.
SECTION 1 500 SERIES CRANKCASE, CRANKSHAFT CAMSHAFT

SECTION 11 600 SERIES CYLINDERS
SECTION 111 700 7000 SERIES GEAR TRAIN
SECTION IV 800 8000 SERIES BACKLASH (GEAR TRAIN)
(A) These fits are either shrink fits controlled by machining, fits that may readily be
adjusted, or fits where wear does not normally occur, in each case the fit must
be held to the manufacturing tolerance.
(B) Side clearance on piston rings must be measured with face of ring flush with
piston.
(D) These dimensions shown are measured at bottom of piston skirt at right angles
to piston pin.
(E) Permissible wear of the crankshaft (rod and main bearing journals) to be minus
0.0015 on the diameter.
(L) Loose fit; wherein a definite clearance is mentioned between the mating
surfaces.
SSP1776 February 15, 1980"
Indicates cut-off date for data retrieved prior to publication.
Island Enterprises
PART IV VERTICAL ENGINES

SECTION I CRANKCASE, CRANKSHAFT AND CAMSHAFT
Chut No~nekture Dimsndons

Ref. Ref.
Mtr. Mlr.
Min. Serv. Mi. Scrv.
Nela Old
a M´•x. a Mix.
M´•x. MP~.
500 All Main Bearings and .0015L

I~ln:is’ ’ ’ Crankshaft .0045L .0060L
L1-V Main Bearings and Crankshaft .0011L

(Except Front) .0041L .0050L
V Front Main Bearing and .0011L

L1 Front Main Bearing and .0015 L

ALL Diameter of Main Bearing 2.3745

Journal on Crankshaft 2.376 (E)
500 ~94i5i:i:IL Crankcase Bearing Bore 2.566

Diameter ’(All) 2.567 2.5685
Crankcase Bearing Bore 2.6865

Diameter (All) 2.6875 2.6890
501 Connecting Rod Bearing and .0008L

;ii ALL Diameter of

Journal
in.)
on
Connecting Rod
Crankshaft(2-1/8 2.1235
2.125 (E)
501 ALL Connecting Rod Bearing

(Measured at Axis 300 on 2.2870
Each Side) 2.2875
Connecting Rod Side Clearance .004L

soz
iiB~4.:i ALL
.010L .016L
503 Connecting Rod Alignment .010 in 10 Inches
504 ALL Connecting Rod Twist .012 in 10 Inches
505 ALL Crankshaft Run-Out at Center

iii~iliili Main Bearings

Max. Run-Out No.2 and 3 Journals .005 .0075


Crankshaft and Crankcase Front .006L

6061: pg~iiil
’LLA End Clearance .015L .025L
508 ALL Crankshaft Propeller Flange

Run-Out .002 .005
ALL Crankshaft Timing Gear and .0000

511 8~j:i: ALL Tappet Body and Crankcase .0010L

.0033L .004L
SSP1776 4-1
Island Enterprises

SECTION 1 CRANKCASE, CRANKSHAFT AND CAMSHAFT
Ref. Ref. Chut Nomenckture Dimendons I Clearancel

Mfr. Mh´•.
Near Old Min. 9e~v. I Min. Serv.
B Max.
Max. Max.
511 O. D. of Tappet .7169
: : : :I I. D. Tappet
Crankcase
Bore in
.7177
.7187
.7200
.7166
.7203
512 Tappet Plunger Assembly .0010L

andBody Hyperbolic .0067L .0087L
513 Tappet Socket and Body .002L

(Hyperbolic) .007L .009L
514 Camshaft and Crankcase .002L

i~Ii:I .004L .006L
515 I:f~31::I:IALL Camshaft End Clearance .002L

.009L .015L
516 IBa8:i:ilALL I Camshaft Run-Out at Center .000

Bearing Journal .001 .006
517 Counterveight Bushing and .0013T

518 liaz~iiiilv I Counterveight Roller End .007L

519 I:L8a::::IV Counterveight and Crankshaft .003L

Side Clearance* I I I .013L .017L
520 Countenveight Bore and Washer .0002L

O. D. .0030L (A)
i. D. of
Countarweight .7485
Bushing .7505 .7512
522 O. D. of CounteMTeight Roller

(P/N 73338) (See latest
edition of Service Instruc- .5255
tion No. 1012) .5260
541 ALL Rear Crankshaft S~line .0002T

iiiiiliiiiiiji Bushing and Crankshaft .0015T (A)
+Measure below roller next to nat.
SSP1776 4-2
Island Enterprises

i
521 519
517
r i
Crankcase, Crankshaft, Bearings, Camshaft

and Counterweights
SSP1776 4-3
Island Enterprises
BERV ICE TABLE OC: LlnnlTB
PART IV VERTICAL ENG IN ES

0 6 0 8 8
515’ i I ~Uh
a
516
(I
SaS
a
Is sl Is a, I l_s4~___ls
5137 1 512
Longitudinal Section Thru Engine

Camshaft, Tappet Body and Crankshaft
SSP1776 4-4
Island Enterprises
BERV ICE TABLE OF Llnnl´•rs
PART IV VERTICAL ENG IN ES

Ch;ut Nomsnchture Dimenalons

Ref. Ref.
Mtr. WI.
Min. Ssrv. Min. Serv.
New Old
a Max. a Max.
Max. Max.
600 iR.:i:IALL Connecting Rod and Connecting Bushing to be Burnished in Place

lifliiiit Rod Bushing
Finished I. D. of Connecting 1.1254

Rod Bushing 1.1262
601 L Length Between Connecting 6.4985

illlllllll
´•´•´•I
Rod Bearing Centers 6.5015
iiilililii V Length Between Connecting 6.7485

Rod Bearing Centers 6.7515
ALL Connecting Rod Bushing and .0008L
604’ ~’
Piston Pin .0021L .0025L
603 ALL Piston Pin and .0003L
i~2-:i1 Piston1.1246
.0014L .0018L
ALL Diameter of Piston Pin Hole 1.1249

in Piston 1.1254
ALL Diameter of Piston Pin 1.1241
~3i:i V Piston and Piston Pin mug .M)02L

.0010L .002L
V Diameter of Piston Pin Plug* 1.1242

1.1247
605 :9: ALL Piston Pin and Piston Pin

mug (Nitrided and Chome .0005L
Cylinders) .0025L .005L
V Diameter of Piston Pin Plug* .5655

.5665
L Diameter of Piston Pin Plug"" .7605

.7615
L Diameter of Piston Pin Plug*" .8405

(Thin Wall Pin) .8415
*See latest edition of Service Instruction No. 1267.

iijiiiiiiiiiiil **See latest edition of Service Bulletin No. 316.
606 :B~ ALL Piston Ring and Piston Side

Clearance (Top Ring Comp.) .0025L
606 :5%~5.: ALL(As Piston Ring and Piston Side

lil.llllllll Applicable) Clearance (2nd Ring Comp.) .000
Full or Half Wedge .004L .006L(B)
iiiiiiiiijiji
ALL Piston Ring and Piston Side .002L
Clearance (Oil Regulating) .004L .006L(B)
ALL(As Piston Ring and Piston Side .003L

Applicable) Clearance (Oil Scraper) .0055L .007L(B)
ALL(As PistonRing and Piston Side

lilillli!il Applicable) Clearance(3rd Ring Comp.) .ODO
HalfWedge .004L .006L(B)
iiiiiiiiiii
SSP1776 4-5
Island Enterprises


Ma. I I Ma.
Ne´•ar Old Mi. Serv. Min. Serv.
a Max. a Max.
Max. Max.
607 Piston Ring Gap (Compression)

Chrome Cylinders (Straight .020
Barrels) .030 .047
ALL Piston Ring Gap (Compression)

(Choke Barrels) .055 .067
ALL Piston Ring Gap (Oil Regulating) .015

(All Barrles) .030 .047
ilALL (As Piston Ring Gap (Oil Scraper) .015

Applicable) (All Barrels) .030 .047
For Choke Barrels Ring gap is measured within 4 inches from bottom. Ring gap at top of travel must not be less
than .0075.
Engine and Piston Application Min. Piston Diameter Cylinder Barrel

Max.
Clearance
Engine Chart
Type of Maximum Piston Skirt
Code Letter Piston Number Top Bottom Type of Piston Surface Diameter Cyl.
sos i~lWiii L 67266, 71553, 73620 4.8395 4.8540 Forged-Round C 4.8805 .02251.
sos L 73932 4.8395 4.8540 Forged-Round N 4.8805 .0225L
sos I;:na:I: L 75984 4.8395 4.8590 Forged-Cam C 4.8805 .018L
610 :SMi:i: L 75984, 76172+ 4.8395 4.8590 Forged-Cam N 4.8805 .018L
V 71940, 72249, 72578,
73947Y, 73976 5.0905 5.1040 Forged-Round C 5.1305 .0225L
V 71940, 72249, 73947,
73976 5.0905 5.1040 Forged-Round N 5.1305 .023 L
V 74242, 75617 5.0790 5.1090 Forged-Cam C-N 5.1305 .018L
V 78203, 78762, LW-1o2o7W,
LW-1o208 5.0790 5.1090 Forged-Cam C-N 5.1305 .D18L
NOTES:
To find the average diameter of cylinder in an area 4" above Maximum taper and out-of-round permitted for cylinder in
bottom of barrel: First, measure diameter at right angles service is.oo45 inch.
from plane in which valves are located. Second. measure
diameter through the plane in which valves are located. Add See Service Instruction No. 1243 for identification of cast
both diameters; this sum, divided by 2, represents the average a"d forged pistons. The suffix ’5" that will be found with
diameter of the cylinder. the part number on 73947, 73976, 74242, 75984, 78203,
78762, LW-102o7, LW-1o20s pistons indicates the piston
weight is within the limits specified for any group of pistons
"=High Compression. and may be substituted for any like piston on a particular
engine. Other pistons are manufactured within weight limits
Cylinder Barrel: N=nitride hardened, C=chrome plated, that do not require any weight controlled piston for
liiiliiiii replacement.
To find the average out-of-round, measure diameter of
cylinder inan area 4" above bottom of barrel: First, measure Piston diameter at top is measured at top ring land (between
ii diameter at right angles from plane in which valves are top and second compression ring grooves) at right angle to
I0cafed. Second, measure diameter through the plane in
Ij.iijlili piston pin hole; diameter at bottom of piston is measured at
which valves are located. Difference between diameters must the bottom of the piston skirt at right angles to the piston
not exceed .0045 inch. pin. See Service Instruction No. 1243 for illustration.
SSP1776 4-6
Island Enterprises

Chart NomeneLPtuw Dimensions Clearances

Ref. Ref.
Mfr. Mit.
Min. Serv. Min. Setv.
New OLd
a Max. a Max.
Max. Max.
611 L Exhaust Valve Seat and Cylinder .0065T

Head (Flat Seat) .010T (A)
ALL Exhaust Valve Seat and Cylinder .0075T

Head (Allison Seat) .OllT (A)
ALL O. D. Exhaust Seat (Allison 1.9355

Seat) 1.937
L O. D. Exhaust Seat (Flat 2.0965

Seat) 2.098
ALL I. D. Exhaust Seat Hole in 1.926

Cylinder Head (Allison Seat) 1.928
L I. D. Exhaust Seat Hole in 2.088

: j´•´•´•: Cylinder Head (Flat Seat) 2.090
612 ALL Intake Valve Seat and Cylinder .0065T

Head .010T (A)
O. D. Intake Seat (Aliison 2.1675
Seat) 2.169
liliiiiiiiiljll 0. D. Intake Seat (Flat 2.3145

Seat) 2.316
....V O. D. Intake Seat 2.2885

2.290
L I. D. Intake Seat Hole in 2.159

C~linder Head (Allison Seat) 2.161
L I. D. Intake Seat Hole in 2.306

Cylinder Head (Flat Seat) 2.308
V I. D. Intake Seat Hole in 2.280

Cylinder Head 2.282
613 5:~61:ilALL Exhaust Valve Guide and .001T

ii:i Cylinder Head .0025T (A)
s~:i:l ALL O. D. Exhaust Valve Guide .6633

(1/2 in. Exhaust Valve) .6638
L O. D. Exhaust Valve Guide .5933

ALL I. D. Exhaust Valve Guide

Hole in Cylinder Head .6613--
L I. D. Exhaust Valve Guide

614:6a~ ALL Intake Valve Guide and .001T

C~linder Head .0025T (A)
ALL O. D. Intake Valve Guide .5933

.5938
SSP1776 4-7
Island Enterprises
EIERV ICE TABLE OF LIMITEC

Ref. Ref. Chut Nomsnckture Dimendons Cleannces

Mtr. Mir.
a Max. a Max.
Max. Max.
614 1624.:::::IALL I I. D. Intake Valve Guide .5913

615 Is~B;i:i:IALL I Exhaust Valve Stem and Valve .0035L

Guide .0053L (A)
O. D. Exhaust Valve Stem .4957
.4965 .4937
Service allowable limits of
.4937 is applicable only to
inconel or nimonic valves.
O. D. Exhaust Valve Stem .4332

615 Finished I. D. Exhaust Valve .5000

Guide (1/2 in. Exhaust Valve) .5010
Finished I. D. Exhaust Valve .4360

Guide (7/16 in. Exhaust Valve) .4370
1/2 inch diameter exhaust valves may have exhaust valve guides that are .003 in. over the maximum inside
ter up to 300 hours of service. After 300 hours of service, inside diameter of exhaust valve
limit, anytime
may increase .001 in. during each 100 hours of operation up to the recommended overhaul time for the
,or not to exceed .015 inch over the basic Z. D. See latest edition of Service Instruction No. 1009 for
nded overhaul time.
616 I:::] ALL Intake Valve Stem and Valve .0010L

Guide .0028L .006L
ALL O. D. Intake Valve Stem .4022

.4030 .4010
616 iS%TJI:I:ALL Finished I. D. Intake Valve .4040

Guide .4050
617 Valve and Valve Cap .000

618 Dry Tappet Clearance .028

:iiiiiiil:: .080
619 Valve Rocker Shaft and .0001L

Valve Rocker Bushing .0013L .0025L
619 :L3ai:ilALL Finished I. D. of Valve Rocker

Shaft Bushing in Cylinder .62A6
Head .6261 .6270
620 ALL Valve Rocker Shaft and Valve .0007L

Rocker Bushings .0017L .004L
ALL O. D. Valve Rocker Shaft .6241

.6245 .6231
ALL Finished I. D. of Rocker Arm .6252

I Bushing .6263 .6270
621 ALL Valve rocker Bushing and

Valve Rocker Bushing must be burnished in place.
622 ALL Valve Rocker Shaft Bushing .0022T

and CLlinder Head .0038T (A)
S8P1776 4-8
Island Enterprises
PART I~ VERTICAL ENGINES

ChPrt Nomenekture Dimandon~ Cleu´•nce~

Ref. Ref.
Mh´•. Mir.
Old Sarv. Mfn. Serv.

Ne~a
a MPX. Q M´•x.
M~x. Mp´•,
Valve Rocker Shaft Bushing .7380
622jl
623 L Valve Rocker and Cylinder .002L

Head Side Clearance .020L .024L
625 I Intake and Exhaust Valve .914

Guide Height .954
MEASURE THE VALVE GUIDE HEIGHT

FROM THE VALVE SPRING SEAT
COUNTERBORE IN THE CYLINDER
HEAD TO THE TOP OF VALVE GUIDE.
SSP1776 4-9
Island Enterprises
88RV ICE TABLE OF IIMITB

622
621
623
620
619
618
17 1 r617
951 1---J ~i
950
615
611
CHOKE
606 601
OPTIONAL
604
605
610
601
609
TAPER
Cylinder, Piston, Connecting Rod and Valve Components
SSP1776 4-10
Island Enterprises

SECTION III GEAR TRAIN OIL PUMP
Nomanciature Dimendons Clearances

Ref. Ref. Chut
Mhr. Mis.
Serv. Min. Serv.
New Old
a Max. B Max.
M´•x. Mp~.
Oil Pump and Scavenge Pump .007L

702 I$iQ~Bli’:IIL-V
L1 Oil Pump Drive Gear End .010L

Cle arance .035L .060L
703 I:fi2l~Zi:i:ILV OilPump and Scavenge Pump .007L

Impellers Dia. Clearance .011L .014L
1 Oil Pump Impellers Dia. .007L

Clearance .OllL .014L
V Oil Pump and Scavenge Pump .003L

704
.0055L .006L
Impellers Side Clearance
Oil Pump Impellers- Side .003L

ALL Width of Oil Pump Impellers .995

.997 .994
ALL Width of Oil Scavenge Pump 1.496

Impellers 1.498 1.495
705:I:II CV Oil Pump and Oil Scavenge

Pump Driven Impeller and .001L
L1 Oil Pump Driven Impeller .0010L

and Idler Shaft .0025L .004L
Oil Pump Idler Shaft and Oil .0000

706
Pump Body .0015T (A)
OilPump Idler Shaft and Oil .0000

:::::::i::: Pump Cover .0015T (A)
Oil Pump Idler Shaft and .0000
Scavenge Pump Body .0015T (A)
Oil Pump Drive Shaft Bushing .001T

777 :j L-V
e (A)
and Scavenge Pump Body .003T
L1 Oil Pump Drive Shaft Bushing .001T

ALL Oil Pump Drive Shaft Bushing .001T

778
L1 Oil Pump Drive Shaft Bushing .001T

and Oil Pump Cover .003T (A)
lifiiiiiiit
Oil Pump DriveBushing and .0015L
779 E:~9!:ll L-V
Oil Scavenge Pump Gear .0035L .005L
L1 OilPump Drive Gear and Oil .0015L

.0035L .005L
Pump Cover
ALL Oil Pump Drive Shaft Bushing .0015L

780
and Oil Pump Shaft .0035L .005L
Oil Relief Valve Plunger .001L

705
and Sleeve .003L .005L
fiiiiii
SSP1776 4-11
Island Enterprises
sERV ICE TABLE OP LIMIT8

SECTION III GEAR TRAIN OIL PUMP
Rei. Ref. Chut Nomenclature Dimensions I Clearances

Mtr. Mlr.
NelR Old Min. Serv. Min. Serv.
ii Max. O Max.
Max. Max.
7076 ItrjiiiiijijiiiilL1 I Oil Pump Drive Gear Bushing .002T

7077 I~iiiiiiiiiifililll I OilPump Drive Gear and .0015L
SECTION III GEAR TRAIN FUEL PUMP
782 ]IJ103:I:.:IL-V Fuel Pump Drive Shaftgear .001T

Bushing and Accessory Housing .004T (A)
783 V Fuel Pump Drive Shaftgear .006
784
B V
End Clearance
Fuel
and
Pump Drive Shaftgear
Bushing
.064
.001L
.004L
.074
.006L
SECTION III GEAR TRAIN VACUUM PUMP
793 Vacuum Pump Shaftgear Bushing .0015T

and Accessory Housing Cover .0035T (A)
794 ::ILV Vacuum Pump Shaftgear Bushing
Cover) and Vacuum Pump
Sh aftger(At .002L
.004L .006L
795:I:1IGV Vacuum Pump Shaftgear Bushing .0015T

L1 Vacuum Pump Shaftgear Bushing .0025T
796 Vacuum Pump Shaftgear Bushing
(At Accessory Housing) and .002L
Vacuum Pump Shaft~ear .0045L .006L
797 ~3[51:18LV Vacuum Pump Shaftgear End .008

Clearance .030 .050
799 Vacuum Pump Drive Gear .002T

Bushing andAccessory Housing .004T (A)
7000 Vacuum Pump Drive Gear
and Vacuum Pump
Drive GearBushing .0025L
.0045L .006L
7078 L1 Vacuum Pump Drive Gear and .0013L

Cover .0033L .005L
7079 L1 Vacuum Pump Drive Gear .010

SECTION III GEAR TRAIN TACHOMETER
70021:186::::1L1 Tachometer Driven Gear and .001L

7006 Electric Tachometer Driven .007

Gear End CLearance .025 .047
Electric Tachometer Driven .001L
’iiI Gear and Accessory Housing Cover .003L .004L
SSP1776 4-12
Island Enterprises
E)ERV ICE TABLE OF LlnnlTB

SECTION III GEAR TRAIN TACHOMETER
Chut Nolnenckture Dimensions Clearances

Her. I Her.
Mrs. Mfr.
E~Un. Ssrv. Min. Serv.
New Old
a Men. a Msx.
Mex. Max.
7088 Tachometer Adapter and .0005L

MAGNETO
iiijiiiiiiiiiil SECTION III GEAR TRAIN
7025 :i:1 V Magneto Drive Idler Gear Hub

Bushing and Magneto Drive
Idler Gear Hub ing must be burnished in place.
7026 Magneto Drive Idler Gear Hub

Bushing and Magneto Drive .001L
7027 V Magneto Drive Idler Gear Hub .005

7028 v Magneto Drive Shaft and .002L

Accessory Housing Cover .0045L .006L
7029 Magneto Drive Shaft and .0025L

7030 Magneto Drive Shaft Sleeve .001T

and Magneto Drive Shaft .004T (A)
7031 Magneto Drive Shaft Sleeve .001T

andMagneto Drive Coupling .004T (A)
7032 V Magneto Drive Shaft Gear .002

7039 (iiliiiiiiiiiijilL1 I Magneto Drive Idler Gear .002

End Clearance .030 .0~0
708011 Magneto Drive Idler Gear

Bushing and Magneto Drive .001L
Idler Shaft .003L .004 L
7081 :::I:::::I:I:I Magneto Drive Idler Gear and

Magneto Drive Idler Gear .0005T
Bushing .0025T (A)
L1 Magneto Drive Gear Bushing .002T

’"""llfi and Accessory Housing .004T (A)
7083 L1 Magneto Drive Coupling and .001L

7084 L1 Magneto Drive Gear and .001L

SECTION III GEAR TRAIN GENERATOR
7043 1:I:I LV Generator Drive Gear Bushing .0015T

and Accessory Housing Cover .0035T (A)
7044 E~$iiiil L-V Generator Drive Gear Bushing

(At Cover) and Generator .002L
Drive Gear .004L .006L
7045 LV Generator Drive Gear Bushing .002T
i and Accessory Housing .004T (A)
8SP1776 4-13
Island Enterprises

SECTION III GEAR TRAIN GENERATOR
Rei. lier. Chut Nomsncl´•ture Dimenalons Clearances

Mfr. Mir.
Nea Old Min. Serv. Min. Serv.
a Max. a Max.
Max. Max.
7046 iiiii V Generator Drive Gear Bushing

’ ’ ’i Accessory Housing) and
tA(raeG
Generator Drive
.0025L
.0045L .006L
7047
i pv Generator Drive Gear
Clearance
End .010
.038 .050
SECTION III GEAR TRAIN STARTER
7048’ V Starter Drive Gear Bushing .002T

ililiiiiii and Adapter .004T (A)
I:i:iiiii: Starter Drive Spacer Bushing .002T
and Adapter .004T (A)
7049 V Starter Drive Gear Bushings .002L
and Starter Drive Gear .004L .006L
Starter Drive Spacer and .0015L

Starter Drive Adapter Bushing .003L .004L
7050 V Starter Drive

Adapter and .0005L
jljljlf~ilili Accessory Housing Cover .0025L (A)
7089 Starter Drive Gear End .007
Clearance .011 .015
7090 1 Bendix Drive Shaft (Slip

Coupling) and Accessory .0015L
Housing Bushing .0045L .005L
iiiiiii:ij:i SECTION III GEAR TRAIN ACCESSORY DRIVE
7053 V Accessory Idler Gear Bearing .0001L

and Accessory Drive Gear .0007T (A)
7054 Accessory Drive Gear and .001T
Bushing .003T (A)
V Accesso~ Idler Gear Bearing .0005T
1111111
iiiiiiiiiiiiii and Accessory Drive Shaft Adapter .0005L (A)

7056 Accessory Drive Gear Bushing .0005L
and Accessory Drive Shaft .0017L .004L
7057 P~i:l: Accessory Drive Gear End .004

ji i i i~ji Clearance .012 .017
7086 Accessory Drive Shaftgear .002T

ji~j:i Bushing and Accessory Housing .004T (A)
7087 Accessory Drive Shaftgear .002L
and Accessory Housing Bushing .004L .006L
7091 ´•ili L1 Dual Accessory Idler Gear and .001L

7092~E) L1 Dual Accessory Idler Gear .009

End Clearance .018 .023L
7043 Dual Accessory Drive Gear .005

7094 L1 Dual Accessory Drive Gear .0013L

and Adapter .0028L .0034 L
8SP1776 4-14
Island Enterprises

705
777~ ~f7047 r106
jj~ III ~11 -F~ ~-779

7sa~
´•’K
704 778
703’ 702
VO-455-B a TVO-435-F
OIL PUMP a HYD. PUMP DR.
7057 703
706
705
713
704
704
702
780
901
778~ ~LY1 L777
CROSSWISE ACC. HSG.
Oil Pumps
SSP1776 4-15
Island Enterprises

7012--/ ~7006
VO, TVO-435-A 8 VO, TVO-540

Tachometer Drive
7051
7051
a_i__~
C~t;-:
Oil Relief Valves
SSP1776 4-16
Island Enterprises

----2~
´•i riin ti
i
r
i’ I
´•I r
797
794 ii III C, r--- ;sl it~l u i
0~
i<-Y
Y;c~/
*r~c´•n’
793
784 ’796
X x’ X
~782
783
SSP1776 4-17
Island Enterprises

7093
7094
7091
7092
7079
7078
TVO-455-F
Vacuum Pump and Fuel Pump Dual Drive
VACUUM PUMP PAD
702
795
7077
796
7076
ACCESSORY HSG.
VO-455-BIA 8r TVO-435-F
Vacuum Pump Drive
SSP1776 4-18
Island Enterprises
IERV ICE TABLE OF LIMITs

a ~7088
7002
VO-435-B 8~ TVO-435-F
Tachometer Drive
7081
7039
7080
7000
799
ALTERNATOR
VO-435-B 8r TVO-435-F
Vacuum, Magneto and Alternator Drive
SSP1776 4-19
Island Enterprises
PART IV VERTICAL ENGIN ES

7025
7026
7027
VO, TVO-435-A 8r VO, TVO-540
Magneto and Tachometer Idler Gear
7090
V0-435-8 8( TVO-435-F
Bendix Drive
SSP1776 4-20
Island Enterprises

ACCESSORY HSG
7032
MAGNETO
7084
7083
7082 ’7082
VO-435-BIA
7028 7029
7031’ ’7032 7030
VO, TVO-435-A 8~ VO, TVO-540
Magneto Drives
SSP1776 4-21
Island Enterprises

7047
7045
7043
7044
7049
7046
7050
VO, TVO-435-A 8~ VO,TVO-540
Generator and Starter Drives
SSP1776 4-22
Island Enterprises
EERV ICE TABLE OF LIMITS

CRANKSHAFT 7
~7087
7086
ACCESSORY HSG.
VO-435-BIA
Accessory Drive Gear
7048
7049
7089
VO -435-81A
Starter Drive
SSP1776 4-23
Island Enterprises

7053
7055
VO, TVO-435-A a vo, TVO-540
7056 r7053
8
7055
7054
7057
VO-540
Accessory Drives
4-24
SSP1776
Island Enterprises
BERVIOE TABLE OF LIMITB

SECTION IV BACKLASH
Nomenclature I Dimensions Clearances

Ref. Ref. Chart
Mfr. Mfr.

New Old
Q Max. P Max.
Max. I I Max.
808 06a::::IL1 OilPump Impeilers .005

.015 .020
OilPump and Scavenge Pump .008

Impellers .015 .020
825 Crankshaft Timing Gear and .004

i~ili i l´•’’ Camshaft Gear .015 .020
866 I:1~8i:i:1L-V Electric Tachometer Drive Gear

(Magneto Idler Hub) and .004
Tachometer Driven Gear .015 .020
Generator Drive Gear and .004

867
’ ~:Di:I:l
LV
Ma~eto Drive Idler Gear .015 .020
868 L-V Magneto Drive Shaft (Spline)

and Magneto Drive Shaf$ear .001
(Spline) .005 .008
869 Magneto Drive Shaftgear

(Spline) and Magneto Drive .001
Coupling (Spline) .005 .008
L1 Magneto Drive Shaft (Spline)

(Spline) .0045 .0075
870 Rear Crankshaft Spline

Bushing and Accessory Gear .002
(Spline) .0073 .018
L1 Rear Crankshaft Spline

Bushing and Accessory Drive .004
Quill Shaft (Spline) .0073 .018
V Rear CrankshaftSpline
Bushing and Accessory Drive I I .002
Shaft (Spline) .0073 .018
871 Accessory Drive Gear and .004

Starter Drive Gear .008 .015
:i L1
L1
Accessory Drive Gear and
Starter Drive Gear
Starter Drive Shaftgear and

Starter Drive Gear (Spline)
.002
.016
.000
.002
.004
.022
.004
872 Accessory Drive Gear and

Generator Drive Gear .015 .020
L1 Alternator Drive Shaft

(Spline) and Vacuum and .001
Magneto Drive Shaft (Spline) .004 .006
L1 Alternator Drive Shaft

(Spline) and Alternator .001
(Spline) .005 .007
873 t17~8 L-V Accessory Drive Gear and .004

Vacuum Pump Shaftgear .015 .020
SSP1776 4-25
Island Enterprises
sERV ICE TABLI OF LINIITS

SECTION IV BACKLASH
Ref. Ref. Chart I Nomenclature I Dimensions Clearances

Mfr. Mfr.

Max. Max.
Max. I I Max.
874 V Vacuum Pump Shaftgear and

Oil Pressure Scavenge Pump .004
Gear .015 .020
;ri
884 1 Magneto Drive Idler Gear .006
and Magneto Driven Gear .014 .020
1 Magneto Drive Gear and .006

Magneto Idler Drive Gear .014 .020
895 i:i:i:::::i:i:::IL-V Vacuum Pump Shaftgear and .004

Fuel Pump Drive Shaftgear .010 .015
Oil Pump Drive Gear and .006

Tachometer Drive Shaftgear .014 .020
Tachometer Drive Gear and .002

Tachometer Drive Shaftgear .006 .010
898 liijliiiliiiiililll I Magneto Gear (Spline) and .001

Magneto Drive Shaft (Spline) .0045 .0075
Starter Drive Shaft Gear

(Spline) and Vacuum, Magneto .001
Shaft (Spline) .004 .007
8001 Iti~ililliillililll I Accessory Drive Quill Shaft

(Spline) and Accessory Drive .004
Gear (Spline) .0073 .011
8002 [ilill:iililjL1 I Vacuum Pump Drive Gear

(Spline) and Shaft Vacuum .001
Pump Magneto Drive (Spline) .004 .007
8003 tlililil:iilili~ll I Vacuum, Oil Pump Drive Shaft

Gear and Vacuum Pump Drive .005
Gear I I 1 .015 .020
8004 t8g3::::~L1 Dual Accessory Drive Gear .004

and Idler .D15 .020
8005 L1 Starter Drive Gear and Bendix .016

Drive (Slip Coupling) Gear .026 .031
8006 tS~i:I:1L1 Dual Accessory Idler Gear .004

and Vacuum Pump Drive Gear .015 .020
SSP1776 4-26
Island Enterprises

SECTION IV BACKLASH
DRIVE IDLER GEAR
CAMSHAFTa
GEAR
TACH.\
DRIVEN
867
lu’TACH.
GEAR
1
rt-_ 865
j-,GENERATOR DRIVE
SHAFTGEAR
870
871
i I ii 1~ 873
CRANKSHAFT17- STARTER 8(
GEAR
ACCESSORY
DRIVE GEAR
ACCESSORY DRIVE GEAR
~-VACUUM PUMP
OIL SCAVENGE---\
PUMP GEAR SHAFTGEAR
808

IMPELLERS
FUEL PUMP
DRIVE SHAFTGEAR
VO, TVO-435-A 8( VO, TVO-540

Accessory Drives
4-27
SSP1776
Island Enterprises

SECTION IV BACKLASH
MAGNETODRIVE~ 868~ rMAGNETO DRIVE

COUPLING SHAFTGEAR
\L
869
I MAGNETO DRIVE SHAFT
GENERATOR DRIVE
TACH. DRIVE IDLER GEAR -I I i i SHAFTGEAR
STARTER JAW~
887
STARTER ACCESSORY
VACUUM PUMP SHAFTGEAR
DRIVE GEAR
LFUEL PUMP DRIVE

OIL PRESS. SCAVENGE
PUMP GEAR SHAFTGEAR
VO-TVO-455-A 8r VO, TVO-540

REAR OF ENGINE
Accessory Drives
SSP1776 4-28
Island Enterprises

SECTION IV BACKLASH
CAMSHAFT GEAR
TACHOMETER SHAFT GEAR

MAG. DRIVE
MAG. IDLER
897 ~1 1 r884
STARTER DRIVE
SHAFT GR. BEVEL
TACH. DRIVE
VAC. PUMP DRIVE a Mac
IDLER DRIVE GEAR
CRANKSHAFT
GEARi884
871
8003
!ti STARTER
STARTER DRIVE
VACUUM PUMP
DRIVEN
ACCESSORY DRIVE 896
808
OIL PUMP
DRIVE GR.
OIL PUMP DRIVEN GR.
OIL PUMP IMPELLERS
VO-435-BIA
LEFT SIDE OF ENGINE
Accessory Drives
4-29
SSP1776
Island Enterprises

SECTION IV BACKLASH
8004
8006
TVO-435-F
Vacuum Pump and Fuel Pump Dual Drives
SSP1776 4-30
Island Enterprises

SECTION IV BACKLASH
899
8002
872
872
A LT E R I\IATOR
V0-435-8 TVO-435-F
Vacuum, Magneto and Alternator Drives
SSP1776 4-31
Island Enterprises
SERV ICE TABIE or= ~IMI´•rs

SECTION IV BACKLASH
8005
VO-455-B 8~ TVO-455-F
Bendix Drive
SSP1776 4-32
Island Enterprises

SECTION IV BACKLASH
ACCESSORY HSG.
MAGNETO
869
898
VO-435-BIA
869
868
VO, TVO-435-A 8( VO, TVO-540
Magneto Drives
SSP1776 4-33
Island Enterprises

SECTION IV BACKLASH
871
VO-435-BIA
Starter Drives
870
CRANKSHAFT
8001
ACCESSORY HSG.
VO-435-BIA
Accessory Drive Gear
SSP1776 4-34
Island Enterprises

Rei. Ref.
Thread
New Old Chart Size Nomenclature Torque Limits
900 3/8-24 Connecting Rod Nuts 480 in. Ibs.
V 3/8-24 Connecting Rod Bolt and Nut -Tighten

to This Length 2.255 2.256
901 112-20 Oil Pump Shaft Nut 360 -480 in.lbs.
903 3/8-24 Magneto Nut(To attach drive

member tomagneto) Steel Bushing 300 in. Ibs.
904 10-32 Screw Plate Nuts (To attach ignition

cable outlet plate to magneto) 15 in.ibs.
905 1/4-20 Rocker Box Screws 50 in. Ibs.
906 5/16-18 Exhaust Port Studs

(Driving Torque) 40 in. Ibs. min.
5/16-18 Nuts to Attach Exhaust Stacks

i i to C~linder Head 160 180 in. Ibs.
18MM Spark Plugs 420 in. Ibs.
-I: 5/8-32 Alternator Nut (Quill Shaft) 474 in. Ibs.
910 ~/4-28 Alternator Output Terminal Nut 85 in.lbs.
911 aoo:::::IL1 10-32 Alternator Auxiliary Terminal Nut 30 in. Ibs.
913 ~7iIil L1-L&V 1/16-27 N~ Piston Cooling Nozzle in Crankcase 100 in.lbs.
1/8-27 N~ Injector Nozzle in C~linder Head 60 in. Ibs.
919 &Ili~i:.:ALL 1/4 Hex Head Hose Clamps (Worm 5pe)

and Below 20 in. Ibs.
ALL 5/16 Hex Head Hose Clamps (Worm 5pe)

919-
1
:1ALL "T" Bolt Hose Clamps
Initial Torque......... 35 in. Ibs.
Retorque After Run-in........... 25 in. Ibs.
920 8~1:6:.:11ALL Cylinder Head Drain Back Hose

Clamp 10 in. Ibs.
921 L2-V1 Exhaust Clamp Coupling

V-Band (See Service Instruction No.
1238)

928’~’ ’ ’ ’ (Crankcase Driving Torque) 100 in. Ibs.

929 3/8-16 Cylinder Hold Down Nuts 300 in. Ibs.
I tion No. 1029.

1/2-13
linder Hold Down and Crankcase

Cylinder Hold Down
Parting Flange Nuts’ Tightening

Nuts
Procedures
600 in. Ibs.
See latest edition of Service
SSP1776 4-35
Island Enterprises
sERV ICE TABLE OF LIMIT8

Rei. Rsf.
Thread
New Old Nomenclature
Chart Size Torque Limits
933 Accessory Drive Shaft Nut 75 125 ft. Ibs.
934 Crankshaft Gear Retaining Nut 150 ft.lbs.
938 ALL 1/4-28 Thin Slotted Nut (38 in. Ibs. plus
if :i . ’: :f locking
required
euqrot).ols to reach next
38 in. Ibs.
942 ALL 1/8-21 NPT Carburetor Drain Plug 50 60 in. Llos.
943 10-32 Screws (To attach accessory

drive coupling plate) 25 30 in. Ibs.
944 Carburetor Throttle Lever Screw 20 28 in. Ibs.
945 Accessory
jii,,
Drive Shaft and
Accessory Drive Gear Attaching
Screw 100 120 in. Ibs.
SECTION V SPRINGS
COMP. LOAD
Length
Avco Lye. Wire
Chart At Comp.
Nomenclature Part No. Dia. Mig. Me. Serv.
Length
Min. Max. Max.
9501:I:I ALL Outer Valve Springs

(Angle) 68326 .177 1.46 in. 103 Ib. Illlb. 100 Ib. min.
ALL Outer Valve Springs

(Angle) LW-11796 .182 1.43 in. 114 Ib. 124 Ib. Illlb. min.
ALL Auxiliary Valve

Springs (Angle) 68328 .142 1.33 in. 75 Ib. 83 Ib. 72 Ib. min.
ALL Auxiliary Valve

Springs (Angle) LW-11797 .142 1.33 in. 73 Ib. 83 Ib. 70 Ib. min.
952 Check Valve Springs
.i
Avco Lycoming
Part Numbers Free Length
654-B 1 1 .031 1.03 in. .74 Ib. .94 Ib. .69 Ib. min.
73761 2.065 .041 1.03 in. 3.15 Ib. 3.35 Ib. 3.10 Ib. min.
Oil Pressure Relief

Valve Spring
Avco Lycoming Identification

Part Numbers Dye Free Length
L-V 68542 None 2.38 .067 1.66 in. 15 Ib. 17 Ib. 14 Ib. min.
L-V LW-14029 White 2.28 .072 1.66 in. 20 Ib. 22 Ib. 17 Ib. min.
954 Accessory Drive

Coupling Spring
Avco Lycoming
Part Numbers Free LRngth
V-AS 74616 1.25 .092 1.10 23 Ib. 26 Ib. 20 Ib.

APPLICABLE
S8P1776 4-36
Island Enterprises
STANDARD TORQUE
TABLE II
TABLEI
PIPE PLUGS
Toraue Torque Torque

Thread In. Lbs.
1116-27 NPT 40
10 49 1/2 900 75
1/8-27 NPT 40
1/4 96 9/16 1320 110
1/4-18 NPT 85
5/16 204 17 5/8 1800 150
3/8 360
3/8-18 NPT 110
30 3/4 3240 270
1/2-14 NPT 160
7/16 600 50
4-14 NPT 0
1-111 NPT 315
TABLE IV
TABLE II1
FLEXIBLE HOSE
OR TUBE FITTINGS
Thd. Pitch On Part ANG LE OF TU RN Torque

Tube Size Thread In. Lbs.
To Be Ti tened Aluminum pper
rea er Inch Asbestos Asbestos
(-3) 3/16 3/8-24 30
8 1350 670 (-4) 1/4 7/16-20 30
10 1350 670 (-5) 5/16 1/2-20 35
12 1800 (-6) 3/8 9/16-18 35
1 -8 1 3/4-16 60
16 2700 1350
18 2700 1350
-10 5/8 7/8-14 70
20 27 135
24 3 1
28 3 1
NOTE TABLE V
Install all crush type gaskets except the self centering STUDS
type, with the unbroken surface against the flange of MIN. DRIVING TORQUE
the part until the sealing surfaces are in contact and Threads in. Cb s.

appropriate thread size. 114-20 15
5/16-18 25
SSP1776 4-37
Island Enterprises
BERV ICE TABLE OF LIMITE

SECTION VSPECIAL TORQUE AND SPRINGS
907
51~i:
950-\
905~ 1 II\
951
906
920
SSP1776 4-38
Island Enterprises
BERV ICE TABLE OF Lll\nlTB

SECTION V SPECIAL TORQUE AND SPRINGS
911
I I II I I I I I s´•:
Fl ’FZ
911~ ’-911
ALTERNATOR a ALTERNATOR DRIVE
903
I:
j;
i?
901
‘‘t)L~1
OIL PUMP MAGNETO
SSP1776 4-39
Island Enterprises

870~ Y~
VO, TV0-435-A 8r 7V0-540
870
VO-540
Accessory Drives
SSP1776 4-40
Island Enterprises

953
952
921
919
920
919-1
I i,

SSP1776 4-41
Island Enterprises

LYC 60294 9 2 Overhaul 76series1975 1996 PDF

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LYC 60294 9 2 Overhaul 76series1975 1996 PDF

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Overhaul Ma aua I

L~AVCO LYCOMING WILLIAMSPORT DIVISION

Second Printing Pa rt No. 60294-9

Aug ust 1980 Price $23.00

60294-9-2 76 Series Engine Over- 60294-9 August 1980

Previous revisions to this publication This revision consists of:

TO THE OWNER OF THIS MANUAL

IN ADDITION TO THIS MANUAL AND SUBSEQUENT REVISIONS, ADDITIONAL

equipment or part thereof.

Revised June 1996

SECTION PAGE SECTION PAGE

1. INTRODUCTION 1´•1 5. CYLINDERS. PISTONS AND VALVE TRAIN

TABLE OF CONTENTS (CONT.)

nature, warranty. The proper forms must be completed by your

part number, considered the bottom Cylinders are numbered from

may be ordered from the department listed in paragraph

Figure 1-1. Typical 4 Cylinder Engine

Desaiotion of Engine Model Code

L Lefthand Engine Rofation 000* E Fbwer Secfion 8

V -vertical Helicopter B -Accessory Section

H -Horizontal Helicopter 4 coun~weism Application

A Aerobotic D --Duol Mogneto

G Gewed Nose Section

S are reflectedin this Section

2-13.Cooling System. These engines are designed to be

vides the magnetic energy for both circuits. Consult the

TACHOMETER DRIVE GEAR

RATIO .50 1.00

PROP GOV. DRIVE GEAR

PROP GOV DR. GEAR

,RATIO I:I ii´• i I~ NO´• OF TEETH ~I

OIL PUMP IMPELL

VACUUM 8 OIL PUMPDR. GEAR

NO. OF TEETH 22 MAGNETO GEAR

f ~--VACUUM PUMP DR. GEAR

HYDRAULIC PUMP DR. GEAR

Figure 2-2. Gear Train Diagram 4 Cylinder Engine

(NO.2 I -A 2 CAM BRt

INT. VALVE TRAIN

OIL PRESS VALVE

THER)IIO OIL PRESS.

Figure 2-3. Oil Lubrication Schematic

GENERAL OVERHAUL PROCEDURES

to machined surfaces. In particular, wire brushes and

INSPECTION 3-23. Screwed Fittings. Screwed fittings (any parts such

ner in which it is broken. The procedure for removing and

quired. 3-35. Corrosion-Prevention. Prior to assembly of

3-44.Arbitrary Replacement ofParts. It is recommended

Figure 4-1. Magneto and Harness Assembly

accessories. Consult the manufacturer’s applicable REASSEMBLY

The advance timing mark is specified on the engine

position. The right main breaker monitored by the green

4-22.Ignition Haness. Prior to inserting spark plug lead

Figure 4-3. Ignition Wiring Diagram

CYLINDERS, PISTONS AND VALVE TRAIN