Overhaul Manual FOR Gtsio-520 Series Aircraft Engines: Faa Approved MARCH 1981 FORM X-30045A

OVERHAUL MANUAL
FOR
GTSIO-520 SERIES
AIRCRAFT ENGINES
FAA APPROVED
FORM X-30045A MARCH 1981
CURRENT STATUS OF PAGES AS OF
MARCH 1981
INSERT LATEST PAGES DESTROY SUPERSEDED PAGES
THE PAGES IN THIS PUBLICATION CONSIST OF THE FOLLOWING:
MODELS GTSIO-520-C, D, H, K, L, M and N

PAGE ISSUE PAGE ISSUE
ithru iv Original B-1 March 1981
V June 1980 B-2 October 1980
vi thru viii Original B-3 Original
ix thru x March 1981 B-4 March 1981
A-1-1 October 1980 B-5 Original
A-1 -2 March 1981 B-6 June 1980
A-2-1/A-2-2 June 1980 B-7 thru B-10 Original
A-3-1 Original B-1l thru B-13 June 1980
A-3-2 March 1981 B-14 thru B-21 Original
A-3-3 thru A-3-6 Original B-22 March 1981
A-4-1 thru A-4-13 Original B-23 thru B-25 Original
A-4-14 March 1981 B-26 October 1980
A-4-15 thru A-4-17 Original B-27/B-28 Original
A-4-18 October 1980 C-1-1 thru C-1-7 Original
A-4-19 thru A-4-20 June 1980 C-1 -8 June 1980
A-4-21 thru A-4-25 Original C-1-9 thru C-1-16 Original
A-4-26 June 1980 C-2-1 Original
A-4-27 thru A-4-29 Original C-2-2 June 1980
A-4--30 March 1981 C-2-3 Original
A-5-1 thru A-5-4 Original C-2-4 June 1980
A-6-1 June 1980 C-2-5 thru C-2-6 Original
A-6-2 Original C-2-7 thru C-2-8 June 1980
A-8-1 thru A-8-2 Original C-2-13 thru C-2-16 June 1980
A-9-4 thru A-9-6 June 1980 C-3-3 thru C-3-4 June 1980
A-10-1 Original C-3-5 thru C-3-6 Original
A-10-2 June 1980 C-3-7 thru C-3-8 June 1980
A-10-5/A-10-6 June 1980 C-3-15 thru C-3-18 June 1980
A-1 1-3 June 1980 C-4-3 June 1980
A-1 1-4 Original C-4-4 thru C-4-20 Original
A-1 2-1 March 1981 C-5-1 thru C-5-2 Original
A-12-4 June 1980 C-5-5 thru C-5-8 Original
A-12-5 thru A-12-6 Original C-5-9 March 1981
A-1 2-7 /A-1 2-8 March 1981 C-5-10 thru C-5-12 Original
A-13-3 March 1981 C-6-1 thru C-6-2 Original
A-1 3-4 Original C-6-3 thru C-6-4 June 1980
A-13-5/A-13-6 June 1980 C-6-5 thru C-6-1 2 Original
C-7-1 thru C-7-18 October 1980
FOREWORD
i-1. COMPOSITION. i-7. Chapter C.
i-2. This publication is constructed to give i-8. This chapter contains the Difference Data
adequate information for complete overhaul instructions for all engine models as listed in the
operations for the models covered throughout Table of Contents. This chapter consists of individ-
these three (3) Chapters A, B, and C. ual sections, each relating to a particular engine
model. Each section, along with the instructions
The basic engine overhaul (Chapter A) is written to for the basic model in Chapter A, provide complete
a hypothetical GTSIO-520 engine model, covering coverage for overhaul. The instructions in the
the most common basic items of all engines Difference Data Section are to be used in lieu of
involved. Any differences between Chapter A (the those for the same assemblies in the basic model
basic) and the letter model engines is adequately
covered by the use of Difference Data Section, i-9. AVAILABILITY.
Chapter C. Chapter B is the combined listing of the
Table of Limits for all engines covered in this i-10. Further copies of this and other Teledyne
manual. Personnel overhauling any engine model Contintal Motors aircraft service publications may
covered by this consolidated manual will be con- be purchased through Teledyne Continental
cerned only with the Difference Data Section, Approved Distributors and Parts Dealers for air-
indexed by the letter of his particular engine craft engine parts. It is requested that all orders for
model, Chapter A (the basic), and Chapter B Table such publications be placed with these facilities.
of Limits. All pages, figures and tables in this
manual are numbered by the following system: i-11. SERVICE BULLETINS.
Page A- 13 -7 refers to the seventh page of Section
13 of Chapter A. i-12. Important changes in part numbers, inter-
changeability of parts, urgent inspection, man-
i-3. Chapter A. datory replacements and modernization infor-
mation are among the subjects of limited interest
i-4. This chapter contains complete overhaul and duration covered by factory Service Bulletins,
instructions for the basic GTSIO 520 engine. This which are distributed to all Approved Distributors
chapter consists of (14) sections numbered I of aircraft engines and parts and are available for
through XIV. These sections cover the Intro- study at their offices. Service Bulletins of interest
duction, Specification Limits, General Description, to aircraft owners, operators and maintenance
Illustrations, Special Tools and Equipment, personnel may be obtained by direct mail on an
Unpacking and Preparation for Service, Storage or annual subscription basis. The charge for this
Shipment, Disassembly, Cleaning, Inspection, service covers only postage and handling.
Repair and Replacement, Assembly of Sub-
assemblies. Final Assembly, Repair and Testing of
i-13. SERVICE REPORTS AND INQUIRIES.
Accessories and Testing after Overhaul, of the basic
model engine. Hereafter, through this manual i-14. It is the policy of Teledyne Continental
Chapter A will be known as the basic model Motors to handle all reports of service difficulty
GTSIO-520. and requests for information through Approved
Distributors. These facilities are constantly in
i-5. Chapter B. touch with operation and repair. You will find
them more than willing to help solve your
i-6. This chapter consists of the Table of Limits maintenance problems and well equipped with
for all engines covered in this consolidated manual. experience and facilities to perform any necessary
The index numbers on the Limits and Lubrication maintenance work on Teledyne Continental
Chart are listed in the Table of Limits and are aircraft engines. There is an Approved Distributor
referred to as reference numbers. at most major airports.
i
.. . ......
.... .
...... .. .A-6-1
.A-7-1
.A-7-1
.A-7-2
.A-6-1
A-7-5
A-7-2
A-7-3
A-74
A-7-5
A-7-3
CHAPTER A (BASIC)
TABLE OF CONTENTS
Section Page
Forew ord . . . . . . . . . . . . . . . . . .
i-1. COMPOSITION ........... i.
i-9. AVAILABILITY ...........
i11. SERVICE BULLETINS.......
i-13. SERVICE REPORTS ........
I INTRODUCTION A-1-1
1-1. Scope . . . . . . . . . . . . A-1-1
1-3. Difference Data Sections... A-1-1
1-5. Related Manuals ....... A-1-1
1-6 Definition of Terms..... A-1-1
1-7 Cylinder Arrangement .... A-1-1
1-9 Aircraft Engine Nameplates A-1-1
1-8 Definitions and Abbreviations A-1-2
II. SPECIFICATIONS, LIMITS AND CHARTS A-2- 1
III GENERAL DESCRIPTION A-3-1

3-1. Construction .. . . . . . A-3-1
3-2. Functional Systems ......... A-3-2
IV ILLUSTRATION S A-4-1
V SPECIAL TOOLS AND EQUIPMENT A-5-1
VI UNPACKING AND PREPARATION FOR SERVICE, STORAGE OR SHIPMENT A-6-1

6-1. Unpacking ................... .
6-2. Preparation for Service ............. .
6-3. Preparation for Storage ............ .
VII DISASSEMBLY A-7-1

7-1 Aircraft Parts and Accessories . .
7-2 Extent of Disassembly ......... . . .
.
7-3 Parts to be Discarded .......... .
74 Disassembly Stand ........... .
7-5 Preliminary Cleaning .......... .
7-6 Ignition System ............ .
7-7 Fuel Injection System ......... .
7-8 Induction System ........... .
7-9 Magneto and Accessory Drives. .
7-10 Oil Sump ................ .
7-11 Oil Cooler . . . . . . . .. . . . .. . .
7 12 Alternator Assembly .......... .
7-13 Starter and Starter Drive Adapter.. .
7-14 Oil Pump Assembly .......... .
7-15 Cylinders and Pistons......... .
7-16 Crankcase .. . . . .. . .. . .. .. .
7-17 Camshaft Assembly .......... .
7-18 Crankshaft Assembly .......... .
ii
CHAPTER A TABLE OF CONTENTS (continued)
Section Page
VIII CLEANING PARTS A-8-1
8 1 Materials and Processes. ............................... A-8-1
8-2 Specific Parts. .................................... A-8-1
8-3 Valves. ....................................... A-8-1
8-4 Cylinders. ...................................... A-8-1
8-5 Pistons. ....................................... A-8-2
8-6 Crankshaft. ..................................... A-8-2
8-7 Crankcase. ..................................... A-8-2
8-8 Ball Bearings. ................................... A-8-2
IX INSPECTION A-9-1
9-1 Definition of Terms .. .. ... ..... .. .. .. .. .... . ... . .. .. A 9-
9-2 Protection from Corrosion. ............................. A-9-1
9-3 Visual Inspection. .................................. A-9-1
9-4 Magnetic Particle Inspection. ............................ A-9-2
9-5 Fluorescent Particle Inspection. .......................... A-9-2
9-6 Dimensional Inspcction. ........................... A-9-2
9-7 Protective Coating. ................................. A-9-2
9-8 Application of "Alodine 1200".............................A-9-2
9-9 Repair of "Alodized" Surfaces . . . . ........................ A-9-3
9-10 Enamel Coatings. .................................. A-9-3
9-11 Specific Inspections. ................................ A-9-3
9-12 Crankcase. ..................................... A-9-3
9-13 Crankshaft and Propeller Driveshaft. ........................ A-94
9-14 Crankshaft and Counterweight Bushings. ...................... A-94
9-15 Camshaft. ...................................... A-9-5
9-16 Connecting Rods. .................................. A-9-5
9-17 Gears. ........................................ A-9-5
9-18 Pistons and Rings. .............. ................. A-9-5
9-19 Cylinders. ...................................... A-9-5
9-20 Hydraulic Valve Lifters. .............................. A-9-6
9-21 Intake Tubes. .................................... A-9-6
9-22 Lubrication System. ................................ A-9-6
9-2 3 Fuel Injection System. ............................... A-9-6
9-24 Ignition System. ................................. A-9-6
X REPAIR AND REPLACEMENT A-10-1

10-1 Castings. ...................................... A-1b-1
10-2 Stud Replacement. ................................. A-10-1
10-3 Helical Coil Insert Installation. ........................... A-10-1
104 Cylinders. ...................................... A-10-2
10-5 Crankshaft Assembly. ................................ A-10-3
10-6 Idler Gear. ..................................... A-104
10-7 Magneto and Accessory Drive Adapter Assembly. ................. A- 10-4
10-8 Tachometer Drive Housing. ............................. A- 10-4
10-9 Starter Drive Adapter. ............................... A-1 0-4
10-10 Oil Pump Assembly. ................................ A-1O0-4
10-11 Ignition Cables. ................................... A-10-4
10-12 100% Replacement Parts At Normal Major Overhaul. ................ A-10-5
iii
Section Page
XI ASSEMBLY OF SUBASSEMBLIES A-11-1
11-1 New Parts .. . . . . . . . . . . A-1 1-1
11-2 Tightening Torques .................. A-11-1
11-3 Final Cleaning ..................... A-1 -
11-4 Lubrication . . ... . . . . . . . . . . . . . . .. . A-1 1-1
11-5 Oil Pump Assembly .................. A-11-1
11-6 Starter Adapter Assembly .............. A-112
11-7 Cylinders ........................ A-1 1-2
11-8 Piston and Ring Assemblies .............. A-1 1-3
11-9 Pushrod Housings ................... A113
11-10 Crankshaft and Connecting Rods........... A-11-3
11-11 Camshaft ........................ A-1 1-4
11-12 Alternator Assembly .................. A-1 1
11-13 Crankcase . . . . . . . . . . . . . . . . . . . . . . . A-1 1-4
11-14 Fuel Injection Control and Air Throttle Body Assembly A- 1 1-4
O il Cooler . . . . . . . . . . . . . . . . . . . . . . . A- 114
XII FINAL ASSEMBLY A-12-1

12-1 General Instructions.... A-12-1
12-2 Crankcase ......... A-12-1
12-3 Crankshaft Assembly.... A-12-1
12-4 Camshaft Assembly .... A-12-1
12-5 Propeller Shaft ....... A-12-1
12-6 Crankcase Reassembly... A-12-2
12-7 Cylinders .......... A-12-3
12-8 Oil Pump .......... A-12-4
12 9 Starter Adapter ...... A-12-4
12-1 0 Alternator Assembly.... A-12-4
12-11 Oil Cooler......... A-12-5
12-12 Magneto and Accessory Drive Adapters A-12-5
12-13 Oil Sump . A 12-5
12-14 Induction System ..... A-12-5
12-15 Fuel Injection System ... A-12-6
12-16 Magneto Drive Gears.... A-12-6
12-17 Placing Crankshaft in Timing Position A-12-6
12-18 Magnetos .......... A-12-6
12-19 Ignition Harness ...... A-12-7
12-20 Fuel Lines ......... A-12-7
12-21 Final Parts ......... A-12-7
XIII REPAIR AND TESTING OF ACCESSORIES A-13-1

13-1 Hydraulic Valve Tappets .. .. . A13-1
13-2 Disassembly .. . . . . . A-13-1
13-3 Cleaning and Inspection........ A-13-1
13-4 Testing ................ A-13-2
13-5 Reassembly .............. A 13-2
13-6 Oil Cooler ............... A-13-3
13-7 Testing ................ A-13-4
13-8 Lubrication .............. A-134
13-9 Accessories .............. A-134
iv
Section Page
XIV TESTING AFTER OVERHAUL A- 14-1
14-2 Test Equipment .................... A-14-1
14-3 Engine Test After Overhaul. ........................... A-14-2
14-4 Starting Procedure ...... ............ A-14-2
14-5 Preservation. ..................................... A-14-2
14-6 Engine Run-In After Top Overhaul Of One Or More Cylinders. ........... A-14 3
CHAPTER A
LIST OF ILLUSTRATIONS
Figure No. Title Page

A-4-1 Cylinder Numbering Diagram ........................... A4-1
A-4-2 Three-Quarter View GTSIO-5 20-C. ....................... A4-2
A4-3 Three-Quarter View CTSIO-520D ....................... .. A-4-2
A4-4 Three-Quarter View CTSIO-5 20-H ........................ A4-3
A-4-5 Three-Quarter View GTSIO-5 20-K. ....................... A-4-3
A4-6 Three-Quarter View GTSIO-520-L........................ A4-4
A4-7 Three-Quarter View GTSIO-520-M. ....................... A44
A-4-8 Gear Train Diagram ................................ A-4-5
A-4-9 Lubrication System Diagram. .......................... A4-6
A4-10 Cutaway View of Hydraulic Valve Lifter. .................... A4-7
A4-1 1 Magneto and Accessory Drives .......................... A4-8
A-4-12 Oil Sump. .................................... A-4-9
A-4-13 Alternator Assembly. .............................. A-4-1 0
A4-14 Oil Cooler. .................................... A-4-1 1
A.4-15 Starter Adapter .................................. A4-12
A4-16 Oil Pump Assembly. ............................... A-4-13
A4-17 Cylinder and Piston Assembly. .......................... A-4-14
A4-18 Crankcase Assembly. ............................... A-4-15
A4-19 Camshaft Assembly. ............................... A-4-17
A-4-20 Crankshaft Assembly. .............................. A-4-18
A-4-2 1 Stud Location. .................................. A-4-19
A-4-22 Inspecting Ring Side Clearance. ........................ A-4-19
A-4-2 3 Cylinder Machining Dimensions. ......................... A-4-20
A-4-24 Installing Typical Helical Coil Insert. ....................... A-4-2 1
A-4-2 5 Installing Spark Plug Hole Helical Coil Insert. .................. A-4-21
A-4-26 Expanding Spark Plug Hole Helical Coil Insert. ................. A-4-2 1
A-4-27 Removing Spark Plug Hole Helical Coil Insert. .................. A-4-2 1
A4-28 Valve Rocker Bearing Dimensions. ........................ A-4-2 1
A-4-29 Connecting Rod and Bushing Dimensions and Installation. ........... A-4-2 2
A4-30 Counterweight with Oversize Bushings. ..................... A-4-2 3
A4-31 Installing New Starter Adapter Needle Bearing. ................. A-4-23
A-4-32 Exploded View of Ignition System. ....................... A-4-24
A4-33 Alternator Drive Gear Installed. ......................... A-4-26
A-4-34 Valve Spring Installation. ............................ A-4-26
A-4-35 Alignment of Timing Marks. ........................... A-4-26
A-4-36 Checking Rocker Arm Clearance. ........................ A-4-26
A-4- 37 Installing Cylinder Baffles. ............................ A-4-26
June 1980 v
CHAPTER A LIST OF ILLUSTRATIONS (continued)

A-4-38 Torquing Sequence ......................... A-4-2 7
A-4-39 Installing Cylinder.......................... A-4-27
A-4-40 Timing Marks ........................... A-4-28
A-4-41 Installing Oil Seal on Prop Drive Shaft Gear ................ A-4- 29
A442 Prop Drive Shaft Gear and Oil Seal Installed
with Retaining Ring and Spring in Cavity . . .. . . . . . . . ... . . A-4-29
A-4-43 Wiring Diagram.................................................... A-4-3 0
A-5-1 Borrough's Cylinder Base Nut Wrenches................. A-5-2
A-5-2 Starter Adapter Bearing Installer.................... A-5 -2
A-5-3 Piston Ring Compressor ....................... A-5-2
A-5-4 Push Rod Spring Compressor. ................... A-5-2
A-5-5 Valve Lifter Bleed Down Tester .................... A- 5-2
A-5-6 Schematic Diagram of a Differential Pressure Tester ............ A-5-3
A-5-7 Engine Transportation Stand ..................... A-5-3
A-5-8 Valve Spring Compressor....................... A-5-3
CHAPTER B (TABLE OF LIMITS)

LIST OF TABLES
Table No. Page

1 Table of Limits...................... B-1
.. .. .. .. . .
2 Tightening Torques.................... . ... .. .. . . B-9
3 General Use -Tightening Torques............... .. ... . .. .. B-9
4 Pipe Plugs ....................... B-10
5 Magnetic Particle Inspection............... .. ... .. . .. B-11
6 Critical New Parts Dimensions ............... .. ... .. . .. B-12
7 Inspection Chart ..................... .. ... .. .. . B-14
8 Standard and Oversize Stud Identification ........... . .. .. .. .. . B-24
9 Stud Setting Heights.................... . .. ... .. . . B-2 5
10 Helical Coil and Special Tool Data .............. . .. ... .. . . B-26
11 Crankshafts and Crankcases................. . .. ... .. . . B-26
12 Table of Lubricants .................... B-2 7
CHAPTER B
Figure No. TITLE Page

B-1 LIMITS CHART (Chart 1) ............ B-5
....................
B-2 LIMITS CHART (Chart 2) ............ .................... B-6
B-5 CRANKCASE STUD HEIGHTS .......... .................... B-24
vi
CHAPTER C (DIFFERENCE DATA)
TABLE OF CONTENTS
Section Page
1. DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-520-C C-1-1
General Information ...............-............. C-1-2
Detail Engine Specifications ........................ C-1-2
Operating Test Limits ........................... C-1-4
Major Overhaul Test Run..........................C-i-5
Start Oil Consumption Determination C-1-5
Fuel Injection System ........................... C-1-6
Cleaning, Inspection and Repair ....................... C-1-6
Reassembly................................C-1-6
Induction System.............................C-1-6
Cleaning,Inspection and Repair ........................ C-1-7
Reassembly............................... C-1-7
Crankcase ................................ C-1-7
Magneto and Accessory Drives........................C-i-7
Cleaning,Inspection and Repair........................C-1-7
Reassembly ............................... Cx1-7
Turbocharger Oil Inlet Adapter ....................... C-1-
Improved Valve Stem and Guide Q C-1-
II. DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-520-D C-2-1

General Information .............................. C-2-2
Operating Test Limits...........................C-2-4
Major Overhaul Test Run ......................... C-2-5
Start Oil Consumption Determination.....................C-2-6
Fuel Injection System...........................C-2-6
Disassembly...............................C-2-6
Cleaning, Inspection and Repair ....................... C-2-6
Reassembly...............................C-2-6
Induction System ............................ C-2-7
Disassembly...............................C-2-7
Cleaning,Inspection and Repair........................C-2-7
Reassembly...............................C-2-7
Turbocharger Oil Inlet Adapter ....................... C-2-7
Improved Valve Stem and Guide Lubrication..................C-2-7
III. DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-5 20-H C-3-1
General Information ........................... C-3-2
Major Overhaul Test Run..........................C-3-5
Disassembly...............................C-3-6
Cleaning, Inspection and Repair ....................... C-3 -6
Reassembly...............................C-3-7
Disassembly...............................C-3-7
Cleaning,Inspection and Repair ....................... C-3-7
vii
CHAPTER C TABLE OF CONTENTS (continued)
Section Page
III CONTINUED
Reassem bly...............................C 3-7
Improved Valve Stem and Guide.......................C-3-7
Turbocharger Oil Inlet Adapter ....................... C-3-8
IV. DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-5 20-K C-4-1
General Information...........................CA4-2
Exhaust Assembly............................ C4-6
Removal and Disassembly......................... C4-6
Assembly and Installation ......................... C-4-6
Hot Prime Equipment...........................C-4-6
Removal and Disassembly......................... C4-6
Assembly and Installation ......................... C4-6
Induction System .............................- 4-6
Removal and Disassembly .......................... 4-6
Oil Sump............................... C4-47
Removal and Disassembly ..........................- 4-7
Assembly and Installation ......................... C4-7
Oil Cooler ................................- 4-7
Removal and Disassembly.........................CA4-7
Oil Pump Assembly ............................ -4-7
Removal and Disassembly ..........................- 4-7
V. DIFFERENCE DATA SECTION FOR THE MODEL GTSIO 520-L C-5-1

General Information ............................- 5-2
Detail Engine Specifications .........................- 5-2
Operating Test Limits ........................... 2-5-4
Cleaning, Repair and Replacement ...................... -5-6
Reassembly...............................C-5-6
Cleaning, Inspection and Repair ...................... C-6
Reassembly ............................... -5-6
VI. DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-520-M C-6-1

General Information............................C-6-2
Operating Test Limits ........................... -6-4
Top or Minor and Major Overhaul Test Run ...................- 6-5
Start Oil Consumption Determination ..................... C-6-5
Viii
CHAPTER C TABLE OF CONTENTS (continued)
Section Page
VI CONTINUED
Cleaning, Repair and Replacement......................C-6-6
Reassembly...............................C-6-6
Cleaning, Inspection and Repair.......................C-6-6
Reassembly...............................C-6-6
VII. DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-520N C-7-1

General Information ............................. C-7-2
Detail Engine Specifications..........................C-7-2
Operating Test Limits ............................ C-7-4
Special Test Items Required or Equivalent ................... C-7-5
Major Overhaul Test Run...........................C-7-6
Start Oil Consumption Determination ..................... C-7-6
Inducation System..............................C-7-7
Cleaning, Repair and Replacement.......................C-7-7
Reassembly.................................C-7-7
Fuel Injection System ............................ C-7-7
Cleaning, Inspection and Repair........................C-7-7
Reassembly ................................. C-7-7
Fuel Injection Adjustment Procedures....................C-7-18
CHAPTER C

C 11 Fuel Injections System (GTSIO-520 C) .................... C-1-9
C- 12 Induction System (GTSIO-520-C) ...................... C-1-10
C- 1-3 Crankcase Assembly (GTSIO-5 20-C) ..................... C-1-11
C-1-4 Magneto and Accessory Drives (GTSIO-520-C) ................. C-1-12
C-1-5 Fuel Manifold Valve Fitting Location (GTSIO-520-C) .............. C-1-13
C-1-6 Control Valve Fitting Locations (GTSIO-520-C).................C-1-14
C-1-7 Fuel Pump Fitting Locations (GTSIO-520-C)..................C-1-15
C-1-8 Cran kcase Stud Setting Heights ....................... C-1-16
C-2-1 Fuel Injections System (GTSIO-520 D) .................... C-2-9
C-2-2 Induction System (GISIO-520-D) ...................... C-2 -10
C-2-3 Fuel Manifold Valve Fitting Locations (GTSIO-520-D) .............. C-2-11
C-2-4 Control Valve Fitting Locations (GTSIO-5 20-D).................C-2-12
C-2-5 Fuel Pump Fitting Locations (GTSIO-520-D)..................C-2-13
C-3-1 Fuel Injection System (GTSIO-5 20-H) .................... C-3-9
C-3-2 Induction System (GTSIO-520-H) ...................... C-3-11
C-3-3 Control Valve Fitting Locations (GTSIO-520 H).................C-3-12
C-3-4 Manifold Valve Fitting Locations (GTSIO-520-H) ................ C-3-13
C-3-5 Fuel Pump Fitting Locations (GTSIO-5 20-H)..................C-3-14
C4-1 Exhaust Assembly (GTSIO-520-K). .~....................C4-8
C4-2 [lot Prime Equipment (GTSIO-5 20-K).................... C4-9
C4-3 Fuel Injection System (GTSIO-520-K).................... C4-10
C-4-4 Induction System (GTSIO-520-K) ...................... C4-11
C-4-5 Oil Sump(GTSIO-5 20-K)......................... C4-13
MARCH 1981 ix
CHAPTER C LIST OF ILLUSTRATIONS (continued)
Figure No. Tide Page

C-4-6 Oil Cooler (G'TSIO-5 20-K)........... .. . . . . . . . . . . . .C -4-14
C-4-7 Oil Pump Assembly(GTSIO-520-K) ....... .. . . . . . . . . . . . .C -4-15
C-4-8 Crankcase Stud Setting Heights (G'TSIO-520-K) .. .. . . . . . . . . . . . .C-4-16
C-4-9 Fuel Pump Fitting Locations(GTSIO-5 20-K).... .. . . . . . . . . . . . .C-4-17
C-4-10 Fuel Manifold Fitting Locations (GTSIO-5 20-K).. .. . . . . . . . . . . . .C-4-18
C-4-11 Air Throttle & Controller Fitting Locations (K) ... .. . . . . . . . . . ...C4 -19
C-5-1 Induction System (GTSIO-520 L) ........ .. . . . . . . . . . . . .C-5-8
C-5-2 Fuel Injection System (GTSIO-520L) ...... .. . . . . . . . . . . . .C-5-9
C-5-3 Manifold Valve Fitting Locations (GTSIO-5 20-L) .. .. . . . . . . . . . . . .C-5 10
C-5-4 Control Valve Fitting Locations (GTSIO-520-L)... .............. C-5-1 1
C-5-5 Fuel Pump Fitting Locations (GTSIO-520-L).... .. . . . . . . . . . . . .C-5-12
C-5 -6 Crankcase Stud Setting Heights (GTSIO-5 20 M). ............. C-513
C-6-1 Induction System (GTSIO-520-M)........ .. . . . . . . . . . . . .C-6-8
C-6-2 Fuel Injection System (GTSIO-520-M) ...... .. . . . . . . . . . . . .C-6-9
C-6-3 Manifold Valve Fitting Locations (GTSIO-520-M) .. . . . . . .. . . . . .C-6-1 0
C-6-4 Control Valve Fitting Locations (GTSIO-520-M) .. . . . .. . . . . . . .C-6-11
C-6-5 Fuel Pump Fitting Locations (GTSIO-5 20-M).... . ..... . .... . . ... . ... . C-6-12
C-6-6 Crankcasc Stud Setting Hcights(GTSIO-520-M) ... .. . . . . . .. . . . . .C-6-13
C-7-1 Induction System (GTSIO-520-N)......................C-7-9
C-7-2 Fuel Injection System (GTSIO-520-N) ................... C-7-10
C-7-3 Manifold Valve Fitting Locations (GTSIO-520-N)...............C-7-11
C-7-4 Fuel Control Fitting Locations (GTSIO-520-N) ............... C-7-12
C-7-5 Fuel Pump Fitting Locations (GTSIO 520-N) ................ C-7-13
C-7-6 Crankcase Stud Setting Heights (GTSIO-520-N)...............C-7-14
Graph No.
C-7-1 Fuel Flow Limits (GTSIO-520-N)......................C-7-15
C-7-2 100% Power Fuel Pump Pressure Limits (GTSIO-520-N)...........C-7-16
C-7-3 Meterer Fuel Pressure vs. Fuel Flow (GTSIO-520-N).............C-7-17
x MARCH 1981
SECTION I
INTRODUCTION
1-1. SCOPE. 1-6. DEFINITION OF TERMS. Front, rear, left

and right, as used in this manual, refer to the
1-2. This Chapter comprises the overhaul in- engine as viewed by the mechanic in a normal
structions for a hypothetical GTSIO-520 engine, position, facing the accessory end.
hereafter referred to as the "basic" engine. This
is a 6 cylinder horizontally opposed, geared, turbo- 1-7. CYLINDER ARRANGEMENT. Cylinders
charged, fuel injected, air cooled, 4 cycle engine are numbered starting from the rear, with odd
manufacturered by Teledyne Continental Motors, numbers on the right and even numbers on the left.
Aircraft Products Division, Mobile, Alabama.
1-8. AIRCRAFT ENGINE NAMEPLATES.
BEFORE Teledyne Continental Motors can issue
1-3. DIFFERENCE DATA SECTIONS. anyone a new nameplate, the person involved must
first contact his local FAA office and obtain
1-4. Sections I thru XIV of this manual contain approval from them in accordance with FAR Part
overhaul instructions for the basic engine. Overhaul 45, Section 45.13 (b).
and test instructions for specific models are pro-
vided in the latter sections by the use of Difference In addition, if the old nameplate has been lost, it
Data Sections. will be necessary to supply a notarized statement
to that effect, giving the engine model and full
1-5. RELATED PUBLICATIONS. Detail part serial number along with the evidence of FAA
numbers and service assemblies for this engine are approval.
contained in Parts Catalog X-30046A. Operating
instructions are contained in Operator's Handbooks The old nameplate (when available) must be
as follows: GTSIO-520-C, X-30047; GTSIO-520-D, submitted to TCM along with evidence of FAA
X-30079, GTSIO-520-F, X-30128, GTSIO-520-H, X- approval, and a remittance in the amount listed in
30129, GTSIO 520-L, X 30532, GTSIO-520-M, X-
current price list to cover costs involved in the
30533, and GTSIO-520-N, X-30551. handling, stamping and mailing of a new,
permanently-stamped nameplate.
a. Service instructions for the Prestolite
Starter and Alternator may be obtained from the Because we did not, in all cases, make it mandatory
Prestolite Company, Division of Eltra Corporation, in the past, we wish to emphasize that a nameplate
51 1 Hamilton Street, Toledo, Ohio 43601. wll not be supplied at the request of anyone unless
the remittance is received with the request.
b. Service instructions for the Bcndix
Magnetos may be obtained from Bendix Electrical All request, along with the correct remittance,
Components Division, Sidney, New York 13838. should be sent to the following address to expedite
shipment:
C. Service instructions for the Delco-Remy Teledyne Continental Motors
Starter and Alternator may be obtained from Attn: Service Department
Delco-Remy Division, General Motors Corporation, P. 0. Box 90
Anderson, Indiana. Mobile, Alabama 36601
OCTOBER 1980 A-1-1

If, for any reason, it becomes necessary to check on Term Explanation
the status of your nameplate, call (205) 438-34 11
and ask for "Service Department," or address your in.("); Inches
inquiry to the Mobile address given above Hex.; Hexagon
specifying "Attn: Service Department." hr.: Hour
Left Side: Side on which No's 2, 4 and 6
1- 9. DEFINITIONS AND ABBREVIATIONS cylinders are located
Lbs.: Pounds
Term Explanation Lock Wire: Soft steel wire used to safety con-
nections, etc.
A.B.C.: After Bottom Center Man.: Manifold or manometer
Approx.: Approximately Max.: Maximum
A.T.C.: After Top Center Min.: Minimum
Bar.: Barometric 3 0': Thirty minutes of angle (60' equal
B.B.C.: Before Bottom Center one degree)
Brake Horsepower N.P.T.: National pipe thread (tapered)
B.T.C.: Before Top Center N.C.: National Coarse (thread)
F.A.A..: Federal Aviation Administration N. F.: National Fine (thread)
O.D.: outside Diameter
c.f.m.: Cubic feet per minute Press.: Pressure
Center of Gravity pS.i.: Pounds per square inch
Dia.: Diameter Rear: Accessory end of engine
Degrees of Angle Right Side: Side on which No.'s 1,3 and 5
0
F: Degrees Fahrenheit cylinders are located
Fig.: Figure (Illustration) R. P.M.: Revolutions per minute
Front: Propeller End Std.: Standard
T. D. C.: Top dead center
ft.: Foot or feet
Temp.: Temperature
G.P.M.: Gallons per minute Torque: Force x lever arm (125 ft. - lbs.
1120: Water torque = 125 lbs. force applied one
Hg.: Mercury ft. from bolt center or 62-1/2 lbs.
Inside Diameter applied 2 ft. from center)
A-1-2 MARCH 1981

PURCHASED ACCESSORIES TMEAUELMT
TEMPERATURE LIMITS
Accessory Qty. Indicated Condition Minimum Maximum

Controller................... 1 Oil temperature at take-off 75F -
Regulator Assembly, Fuel Pressure...... 1 Oil temperature - 240 0 F
Magneto. ................... 2 Cylinder head temperature - 4600 F
Starter..................... 1 (bayonet thermocouple)*
Alternator................... 1 Magneto temperature - 170F
Turbocharger................. 1 (at coil hold-down screw)
Oil Cooler ................... 1 * Installed in tapped holc in bottom of cylinder hcad. Applicable only
Intercooler.................. 1 with downdraft cooling system.
Fuel Pump .1.......... .
Spark Plugs. ................. 12
IGNITION SYSTEM DETAILS PRESSURE LIMITS
Feature Value Indication Minimum Maximum

Left magneto fires lower No. 1, 3, 5 and Oil pressure (idling) 10 psi -
upper No. 2, 4, 6 plugs. Oil pressure (in flight) 30 psi 60 psi
Oil pressure ( with cold oil) - 100 psi
Right magneto fires upper No. 1, 3, 5
and lower No. 2, 4, 6 plugs
Firing order (cylinder numbers) 1-4- OIL VISCOSITY GRADES

5-2-3-6
AirportAmbient Air Temperature S.A.E. Grade
CHARACTERISTICS AND DIMENSIONS All Temperatures 15W - 50,

20W - 50
Dimension Vadue Or if Temperatuers Are:
Piston strokes per cycle........ 4 Below 400 F. 30 or 10W - 30
Number of cylinders ......... 6 Above 400 F. 50
Cylinder bore (in.).......... 5.25
Piston stroke (in.) . . . . . . . . . 4 Ambient Air Temperature (Sea Level)
June 1980 A-2-1/A-2-2

SECTION III
GENERAL DESCRIPTION
3-1. CONSTRUCTION. and barrel assembly. Valve guides are then reamed
to specific diameters. Special 18mm helical coil
a. GENERAL. The arrangement and thread inserts are installed in upper and lower
appearance of engine parts and components are spark plug holes. Exhaust valves are faced with a
illustrated in Section IV, Chapter A. Additional special heat and corrosion-resistant material. The
information will be found in the Limits and solid valve stem tips are hardened. The outer valve
Lubrication Charts. spring retainers are locked to the stems by tapered,
semi-circular keys which engage in the stem
b. CRANKCASE. Two aluminum alloy cast- grooves. Valve rocker covers are stamped sheet
ings are joined along the vertical center plane to steel cadmium plated. Rocker shafts are fully
form the complete crankcase. The individual cast- machined, chrome plated steel. The rocker shafts
ings (with studs and inserts) will be referred to as are held in place by screws in the cylinder rocker
the "left crankcase" and the "right crankcase" bosses. Valve rockers are steel forgings with
throughout this publication. pressed-in bronze bushings, hardened pushrod
sockets and rocker faces. Pushrods are composed
1. Bosses molded in the crankcase castings are of steel tubes and pressed in, hardened, forged steel
line bored in the assembled castings to form ball ends which are center drilled for oil passages.
bearings for the camshaft and seats for the pre- The pushrod housings are beaded steel tubes. The
cision, steel-backed, lead-alloy lined crankshaft bead at the cylinder end retains a washer and seal
main bearing inserts. Provision has been made in ring. The bead at the crankcase end retains a heavy
the crankcase halves at the top front to support the spring, washer, seal ring and a second washer.
propeller driveshaft. Precision guides are bored
through lateral bosses for the tappets and for the d. VALVE MECHANISM. Oil fed to hy-
governor drive shaft. A needle bearing is pressed draulic valve lifters, under pressure from the
into the right crankcase, to the right of the rear crankcase main galleries, is divided between the
main bearing, to support the front end of the overhead system, the lifter guide surfaces and the
starter shaftgear. reservoirs inside the lifters. The oil which reaches
the pushrod ends is forced through the pushrods to
2. Cylinder mounting pads on the left crank- the drilled rockers and the groove between their
case are further forward than the corresponding bushings. Each valve rocker directs a portion of its
pads on the right crankcase to permit each con- oil, through a nozzle, towards the respective
necting rod to work on a separate crankpin. Each valve stem. The oil spray from the rockers lubri-
pad has six studs and two through bolts for cates the valve stems and springs. Oil is returned to
attaching cylinder base flanges. The governor the crankcase through the pushrod housings which
mount pad is located on the side of the left are sealed to cylinder heads and crankcase by
crankcase at the lower front corner. The alternator rubber seals. Drain holes in valve lifter guides direct
pad is located on the right crankcase at the front. the returning oil to the sump.
3. The crankcase interior is ventilated by a e. CRANKSHAFT. The six-throw steel alloy

breather consisting of a tube and baffle assembly forging is machined all over except for some sur-
with a side extension for hose attachment. The faces of the crankcheeks. The main bearing
breather assembly is pressed into the upper left journals and crankpins are nitrided after grinding.
crankcase. The front end of the crankshaft has an internal
spline which mates with a quill shaft to drive the
C. CYLINDERS. The aluminum alloy heads reduction gear. The reduction gear in turn drives
are heated and valve seats and guides are installed the propeller driveshaft which has a flange formed
prior to the head being screwed and shrunk onto on the front for attachment of the propeller. The
the steel alloy barrel to make the permanent head crankshaft has side blades projecting from the
A-3-1
crankcheeks and are machined for the installation tappets is that the ball socket of the old tapered
of third order counterweights. Oscillation of the from the center nearly to the O.D., while the
counterweights on their pins dampen crankshaft newer design, which must use the new snap ring,
torsional vibration. The crankshaft gear is shrunk shoulders roughly half way between the center and
onto the crankshaft and is located by a dowel. the O.D. The socket hole diameter differences are
A snythetic rubber oil seal which is stretched over 1/16" for the old and 1/8" for the new.
the crankshaft is seated between the crankcase
castings in the front shaft exit, and is sealed to the 3-2. FUNCTIONAL SYSTEMS.
crankshaft by a helical spring inside the seal cavity.
a. GEAR TRAIN. Figure A-4-8. When starting
f. CONNECTING RODS. The "I" beam-type the engine torque is transmitted from the starter
(16), through adapter components (17 thru 21) to
connecting rods have split bronze piston pin
bushings and two identical precision inserts (of the the crankshaft gear (1). As the wormwheel (19) is
same type as the main bearings) at the crankpin turned, the clutch spring (20) is tightened onto the
end. Weight variation of two rods in any one bay is wormwheel hub and grips the knurled drum of the
limited to 1/2 ounce. shaftgear (21). After the engine is started, spring
(20) is returned to its normal position, thus
g. PISTONS. Pistons are aluminum alloy cast- disengaging the starter. The shaftgear (21) is now
ings or forgings. The skirts are solid and have cy- used to transmit torque from the crankshaft gear
lindrical relief cuts at the bottom to clear crank- (1) to the generator drive pulley.
shaft counterweights. All GTSIO-520 series engines
built since 1975 incorporate a four (4) ring piston 1. Torque from the crankshaft (2) is trans-
and ring assembly replacing the original five (5) mitted by the crankshaft gear (1) directly to the
ring model. Some engines in current production are idler gear (12) and camshaft gear (3)
manufactured with a piston which incorporates a
cast steel insert into which the top ring groove is 2. The idler gear (12) drives the magneto
machined. Because of the weight difference, these drive gears (14, 15). Optional accessories mounted
piston configurations are not to be intermixed. on the crankcase upper rear are driven by internal
Piston pins are full floating ground steel tubes with splines of magneto drive gears.
permanently forged-in aluminum plugs. Weight
variation is limited to 1/2 ounce in opposite bays. 3. The fuel pump drive gear (22) is driven by
the camshaft cluster gear (3). The splined end of
the oil pump and tachometer drive gear (8) mates
h. CAMSHAFT. A steel alloy forging is with internal splines of the camshaft gear (3) and
machined on four journals, nine camlobes and the transmits torque to the oil pump drive gear (9) and
gear mount flange at the rear end. The lobes and tachometer drive gear (1 1). The governor drive
journals are hardened and ground. A groove around bevel gear (6) on the front of the camshaft (4)
the front journal passes engine oil from the right drives the governor driven bevel gear (7).
crankcase cross passage to the left crankcase
passage. The camshaft gear is attached by four 4. The internal splined front end of the
unequally spaced bolts to locate its timing mark in crankshaft (2) transmits torque to the propeller
relation to the camlobes. A cluster gear is bolted shaft drive gear (24) through an externally splined
with the camshaft gear and drives the fuel pump quill shaft (23). The drive gear (24) then drives the
gear. propeller shaft gear (25).
i. TAPPETS. The barrel-type hydraulic b. LUBRICATION SYSTEM. Figure A-4-9

tappets may be removed and replaced without
complete disassembly of the engine, as described in 1. The engine oil supply is contained in the
Section XIII. The construction and operation of sump. The oil is sucked from the sump through the
the tappets are described in paragraph A-3-1d and oil suction tube, to the oil pump to fill the volume
figure A-4-10. Current tappets incorporate a new being continually displaced by the rotation of the
snap ring, which is red in color. The most pump gears. From the pump gear chamber, oil is
discernible difference between the new and old directed to the oil filter chamber and the tacho-
A-3-2 MARCH 1981

meter drive gear. If the filter should become inner dome. Oil in the crankcase is returned to the
clogged, the spring-loaded by-pass valve will open sump through drain holes.
permitting oil to flow from the gear chamber to
the oil filter outlet. From the oil filter outlet, a 6. The turbocharger is lubricated by oil from
passage leads to the oil pressure relief valve. If, at the crankcase left gallery directed to the turbo-
any time, the oil pressure exceeds the limit of the charger oil inlet through a hose. Oil leaves the
preset, spring-loaded relief valve, oil is passed back turbocharger at the oil outlet port through a hose
to the inlet side of the pump. to an oil separator and from these through a hose
to the scavenge pump inlet.
2. From the outlet side of the pump, oil is
directed to the full flow replaceable element oil c. INDUCTION SYSTEM. The induction
filter. A by-pass valve is incorporated in the filter system consists of a turbocharger, intake mani-
adapter in the event the element becomes clogged. fold assembly, intake tubes, air manifold tubes and
From the filter discharge port, oil is directed to the air throttle assembly. In addition most models
oil cooler. Oil passing through the oil temperature include, in the induction system, an inter-cooler
control valve is directed either through the cooler capable of 40% effectivity with a static cooling air
or directly to the gallery in the left crankcase. This pressure drop across the cooler of 6" H 2 0 pres-
depends on the oil temperature. In this manner, sure.
engine oil temperature is maintained at 1700 F.
From the right crankcase oil gallery, oil is directed The exhaust gas driven turbocharger supplies air at
to the right side valve lifter guides and valve a higher velocity and greater density than attain-
mechanisms. Oil is directed from the right gallery, able from ambient conditions. Air from the turbo-
through a passage, to the propeller driver and charger discharge side is directed to the air throttle
driven gears. Passages from the left gallery direct body which controls the quantity of air to be
oil to the main crankshaft bearings, prop shaft inducted in accordance with the setting of the
bearings, camshaft bearings, valve lifter guides, injector system fuel control unit. From the air
valve mechanisms and the governor drive bearings. throttle body the induction air is directed through
Oil is introduced to the propeller governor through the manifold riser and intake tubes to the cylinder
a drilled passage and port in the governor mount intake ports.
pad. From the governor, oil re-enters the crankcase
through a return port in the mount pad. The oil is The turbocharger-to-fuel injection system manifold
directed to the oil transfer tube, which is located in provides pressurized air from the turbocharger
the center of the propeller shaft, and on to the discharge side to the fuel pump and injector
propeller. nozzles.
3. From a groove in the rear main bearing, oil In most installations, the turbocharger has a dual
is directed through drilled passages to the starter scroll feature to provide turbo-bleed air for cabin
adapter bearing, idler gear bearing and from the pressurization in addition to the engine require-
idler gear bearing to the two magneto bearings. ments. The turbo-bleed air is provided through a
sonic venturi which limits the bleed air to approxi-
4. Oil from the starter shaftgear bearing is mately six pounds of air per minute at sonic flow.
conducted through a passage in the shaftgear to
two radial holes from which it is sprayed onto the d. IGNITION SYSTEM. High voltage current
shaftgear drum and bearing surface under the is generated and distributed to the upper spark
clutch spring. Other parts of the starter drive are plugs of the right side cylinders and lower spark
lubricated by this spray. Oil drains back into the plugs of the left side cylinders by a magneto
crankcase through a hole in the bottom front side mounted on the front of the right crankcase
of the adapter and a slot in the bottom of the accessory pad. While the left magneto, mounted on
clutch spring sleeve. the front of the left crankcase accessory pad,
supplies high voltage current to the upper left
5. Each cylinder wall and piston is lubricated cylinder spark plugs and the lower right cylinder
by individual oil squirt nozzles. These nozzles spark plugs,. it is also equipped with a double
direct a continuous stream of oil at the piston breaker. The double breaker magneto serves a dual
A-3-3
purpose. When cranking the engine, the retard actuates to cause the auxiliary fuel pump to
breaker and a starting vibrator are in effect, causing operate at a high speed if the engine-driven pump
a shower of high voltage sparks to start the engine. pressure drops below 5 PSI. The auxiliary fuel
As the engine is started and cranking motor is pump switch must be ON for the fuel pressure
disengaged, the retard breaker and starting vibrator switch to operate.
are no longer transmitting spark and the engine is
running on the advance breakers from both 3. FUEL DISCHARGE NOZZLES. From
magnetos. The battery operated starting vibrator the fuel manifold, individual fuel lines carry
furnishes electrical current to the magneto for the metered fuel to the fuel discharge nozzles, one
retarded ignition starting, regardless of engine for each cylinder. These nozzles are installed in the
cranking speed. Spark is transmitted to the spark cylinder heads outside each intake valve. An air
plugs through high tension cables which pass bleed and nozzle pressurization arrangement
through braided, flexible, shielded conduit supplies pressurized air to the nozzle. The air bleed
assemblies. These assemblies are connected to the arrangement aids in vaporization of fuel and by
magnetos by coupling nuts and to the spark plugs breaking the high vacuum at idle, maintains the
by nuts. fuel lines solidly filled and ready for instant
acceleration of the engine. Nozzles are stamped
e. FUEL INJECTION SYSTEM. with a letter on the hex of the nozzle body.
Replacement nozzles must match.
1. GENERAL. The fuel injection system is a
simple, low pressure system of injecting fuel into
the intake valve port in the cylinder head. It is a 4. FUEL MANIFOLD. From the fuel control
multi-nozzle, continuous flow type system which unit, fuel is delivered to the fuel manifold which
controls fuel flow to match engine airflow. Any provides a central point for dividing fuel to the
change in throttle position, engine speed, or a individual cylinders.
combination of both, causes changes in fuel flow in
correct relation to engine airflow. A manual In the fuel manifold, a diaphragm and plunger
mixture control and a flow gage, indicating meter- valve raises or lowers, by fuel pressure, to open or
ed fuel pressure, are provided for precise leaning at close the individual cylinder fuel supply port
any combination of altitude and power setting. simultaneously. A piston type check valve serves to
The continuous flow system uses a typical rotary insure that the plunger fully opens the outlet ports
vane fuel pump. There are no running parts in this before fuel flow starts. Thus, there is no unbalance
system except for the engine - driven fuel pump. restrictions to fuel flow in the fuel manifold. A
fine mesh screen is included in the fuel manifold as
2. FUEL - AIR CONTROL UNIT. The additional protection of the injection nozzles
function of the fuel-air control unit is to control against dirt or foreign matter.
engine air intake and to set the metered fuel
pressure for proper fuel-air ratio. There are three 5. FUEL INJECTION PUMP. The fuel pump
control elements in this unit, one for air, and two is a positive-displacement, rotating vane type. It
for fuel; one of which is for fuel mixture and the has a shaft for connection to the accessory drive
other for fuel metering. section of the engine. Fuel enters the pump at the
swirl well of the vapor separator. Here, vapor is
Main fuel enters the control unit through a strainer separated by a swirling motion so that only liquid
and passes to the metering valve. The position of fuel is fed to the pump. The vapor is drawn from
the metering valve controls the fuel passed to the the top center of the swirl well by a small pressure
manifold valve and nozzles. A linkage connecting jet of fuel and is fed into the vapor return line and
the metering valve to the air throttle proportions returned to the fuel tank. Since the pump is
air-flow to fuel-flow. The position of the mixture engine-driven, changes in engine speed affect total
valve determines the amount of fuel returned to pump flow proportionally. The pump supplies
the fuel pump. The fuel control portions of the more fuel than is required by the engines. There-
fuel-air control unit is enclosed in a shroud and is fore, a relief valve is provided to maintain a
blast air cooled to help prevent vapor lock. A fuel constant fuel pump pressure. A check valve is
pressure switch, connected to the fuel control unit, provided so that the auxiliary pump pressure can
A-3-4
bypass the engine-driven fuel injection pump for variable orifice controlled by an aneroid on the
starting. In case of engine-driven fuel injection pump. The aneroid is controlled by the super-
pump failure, the auxiliary fuel pump will operate charger discharge pressure. The variable orifice
automatically when the auxiliary fuel pump switch controls the pressure from the fuel injection pump
is ON. Incorporated on the fuel injection pump is a at altitude.
A-3 -5 /A-3-6
SECTION IV
ILLUSTRATIONS
6
5
4
3
2
1
FIGURE A4-1. CYLINDER NUMBERING DIAGRAM
A-4-1
FIGURE A-4-2. RIGHT FRONT VIEW - GTSIO-520-C
FIGURE A-4-3. LEFT REAR VIEW - GTSIO-520-D
A4-2
FIGURE A-44. RIGHT FRONT VIEW - GTSIO-520-H
FIGURE A-4-5. LEFT FRONT VIEW - GTSIO-520-K
A-4-3
FIGURE A-4-6. RIGHT FRONT VIEW - GTSIO-520-L
FIGURE A-4-7. RIGHT SIDE VIEW - GTSIO - 520-M
A4-4
.25
24
18
22
11
FIGURE A4-8. GEAR TRAIN DIAGRAM
1. Crankshaft Gear 13. Idler Gear Support Pin

2. Crankshaft 14. Left Magneto Drive Gear
3. Camshaft Cluster Gear 15. Right Magneto Drive Gear
4. Camshaft 16. Starter
5. Hydraulic Tappet 17. Worm Drive Shaft
6. Governor Drive Bevel Gear 18. Starter Worm Gear
7. Governor Driven Bevel Gear 19. Starter Worm Weel
8. Oil Pump and Tach 20. Clutch Spring
Drive Shaftgear 21. Starter Shaftgear
9. Oil Pump Driven Gear 22. Fuel Pump Drive Gear
10. Scavenge Driven Gear 23. Quillshaft Gear
11. Scavenge Driver Gear 24. Prop Shaft Drive Gear
12. Idler Gear Assembly 25. Prop Shaft
A-4-5
FIGURE A-4-9. LUBRICATION SYSTEM DIAGRAM
A-4-6
FIGURE A4-10. CUT-AWAY VIEW OF HYDRAULIC VALVE LIFTER
1. Body
2. Spring, Plunger
3. Housing, Check Valve
4. Spring, Check Valve
5. Plate, Check Valve
6. Plunger
7. Socket
8. Ring, Retaining
9. Oil Groove, Exterior
10. Oil Inlet, Body
11. Oil Groove, Interior
12. Oil Inlet, Plunger
13. Oil Reservoir, Plunger
14. Hole, Oil Discharge
15. Oil Reservoir, Body
16. Hole, Oil Outlet
A-4-7
FIGURE A-4-11. MAGNETO AND ACCESSORY DRIVES
1. Nut, Hex 13. Gasket

2. Washer, Lock 14. Bushing
3. Washer, Plain 15. Seal, Oil
4. Cover 16. Gear
5. Gasket 17. Bushing, Coupling
6. Nut, Hex 18. Retainer
7. Washer, Lock 19. Sleeve
8. Washer, Plain 20. Gear
9. Nut, Hex 21. Bearing
10. Washer, Lock 22. Gear
11. Washer, Plain 2 3. Sleeve
12. Adapter, Accessory
A-4-8
11
FIGURE A4-12. OIL SUMP
1. Gasket, Annular
2. Plug
3. Screw, Ilex Head
4. Washer, Lock
5. Washer, Plain
6. Sump Assembly,Oil
7. Gasket, Oil Sump
8. Screw, Hex Head
9. Screw, Hex Head
10. Washer, Plain
11. Tube Assembly, Suction
12. Gasket, Suction Tube
A4-9
CUT AND BEND AS SHOWN.
Must Not Touch Thrust Washer
AND CUT AS SHOWN.

Not Extend Beyond End Of Shaft.
OTTER PIN HEAD IN SLOT
8
5
12
11
10 4
FIGURE A4-13. ALTERNATOR ASSEMBLY
1. Nut, Hex 8. Key, Woodruff

2. Washer, Lock 9. Washer, Thrust
3. Washer, Plain 10. Gear Assembly, Alternator Driven
4. Alternator Assembly, Complete 11. Bushing
5. Gasket, Alternator 12. Spring, Clutch
6. Pin, Cotter 13. Hub Assembly, Gear Driven
7. Nut, Slotted Hex
A-4-10
6 7
12
15
17
FIGURE A-4-14. OIL COOLER
1. Nut, Hex 11. Washer, Plain

2. Washer, Lock 12. Bolt
3. Washer, Plain 13. Cooler, Engine Oil
4. Nut, Hex 14. Gasket, Oil Cooler-to-Crankcase
5. Washer, Lock 15. Elbow, Oil Inlet
6. Washer, Plain 16. Nut, Hex
7. Washer, Plain 17. O-Ring
8. Washer, Plain 18. Valve Assembly,Oil Temperature
9. O-Ring Control
10. O-Ring 19. Reducer, Bushing
A-4-1 1
1
8
43
30
7
20
FIGURE A-4-15. STARTER ADAPTER
1. Nut, Hex 16. Nut, Slotted Hex 31. Gear, Worm Wheel
2. Washe r, Plain 17. Washer, Plain 3 2. Beari ng, Ball
3. Starter 18. Damper, Torsional 3 3. Spacer
4. O-Ring 19. Key, Woodruff 34. Screw
5. Nut, Hex 20. Screw 3 5. Washer, Tab
6. Washer, Lock 21. Washer, Lock 36. Ring, Retainer
7. Washer, Plain 22. Washer, Plain 3 7. Pin
8. Screw 23. Cover, Starter Adapter 38. Bushing
9. Screw 24. Spacer 39. Gear, Worm
10. Washer, Lock 25. O-Ring 40. Key, Woodruff
11. Gasket 26. Seal, Oil 41. Bearing, Ball
12. Shaftgear, Starter 27. Ring, Retaining 42. Shaft, Worm Drive
13. Ring, Retaining 28. Gasket, Cover-to-Adapter 43. Bearing, Needle
14. Key 29. Adapter Assembly, Starter
15. Spring 30. Spring, Clutch
A-4-12
1 8
.2
3
11
12
13
39
14
15
34 37
16
17 17
40
FIGURE A4-16. OIL PUMP ASSEMBLY
1. Gasket, Oil Pump 19. Spring, Oil By-Pass Valve 36. Seal, Oil
2. Washer, Plain 20. Gasket, Annular 37. Stud
3. Washer, Lock 21. Pin and Plug Assembly, By-Pass Valve 3 8. Gasket, Tach Drive Pad
4. Nut 22. Gear Assembly, Oil Pump Driver 39. Cover, Tach Dri've Pad
5. Housing Assembly, Oil Pump 23. Pin, Dowel 40. Washer, Plain
6. Stud 24. Gear, Bevel, Tach Drive 4 1. Washer, Lock
7. Plug 25. Key, Woodruff 42. Nut
8. Gear Assembly, Oil Pump Driven 26. Body Assembly, Scavenge Pump 43. Gasket, Annular
9. Bushing, Oil Pump Gear 27. Elbow 44. Plug and Screen Assembly
10. Plunger, Oil Pressure Relief Valve 28. Plug 45. Shaft Assembly
11. Spring, Oil Pressure Relief Valve 29. Gear, Scavenge Pump Driver 46. Pin Dowel
12. Washer, Spring Guide 30. Gear Assembly, Scavenge Pump Driven 47. Gear, Bevel, Tach Drive
13. Screw Adjusting 3 1. Bushing 48. Gasket, Gear Box Cover
14. Gasket, Annular 3 2. Washer, Plain 49. Cover
15. Housing, Oil Pressure Relief Valve 33. Washer, Lock 50. Screw
16. Washer, Copper 34. Nut, Plain 5 1. Washer, Lock
17. Nut, Adjusting Screw 35. Cover Assembly, Scavenge Pump 5 2. Washer, Flat
18. Valve, Oil By-Pass
A-4-13
31
20
19
24.
40
FIGURE A-4-17. CYLINDER AND PISTON ASSEMBLY
Note: Current production engines are built with

four ring pistons.Do not intermix.
1. Screw, Fillister 18. Packing, Push Rod Housing 3 5. Ring, Compression

2. Washer, Lock 19. Nut, Flanged 36. Ring, Oil
3. Washer, Plain 20. Nut, Flanged 37. Ring, Scraper
4. Cover, Rocker 21. Cylinder Assembly 38. Ring, Retaining
5. Gasket, Rocker Cover 22. O-Ring, Cylinder Base 3 9. Body, Valve Lifter
6. Screw 23. Key, Valve Spring Retainer 40. Spring, Cylinder Baffle
7. Washer, Tab 24. Roto Coil Assembly, Exhaust 41. Baffle, Cylinder Head
8. Shaft, Valve Rocker 25. Retainer, Valve Spring Intake 42. Insert, Spark Plug Thread
9. Screw, Drive 26. Spring, Valve Outer 43. Plug
10. Bushing, Rocker 27. Spring, Valve Inner 44. Insert, Rocker Shaft
11. Rocker, Valve 28. Retainer, Valve Spring Inner 45. Stud
12. Retainer, Rocker Shaft 29. Valve, Exhaust 46. Gasket
13. Rod Assembly, Push 30. Valve, Intake 47. Nut, Exhaust Flange
14. Housing, Push Rod 31. Pin, Piston 48. Guide, Valve
15. Spring, Push Rod Housing 3 2. Piston 49. Insert, Exhaust Valve
16. Washer, Push Rod Housing 3 3. Ring, Compression 50. Insert, Intake Valve
17. O-Ring, Push Rod Housing 34. Ring, Compression 51. Washer
A-4-14 MARCH 1981

FIGURE A4-18. CRANKCASE ASSEMBLY
A-4-15
1. Rod, Oil Gauge 49. Nut, Hex 97. Bolt, Hex Head
2. O-Ring 50. Washer, Lock 98. Stud
3. Screw 51. Washer, Plain 99. Eye, Lifting, Right Side
4. Tube, Oil Gauge Rod 52. Bolt, Hex Head 100. Eye, Lifting, Left Side
5. O-Ring 53. Nut, Hex 101. Nut, Flanged
6. Ring, Oil Gauge Lock 54. Washer, Lock 102. Washer, Plain
7. Oil Cap and Retainer Assembly 5 5. Washer, Plain 103. Nut, Flanged
8. Gasket, Oil Filler Cap 56. Bolt, Hex Head 104. Washer, Plain
9. Neck Assembly, Oil Filler 57. Washer, Plain 105. Nut, Hex
10. Gasket, Oil Filler Neck 58. Nut 106. Washer, Lock
11. Nut, Hex 59. Washer, Lock 107. Washer, Plain
12. Washer, Lock 60. Washer, Plain 108. Bracket, Engine Mount
13. Washer, Plain 61. Bolt, Hex Head 109. Insert, Thread
14. Cover 62. Bolt, Hex Head 110. Nut, Hex
15. Gasket 63. Washer, Plain 111. Washer, Lock
16. Clamp, Breather Hose 64. Eye, Lifting, Front 112. Washer, Plain
17. Hose 65. Nut, Hex 113. Nut, Flanged
18. Hose 66. Washer, Plain 114. Washer, Plain
19. Tee, Breather 67. 0-Ring 115. Bracket, Engine Mount
20. Nut, Hex 68. Bolt, Hex Head 116. Insert, Thread
21. Washer, Lock 69. Washer, Plain 117. Plug, Timing Hole
22. Washer, Plain 70. 0-Ring 118. Valve, Timing Hole Plug
23. Housing, Needle Bearing 71. Nut, Flanged 119. Pin, Timing Indicator
24. Bearing, Needle 72. Spacer 120. Bolt, Crankcase Thru
25. Gasket, Needle Bearing Housing 73. Nut, Hex 121. Bolt, Crankcase Thru
26. Nut, Hex 74. Washer, Plain 122. Bolt, Crankcase Thru
27. Washer, Lock 75. Nut, Hex 123. Bolt, Crankcase Thru
28. Pin, Idler Gear Support 76. Washer, Lock 124. Bolt, Crankcase Thru
29. Gasket, Idler Gear Support 77. Washer, Plain 125. Bolt, Crankcase Thru
30. Bolt, Hex Head 78. Screw, Hex Head 126. Crankcase, Left
31. Washer, Plain 79. Eye, Lifting 127. Crankcase, Right
32. O-Ring 80. Spacer 128. Nut, Hex
3 3. Bolt, Hex Head 81. Nut, Hex 129. Washer, Lock
34. Washer, Plain 82. Washer, Lock 130. Washer, Plain
35. Bolt, Hex Head 83. Washer, Plain 131. Bracket, Engine Mount
36. Washer, Lock 84. Bolt, Hex 132. Insert, Thread
37. Washer, Plain 85. Washer, Plain 133. Nut, Hex
38. Bolt, Hex Head 86. Nut, Hex 134. Washer, Lock
39. Washer, Plain 87. Washer, Lock 135. Washer, Plain
40. Bolt, Hex Head 88. Washer, Plain 136. Bracket, Engine Mount
41. Washer, Lock 89. Screw, Hex Head 137. Insert, Thread
42. Washer, Plain 90. Valve, Manifold and Bracket 138. Tube, Breather
43. Nut, Hex 91. Nut, Hex 139. Screw, Drive
44. Washer, Lock 92. Washer, Lock 140. Plate, Identification
45. Washer, Plain 93. Washer, Plain 141. Bearing, Needle
46 Washer 94. Bolt, Hex Head 142. Nozzle, Squirt
47. Cover, Governor Pad 95. Eye, Lifting, Rear 143. O-Ring
48. Gasket, Governor Pad 96. Spacer
A-4-16
2
FIGURE A-4-19. CAMSHAFT ASSEMBLY
1. Gear, Bevel, Governor Drivcn

2. Gear, Bevel, Governor Drive
3. Key, Woodruff
4. Screw, Hex Head
5. Gear, Cam Cluster
6. Gear, Camshaft
7. Camshaft
A4-17
32
16
18 29
19
38
39
1
37
FIGURE A-4-20. CRANKSHAFT ASSEMBLY.

1. Pin, Cotter 15. Gear, Crankshaft 29. Tube, Oil Transfer
2. Nut, Slotted, Special 16. Ring, Retainer 30. Sleeve Assembly
3. Bolt, Connecting Rod, Special 17. Screw 31. O-Ring
4. Cap, Connecting Rod 18. Plate, Quill Shaft 3 2. Bearing,Prop Shaft
5. Rod, Connecting 19. Gear, Prop Shaft Drive 3 3. Washer, Prop Shaft Thrust
6. Bearing, Connecting Rod 20. Shaft, Quill, Prop Drive Gear 34. Screw, Hex Head, Drilled
7. Bushing, Piston Pin 21. Screw, Hex Head 3 5. Gear, Idler Accessory Drive
8. Ring, Retainer 22. Plate, Tab Lock 36. Bushing, Idler Gear
9. Plate, Damper 23. Gear, Alternator Drive 3 7. Gear,Idler
10. Pin, Damper 24. Seal, Crankshaft Oil 38. Bearing, Prop Drive Gear
11. Bushing, Damper 25. Reinforcing Ring, Oil Seal 39. Bearing, Crankshaft
12. Counterweight 26. Spring, Oil Seal 40. Dowel, Crankshaft
13. Screw, Hex Head 27. Shaft, Propeller 41. Crankshaft
14. DELETED 28. Sleeve, Oil Transfer 42. Bushing
A-4-18 OCTOBER 1980

FIGURE A-4-21. STUD LOCATION
FIGURE A-4-22. INSPECTION RING SIDE CLEARANCE
June 1980 A-4-19

"D" DIAMETER (INCH ES)
NEW PARTS SERVICE
SIZE MIN. MAX. LIMIT
STANDARD 5.251 5.253 5.256
FIGURE A4-23. CLYINDER MACHINING DIMENSIONS
A-4-20 June 1980

FIGURE A-4-24. INSTALLING TYPICAL FIGURE A-4-27. REMOVING SPARK PLUG
HELICAL COIL INSERT HOLE HELICAL COIL INSERT
FIGURE A-4-25. INSTALLING SPARK PLUG

HOLE HELICAL COIL INSERT
THESE SURFACES MUST

BE SQUARE WITHIN
.002 INCH FULL
INDICATOR READING
IN. DIA.
TWO HOLES
IN LINE SECTION A-A
FIGURE A-4-26. EXPANDING SPARK PLUG FIGURE A-4-28. VALVE ROCKER

HOLE HELICAL COIL INSERT BEARING DIMENSIONS
A-4-21
BREAK SHARP EDGES .01 IN. X
450, IF ORIGINAL CHAMFER WAS
COMPLETELY REMOVED BY BORING
OR REAMING OF REPLACEMENT
BUSHING.
1.00
L BUSHING
A .0005 IN.
MAX. TWIST
(WITH NEW
BUSHING)
BIG END
FIGURE A-4-29.
CONNECTING ROD AND BUSHING
DIMENSIONS AND INSTALLATION
1. Connecting Rod Bushing Removal

and Replacing Tool
2. New Bushing
3. Bushing Split Line
4. Connecting Rod and Cap Assembly
A-4-22
SECTION A-A
FIGURE A-4-30. COUNTERWEIGHT WITH BUSHING
FIGURE A4-31. INSTALLING NEW STARTER ADPATER

NEEDLE BEARING
A-4-23
FIGURE A-4-32. EXPLODED VIEW OF IGNITION SYSTEM
A-4-24
1. High Tension Outlet Plate
2. Ferrule
3. Outlet Plate Grommet
4. Cable Assembly-to-No.1 Lower Spark Plug
5. Cable Assembly-to-No.6 Upper Spark Plug
7. Cable Assembly-ro No.2 Upper Spark Plug
16. Spring
17. Terminal
18. Sleeve
19. Spring
20. Ferrule
21. Nut
22. Ferrule
23. Eyelet
24. Clamp
25. Approved Spark Plug
26. Clamp
27. Screw
28. Nut
29. Clamp
30. Screw
31. Strap
32. Gasket
3 3. Magneto
34. Magneto Holding Washer
3 5. Washer, Lock
36. Nut, Hex, Plain
37. Washer, Plain
38. Bushing,Insulating
39. Bushing, Shouldered
40. Nut, Coupling
41. Washer, Plain
42. Bushing,Insulating
43. Bushing, Shouldered
44. Nut, Couplin
45. Washer, Lock
46. Screw
47. Tubing, Sprial
A-4-25
FEELER GAGE
.005 -. 035
FIGURE A-4-33. ALTERNATOR

DRIVE GEAR INSTALLED
FIGURE A-4-36.
CHECKING ROCKER ARM CLEARANCE
NOTE:
INNER AND OUTER SPRINGS MUST
BEINSTALLED ASSHOWN
FIGURE A-4-34. VALVE SPRING

INSTALLATION
FIGURE A-4-35. ALIGNMENT OF FIGURE A-4-37. INSTALLING

TIMING MARKS CYLINDER BAFFLE
A-4-26 June 1980

FIGURE A-4-38. TORQUING SEQUENCE
ASSEMBLY PROCEDURE assemble bolts with flats, on hex parallel rn

1. Insert thru bolts. of crankbore.
2. Snug bolts No.9, 40, 41 & 45. 4. Both sides of crankcase to be cross torqued
3 . Install cylinders 4 & 5.Tighten stud nuts to simultaneously.
300400 in. lbs.
4. Tighten thru bolts No.1, 4 & 9 to 300400 in.
lbs. in sequence shown.
5. Tighten stud nuts to 500 in. lbs.
6. Tighten thru bolts No.1 & 4 to 690-710 in.
lbs. Tighten No.9 to 500 in.lbs.
7. Repeat above on cylinders 2 & 3.
8. Repeat above on cylinder 6.
9. Tighten bolts No. 27,28,44,45,46 & 47 to 650
in. lbs. in sequence shown.
10. Repeat above on cylinder 1.
11. Tighten bolts No. 38 thru 61 to specified tor-
que in sequence shown.
NOTES
1. All stud and thru bolt threads to be lubricated
with Sunoco Way Oil.
2. Nuts on both ends of thru bolts must be tor-
qued.
3. At bolt locations 27 and 28 in alternator bore, FIGURE A-4-39. INSTALLING CYLINDER
A-4-27
FIGURE A-440. TIMING MARKS
A4-28
FIIGURE A-441. INSTALLING OIL SEAL ON PROPELLER DRIVE SHAFT GEAR
FIGURE A-442. PROPELLER DRIVE SHAFT GEAR OIL SEAL INSTALLED

WITH RETAINING RING AND SPRING IN CAVITY
A-429
UPPER SPARK PLUGS
TO STARTING VIBRATOR
IGNITION SWITCH
STARTER SWITCH
RIGHT MAG. LEFT MAG.

(SINGLE (DOUBLE BREAKER
BREAKER)
LOWER SPARK PLUGS
ENGINE FIRING ORDER 1 4 5 1 2 36

MAGNETO FIRING ORDER 12 3 4 56
FIGURE A4-43. WIRING DIAGRAM
A-4-30 MARCH 1981

SECTION V
SPECIAL TOOLS AND EQUIPMENT
5-1. For most overhaul operations, tools in 5-6. The wrenches shown in Fig. A-5-1 facilitate
general use in Aircraft Engine Overhaul Shops will cylinder base nut removal and replacement. Also
be sufficient. Certain operations, however, are available are wrenches for No.'s 5, 6 cylinder thru
more easily accomplished with the special tools bolt. Borroughs P/N 8031 and 8032.
listed herein.
5-7. The tool in Fig. A-5-2 is used for installing
5-2. It is advisable to have an engine tran- the needle bearing in the starter adapter. This tool
sportation stand with a bed that can be inverted so can be manufactured locally in accordance with
certain parts can be removed or installed easily. A the dimensions specified.
typical engine stand is shown in Fig. A-5-7.
5-8. Fig. A-5-4 is a Pushrod Housing Spring
5-3. A Thomas & Betts Crimping Tool, No. Compressor, designed to enable the mechanic to
WT-217, should be used for installing new outer install the pushrod housings more easily.
sleeves on the ignition harness.
5-9. Use the piston ring compressor shown in
5-4. Special tools for Aircraft Engines in Fig. A-5-3 to check ring gap.
general, and the GTSIO-520 in particular, are
manufactured and sold by the Borroughs' Tool & 5-10. Fig. A-5-5 depicts a valve lifter bleed down
Equipment Corp., 2429 North Burdick Street, tester which enables the mechanic to accurately
Kalamazoo, Michigan 49007. test the performance of hydraulic lifters.
5-5. Fig. A-5-8 depicts Borroughs' Tool No. 5-11. Fig. A-5-6 depicts a typical schematic
2838A used to compress the valve spring while diagram of a differential pressure tester.
removing or replacing the valve.
A-5-1
P/N 5204 RIGHT HAND P/N 5203 LEFT HAND P/N 2882-1 (7/16)
P/N 2882-2 (1/2)
FIGURE A-5-1. BORROUGH'S CLYINDER BASE NUT WRENCHES
010 MAX. R. 52
COLD ROLLED STEEL BAR STOCK
SIDE VIEW END

VIEW
16 x 450 CHAMFER
NOTE: ALL DIMENSIONS IN INCHES
FIGURE A-5-2. STARTER ADAPTER

BEARING INSTALLER
FIGURE A-5-4. PUSH ROD SPRING
COMPRESSOR,BORROUGH'S NO. 68-2
FIGURE A-5-3. PISTON RING COMPRESSOR, FIGURE A-5-5. VALVE LIFTER BLEED DOWN
BORROUGH'S NO. 5201. TESTER, BORROUGH'S NO. BT60C
A-5-2
FIGURE A-5-6. SCHEMATIC DIAGRAM OF A DIFFERENTIAL PRESSURE TESTER
FIGURE A-5-7. FIGURE A-5-8. VALVE SPRING COMPRESSOR,

ENGINE TRANSPORTATION STAND BORROUGH'S NO.2838A
A-5-3/A-5-4
6-1. UNPACKING. After tightening the upper plugs, insert the cable
terminals and screw on the hex coupling nuts.
a. Detach the assembly of shipping crate top Tighten them only moderately. if in doubt as to
and side panels from the crate base and lift off the proper cable connections, refer to the ignition
cover assembly. Engines received from the factory wiring diagram.
are covered by a moisture proof paper shroud.
Attach a chain hoist to the engine lifting eyes C. Install the type of thermocouple on the
before loosening the engine mount bracket attach- cylinder specified by the aircraft manufacturer.
ing bolt nuts. Take up slack in the hoist; then
remove the nuts, washers, horizontal bolts and d. To install the oil gauge pressure line fitting,
shock mounts from the mount brackets and four remove the 3/8 in. pipe plug located in the
supporting steel angle members. Lift the engine crankcase between No. 2 and 4 cylinders. Coat the
straight up until clear of the crate. It is advisable to pipe threads of the fitting with a thin film of
support the engine on an assembly stand while thread lubricant per Table 12.
removing packing materials and installing
accessories. C. For engines requiring an electrical tacho-
meter generator, remove the mounting pad cover
b. Remove dehydrator plugs from the upper and install the tachometer generator. Use a new
spark plug holes. If the engine is to be installed at gasket and new shakeproof internal tooth lock
once, turn the crankshaft as necessary, and inspect washers. Before installing any accessory where the
the interior of each cylinder. If a pool of oil is driving (engine) shaft has an oil seal, apply a film
standing in any cylinder it must be drained before of general purpose grease to the accessory shaft
engine is installed. If compression cannot be built end.
up in any cylinder by turning the crankshaft while
the upper spark plug hole is plugged, remove the f. Remove the plugs in the bottom of the
valve rocker cover from that cylinder, and check cylinder and install the cylinder drain fittings.
valve action. If a valve stem is sticking in its guide,
apply castor oil or engine lubrication oil thinned 6-3. PREPARATION FOR STORAGE. Ref.
with gasoline while the crankshaft is rotated and Service Bulletin M74-9
until the valve operates freely. Use a new gasket
when replacing the valve rocker cover. a. If an engine, which has been in operation,
is to be stored much longer than a week under
C. Remove the plastic caps from the breather, normal climatic conditions, and if periodic running
exhaust ports, etc. to circulate oil is not carried out, it is advisable to
prepare it for storage in the following manner.
6-2. PREPARATION FOR SERVICE. b. Operate the engine until the oil temper-
ature reaches the normal range. Drain the regular
a. The corrosion-preventive oil fed into the oil supply from the sump as completely as possible;
lubricating system and sprayed into cylinders then replace the drain plug.
before shipment of a new engine will mix with
normal engine lubricating oil and will do no harm; C. Fill the oil sump to the full (F) mark on
hence, it does not need to be flushed out. the level gauge with a corrosion-preventive oil
(MIL-C-6529 Type II) which will mix with normal
b. Before installing upper spark plugs, coat oil and which is suitable as a lubricant. This oil
their 18mm threads, with only a film of engine oil. must be preheated to 2250 F.
June 1980 A-6-1

SECTION VII
DISASSEMBLY
7-1. AIRCRAFT PARTS AND ACCESSORIES. 7-5. PRELIMINARY CLEANING. Spray, or

apply with a brush, a solvent used for general
a. Instructions in this section are based on the cleaning of engine parts. Remove caked dirt on
assumption that all parts attached by the aircraft bolt heads and nuts especially. At the same time
manufacturer, except optional pumps, have been the oil sump drain plugs should be removed to
removed. drain any remaining oil.
b. Accessories supplied by the engine manu- CA UTION. ... Do not use a caustic or even mild
facturer may be serviced according to instructions alkaline cleaning solution for external precleaning,
supplied by the applicable accessory manufacturer. as these solutions will also remove the "alodized"
finish of certain aluminum parts.
c. Instructions for the maintenance and over-
haul of the turbocharger is supplied in Teledyne 7-6. IGNITION SYSTEM.
Continental Aircraft Engine Turbocharger Manual,
Form X-30054 or X-30087. a. Disconnect cables from spark plugs.
7-2. EXTENT OF DISASSEMBLY. Line draw- b. Remove one screw from each of the valve
ings reproduced in this section are identical to rocker covers that attaches the lower spark plug
those used in the parts catalog, except for the cable clamps.
order of index numbers assigned to components.
Index numbers herein indicate the order of dis- c. Detach ignition cable retaining clamps from
assembly. In many instances the location of com- fuel discharge brackets.
ponents and attaching parts in the illustration will
be sufficient to enable personnel to accomplish d. Detach clip from cable bracket on top of
disassembly operations. In these instances such crankcase. Disengage band clamps.
disassembly is to be accomplished, even though
there are no printed instructions to that effect, e. Detach high tension cable outlet plates
excepting those parts which need to be removed from magnetos and withdraw them to free cable
only for replacement. Such parts include studs, assemblies.
bushings and other tight fit inserts. The identity of
these will be obvious. f. Remove two attaching nuts, lockwashers
and holding washers from each magneto. Withdraw
7-3. PARTS TO BE DISCARDED. Discard all magnetos forward from the crankcase.
shakeproof washers, lockwires, tab washers, rubber
seal rigs, oil seals, gaskets, cotter pins, hose
connectors and magneto coupling (rubber) bush- 7-7. FUEL INJECTION SYSTEM.
ings in such a manner that they will not be used
again inadvertantly. Care should be taken in a. Disconnect tube from air junction fitting.
removing gaskets from aluminum parts by scraping.
Such removal should be delayed until the part is to b. Disconnect the 1-3-5 side air manifold tube
be cleaned. and the 2-4-6 side air manifold tube from the air
junction fitting and remove air junction fitting.
7-4. DISASSEMBLY STAND. For greatest ease
of disassembly, this engine should be mounted on
an engine stand with a tilting bed. See the c. Disconnect six injection nozzle sleeve
installation drawings for necessary dimensions for assemblies from air fuel nozzle tubes and remove
mounting engine on stand. tubes and sleeves.
A-7-1
d. Disconnect six fuel discharge tubes from remove riser tube and tube assemblies.
manifold valve and nozzles. Compress spring legs of
each clamp and remove clamp. Disconnect hose 7-9. MAGNETO AND ACCESSORY DRIVES
assembly from manifold valve and junction box. (See Figure A-4-11)
Remove nozzles and washers and store in a clean
container. Remove manifold valve and bracket a. On the 1-3-5 crankcase, remove the
assembly. adapter. With the aid of an arbor press remove
bushing and seal from adapter.
NOTE ... Further disassembly of the nozzles
should not be attempted unless flow test equip- b. Remove magneto and accessory drive gear
ment is available. and sleeve assembly magneto drive coupling bush-
ings and retainer.
e. Remove cotter pin, washer and wave wash-
er from rod end of metering unit; then remove nut, c. The 24-6 side will be removed with the
rod end and spring. Remove cotter pin, washer, same procedure used for the 1-3-5 side.
wave washer and link rod.
7-10. OIL SUMP (See Figure A-4-12)
f. Remove four screws and metering unit
shroud. Using a screwdriver pry down the locking a. Drain plug and gasket should have been
ear of tab washers; then remove screws and tab removed when engine was mounted on stand.
washers.Control assembly and shroud are now Remove attaching parts and lift sump from engine.
free to be removed. Remove and discard gasket.
g. The throttle and lever assembly will be b. Remove screws and washers and lift off
removed with the induction system. suction tube assembly. Remove and discard gasket.
h. Remove six screws, washers and fuel pump 7-11. OIL COOLER (Sec Figure A4-14)
shroud. Remove four sets of attaching parts
securing fuel pump and vapor separator to case. a. Remove attaching parts and remove oil
cooler. Remove spacers, "O" ring and discard
i. Remove gear and plug assembly and gasket.
coupling.
b. Remove oil temperature control valve.
NOTE . .. Air Throttle Assembly, Metering and
Mixture Control Assembly and Controller 7-12. ALTERNATOR ASSEMBLY (See Figure
Assembly are calibrated as an integral unit, and A4-1 3)
should not be disassembled unless necessary.
a. Remove alternator and gasket. Discard
7-8. INDUCTION SYSTEM. gasket.
a. Loosen hose clamps, sleeves and remove air b. Remove cotter pin, nut and pull hub
throttle assembly. assembly from alternator shaft. Remove Woodruff
key.
b. Remove attaching parts and lift off inter-
cooler or adapter. c. Separate thrust washer, gear assembly,
clutch spring and hub.
c. Remove attaching parts, along with the
crankcase breather hose so that the induction 7-13. STARTER AND STARTER DRIVE
system can be lifted off as an assembly and be ADAPTER (See Figure A4-15).
disassembled on the bench. Remove and discard
gaskets. a. Remove two sets of attaching parts (1, 2)
and pull starter (3) from the starter adapter studs.
d. Loosen clamps and remove hoses, then Remove and discard "O" ring (4).
A-7-2
b. Remove attaching parts (5 thru 10) and 7-14. OIL PUMP ASSEMBLY (See Fig. A4-16).
pull starter adapter assembly from crankcase cover
studs. Remove and discard gasket (1 1). a. Loosen oil screen plug (4 4 ),by-pass plug
(21) and oil pressure relief valve housing (15) to
c. Clamp spur gear end of shaft gear (12) in facilitate later removal.
shielded vise jaws and remove snap ring (13), key
(14), spring (15), nut (16) and washer (17). Pull b. Remove nine sets of attaching parts (2, 3,
torsional damper (1 8) from shaft and remove 4), but not those indexed (3 2, 33, 34), and pull oil
Woodruff key (19). pump assembly complete from crankcase cover
studs. Remove and discard gasket (1).
d. Remove attaching parts (20, 21, 22) and
pull cover (23), spacer (24), "O" ring (25), oil seal c. Remove oil screen plug(44)and gasket (43).
and retaining ring (27) from shaft.
d. Remove four sets of attaching parts (4041,
e. Use Truarc No. 3 or 23 pliers and remove 42), cover (39) and gasket (38); then remove the
retaining ring (27). Remove spacer (24) and "O" remaining two sets of attaching parts (32, 33, 34)
ring (25) from I.D. of oil seal (26), then use arbor from the two studs (6) and withdraw the scavenge
press to press out oil seal from cover. Remove and pump cover assembly (3 5). Use an arbor press and
discard gasket (28). remove seal (36).
f. To remove the shaftgear and clutch e. Slide scavenge driven gear assembly (30)
assembly from the adapter, support rear side of off shaft (22) and out of scavenge pump body
adapter (29) on blocks and tap shaftgear (12) with (26). Pull scavenge driver gear (29) off shaftgear
a brass drift or pin punch. Remove shaftgear (12), (22) and remove key (25). Remove turbo scavenge
clutch spring (30) and worm wheel (31) as an pump body (26) from oil pump housing (5).
assembly.
f. Remove oil pump driver shaftgear (2 2) and
g. Use a wheel puller or arbor press to press oil pump driven gear assembly (8) from oil pump
the shaftgear (12) from the worm wheel (31), housing (5).
bearing (32) and spacer (3 3).
g. Remove oil pressure relief valve assembly
h. Clamp worm wheel (3 1) in shielded vise (10 thru 17) and by-pass valve (18 thru 21).
and remove retaining screw (34) and tab washer Remove plug (7) to facilitate cleaning. Studs (6)
(35). Rotate spring (30) until its depressed end lies to be removed only if replacement is necessary.
across the upper 1/4 inch hole in the flange. Insert
a 3/16 inch wide screwdriver blade, pry the spring 7-15. CYLINDERS AND PISTONS (See Figure
end outward clear of the drum groove. Hold it out A-4-17).
while pulling the spring away.
a. Rotate engine stand so engine is in inverted
i. Clamp adapter (29) in shielded vise and position. Remove attaching parts (1, 2, 3), covers
remove retaining ring (36) with Truarc No. 5 pliers. (4) and gaskets (5).
Withdraw parts indexed (37 thru 42) as an
assembly. b. Position crankshaft so valve lifters of
cylinder to be removed are on heels of cam lobes
j. Support bushing and drive out pin (37). and both valves are fully closed. Remove screws
Slide worm gear (39) from shaft (42) and remove (6). washers (7), shafts (8), rocker assemblies (9,
Woodruff key (40). Remove bearing (41) from 10, 11, 12), and thrust washers (51). Withdraw
shaft (42). pushrods (13).
k. See Section VIII to remove needle bearing c. Push the pushrod housing (14) against the
(43) from adapter (29). spring (15) until the cylinder flange end is clear.
A-7-3
Lift cylinder end of housing and withdraw from c. Remove four sets of attaching parts (1,
crankcase. Remove spring (15), washers (16), "O" 12, 13), cover (14) and gasket (15).
rings (17) and packings (18).
d. Breather hose (17) was disconnected from
d. Remove one flanged nut (19), and three right crankcase earlier. Disconnect and remove
flanged nuts (20) from each cylinder flange. Rotate hoses (17, 18), breather tee (19) and clamps (16)
engine stand so engine is in upright position. Make as an assembly.
sure piston in cylinder to be removed is top dead
center. Remove remainder of nuts (19, 20). Cradle e. Remove attaching parts (20, 21, 22),
cylinder in arm and withdraw it straight outward. needle bearing housing (23) and gasket (25) from
Catch piston with other hand as it clears the crankcase. Use an arbor press to remove needle
cylinder to prevent damage to piston or crankcase. bearing (24) from needle bearing housing (23).
e. Remove packing (22). Use of a cylindrical f. Remove attaching parts (26, 27), idler gear
wood block anchored to a work bench, with support pin (28) and gasket (29).
provisions for clamping the cylinder in place, is
recommended to facilitate removal of valve springs g. Remove one bolt (30), plain washer (31)
and to prevent dropping of valves. and "O" ring (32): one bolt (33) and plain washer
(34); one bolt (35), lockwasher (36) and plain
f. Compress valve springs and remove keys washer (37); and two bolts (38) and plain washers
(23). Be careful not to cock retainers (24, 25) and (39).
score valve stems. Remove rotocap (24) or retainer
(25), outer spring (26), inner spring (27), and inner h. Rotate engine disassembly stand bed so
retainer (28). Hold valve stems while lifting that right crankcase (127) will be downward. Place
cylinder from its support and lay cylinder on its support under casting.
side. Stone down any nicks before removing valves
(29, 30). i. Remove one set of attaching parts (40, 41,
42).
NOTE ... It is recommended that all exhaust
valves and roto caps be replaced at each major j. Remove four sets of attaching parts (43,
overhaul regardless of condition. 44, 45, 46), governor pad cover (47) and gasket
(48).
g. Remove piston pins (31) and piston (32)
and rings (33 thru 37) as an assembly. Remove k. Remove two sets of attaching parts (58, 59,
rings from piston being careful not to score ring 60), bolt (61), bolt (62), washers (63) and front
lands with ring ends. lifting eye (64); remove three sets of attaching
parts (53, 54, 55), bolts (56) and washers (57).
h. Remove hydraulic valve lifter assemblies
(39). It is recommended that all hydraulic lifters be 1. Remove two sets of attaching parts (65,
replaced at each major overhaul regardless of 66) and "O" rings (67).
condition.
m. Remove one bolt (68), washer (69) and
7-16. CRANKCASE (See Figure A4-18). "O" ring (70); then remove three sets of attaching
parts (71, 72) and two sets of attaching parts ((73,
a. Remove oil gauge rod assembly (1, 2). 74).
Remove one screw (3) and oil gauge rod guide
assembly (4, 5, 6). n. Remove six sets of attaching parts (81, 82,
.83), bolt (84) and washers (85).
b. Unhook and remove oil cap retainer
assembly (7) and gasket (8). Remove the remaining o. Remove two sets of manifold valve attach-
two screws (3) and lift off oil filler neck (9) and ing parts (86, 87, 88), bolts (89) and manifold
gasket (10). valve (90).
A-7-4
NOTE . . Bolts (94 or 97 top only) cannot be a. Use wooden blocks under front and rear
removed without removal of stud (98). main journals of crankshaft during disassembly.
p. Remove two sets of attaching parts (101, b. Remove cotter pin (1), slotted nut (2), bolt
102) and two sets of attaching parts (103, 104). (3) and separate connecting rod cap (4) and rod
(5). Remove bearing inserts (6). Loosely re-
q. Remove four sets of forward mounting leg assemble rod, cap, bolt and nut with their position
attaching parts (105, 106, 107) and mounting leg numbers attached.
(108).
c. Remove retaining rings (8), plates (9) and
r. Remove two sets of rear mounting leg pin (1 0) and lift counterweight assembly (1 2) from
attaching parts (109, 110, 111), one set of attach- crankshaft.
ing parts (1 12, 11 3) and mounting leg (1 15).
d. Remove six screws (1 3) and gear (1 5).
s. Tap crankcase thru. bolts (120 thru. 125)
with a non-marring hammer and remove carefully e. Remove retaining ring (16), two screws
from crankcase so as not to damage threads. (17), plate (18) and pull prop shaft drive gear (19)
Remove and discard "O" rings (143). from prop drive gear quill shaft (20) and crank-
shaft (41).
t. Lift off left crankcase; remove camshaft
assembly and governor driven gear (See Fig.A4-19) f. If necessary, alternator drive gear (23) may
be removed from the prop shaft drive gear (19) by
u. Remove squirt nozzle (142) as necessary. removing four screws (21) and two tab lock plates
(See Figure A-4-18). (22).
7-17. CAMSHAFT ASSEMBLY (See Fig A4-19) g. Remove oil seal assembly (24, 25, 26) from
propeller drive shaft (27). Oil transfer tube sleeve
a. Remove governor drive gear (2) and Wood- (28) can be removed by the use of a drift and an
ruff key (3). arbor press.
b. Remove four screws (4) and lift off gear (5) h. Parts (29 thru 39) were removed as crank-
and gear (6). shaft assembly complete was removed from crank-
case.
7-18. CRANKSHAFT ASSEMBLY (See Figure
A4-2 0). 1. Remove dowel (40) for replacement only.
A-7-5/A-7-6
SECTION VIII
CLEANING PARTS
8-1. MATERIALS AND PROCESSES. e. Various hot and cold working solutions
have been marketed for loosening carbon.
a. Equipment, processes and materials in Any of these may be employed for that purpose if
general use in aircraft engine overhaul shops will be they do not attack the metal; however, most such
entirely satisfactory for cleaning engine parts: Most materials are ineffective against hard carbon de-
light metal parts of these engines are aluminum posits, since they loosen by dissolving adhesive
alloys. rosins which cannot be dissolved after they have
been carbonized by heat.
b. Do not use any strong alkaline solution to
clean aluminum alloy castings or wrought alumi- f. Various blasting techniques can be employ-
num alloy parts, because all such solutions attack ed to remove hard carbon deposits if suitable
the bare surfaces too rapidly to permit cleaning equipment is available. The most suitable types of
without destruction of the finish. For these parts grit for dry blasting are plastic pellets and pro-
use a fortified mineral spirit solvent, sold under cessed natural materials, such as wheat grains and
various trade names, for degreasing. If rosin (oil crushed fruit pits or shells. Air pressure should be
varnish) or stubborn carbon deposits must be the lowest that will produce the desired cleaning
removed from aluminum alloy parts, they may be action. Small holes and finished surfaces which do
immersed in an agitated bath of an inhibited mild not require cleaning should be protected from the
alkaline cleaning solution marketed for that blast by seals and covers, particularly if the grit is
purpose. The bath should be maintained at a sharp. Sand and metal grit and shot used for
temperature of 180 F. to 200 F., and the parts blasting industrial metals are too abrasive and too
should remain in it only long enough to loosen the heavy for use on soft metals such as aluminum.
deposits. Immediately after such cleaning, flush The vapor grit process employs abrasive grit, but of
away all traces of the alkaline material with a jet of much smaller size and carefully controlled grades
wet steam or by repeated brush application of a for various purposes. Carbon may be removed from
mineral spirit solvent. piston heads by the vapor grit blasting process,
using No. 80 grit, which is also suitable for cylinder
CA UTION. ... Any alkaline deposits remaining on head interiors, but much too coarse for finished
engine interiorparts will react with acids formed in piston walls and ring grooves. No. 50 vapor blast
the lubricating oil to form soap, which will cause grit may be used on cylinder heads for more rapid
violent foam and may result in failure of the cleaning. In any event, the cylinder walls and valve
lubricatingsystem. gudes must be shielded. After any blasting process,
blow off all dust with dehumidified compressed air
C. Trichlorethylene condensation plants pro- and make sure that no grains have lodged in
vide excellent degreasing action for steel, alumi- crevices.
num and bronze parts. Their disadvantages lie in
the toxic quality of the vapors, removal of enamel 8-2. SPECIFIC PARTS.
from painted parts, and the drying and hardening
effect on carbon deposits. 8-3. VALVES. Hard carbon may be scraped
from valve heads with a smooth edge scraper,
d. No polishing compound or abrasive paste preferably while the valve is rotated in a high speed
or powder should be needed or employed for polishing head or lathe. After removal of carbon,
cleaning engine parts. Do not use wire brushes or polish the stems first with crocus cloth moistened
wire brush wheels, putty knives, or scrapers to in kerosene, then with dry crocus cloth.
remove hard carbon deposits, since scratches result-
ing from such methods allow a concentration of 8-4- CYLINDERS. Remove oil and loose
stress at the scratch and may cause fatigue failure. material with a mild alkaline cleaner by spraying or
A-8-1
brushing. Remove carbon from the combustion 8-7. CRANKCASE. If possible, the oil passages
chambers by soft grit or vapor grit blasting if should be pressure-flushed with the usual mineral
equipment is available. Mechanically driven wire spirit solvent and inspected as well as possible with
brushes are not recommended for this purpose, due the aid of a flashlight. If the castings are immersed
to the difficulty of avoiding abrasion of the top in an alkaline bath, it is strongly recommended
ends of the barrels. that such treatment be followed by spraying with a
jet of wet steam and this followed by flushing of
8-5. PISTONS. Do not use wire brushes or the oil passages with solvent. After the castings
scrapers of any kind. Soft and moderately hard have dried, inspect them thoroughly for alkaline
carbon deposits may yield to solvent action, which residues, and remove any traces of scum.
should be tried first in preference to harsher
methods. If deposits remain, blast the heads with 8-8. BALL BEARINGS. The grease-sealed
soft grit or by the vapor grit method, first having starter worm shaft bearing should not be soaked in
installed tight-fitting skirt protectors. Ring grooves any solvent. Clean it by wiping with a cloth
may be cleaned by pulling through them lengths of moistened in solvent, and dry it with dehumidified
binder twine or very narrow strips of crocus cloth. compressed air or with a dry cloth. Soak the other
Do not use automotive ring groove scrapers, since starter drive ball bearing in solvent or spray with
the corner radii at the bottoms of the grooves must solvent, and dry with compressed air.
not be altered, nor any metal removed from the
sides. Discoloration and light scoring need not be CA UTION ... Do not spin unlubricated ball bear-
removed from piston skirts. The use of abrasive ings or allow an air blast to rotate them. Spinning
cloth on the skirts is not recommended, because does not give any indication of the bearing
the diameters and cam-ground contour must not be condition and will cause unnecessary wear. A worn
altered. Heavily scored or burned pistons should be bearing spinning at a high rate of speed may blow
discarded. up.
8-6. CRANKSHAFT. After degreasing, includ- Immediately after cleaning bare steel parts and
ing thorough cleaning of oil tubes and the front ball bearings, spray them with or dip them in clean
end recess, polish main journals and crankpins, engine oil or, for longer storage, in a corrosion-
preferably while the shaft is rotated in a lathe at preventive oil mixture. Wrap ball bearings in waxed
approximately 100 R.P.M. First use crocus cloth paper. Wrap or cover other clean parts to protect
moistened in kerosene, then dry crocus cloth. them from abrasive dust in the air.
A-8-2
SECTION IX
INSPECTION
9-1. DEFINITION OF TERMS. The following do not form continuous cover or protect under-
definitions apply to terms used to describe kinds of lying metal; thus oxidation of steel parts is
damage for which parts should be inspected. progressive and destructive.
a. ABRASIONS: Scratching of a surface, j. PITTING (OR SPALLING): Small, deep

either by motion while in contact with another cavities with sharp edges, may be caused in
part, by mechanical cleaning, or by resurfacing hardened steel surfaces by high impacts or in any
with an abrasive cloth or lapping compound. smooth steel part by oxidation.
b. BURNING: As applied to valve heads, this k. RUNOUT: Eccentricity or wobble of a

term indicates roughening or erosion due to high rotating part. Eccentricity of two bored holes or
temperature gases escaping past valve faces. In two shaft diameters. A hole or bushing out-
other instances, it indicates drawing of the temper of-square with a flat surface, usually measured with
of steel; to be in a soft (blue) condition, as a result a dial indicator. Limits stated indicated full
of overheating in absence of lubrication on moving deflection of indicator needle in one revolution of
surfaces, such as gear teeth, subject to high loading. part or indicator support.
c. BURR: A sharp projection of metal from 1. SCORING: Deep grooves in a surface

an edge, usually the result of drilling, boring, caused by abrasion when fine, hard particles are
countersinking, etc.; but may also be caused by forced between moving surfaces, as in bearing and
excessive wear of one or both surfaces adjacent to journal, or by galling when a moving part is not
the burred edge. supplied with lubricant.
d. CORROSION: Deterioration of a surface, 9-2. PROTECTION FROM CORROSION. Bare

usually caused by oxidation of metal. steel should be covered with oil or corrosion-
preventive oil mixture except during the actual
e. ELONGATION: Stretching or increase in inspection operations. Since inspection involves
length. handling of dry steel parts, it is advisable to use a
fingerprint remover solution after each handling;
f. FRETTING: Scuffing or deterioration of a particularly since perspiration and skin oils often
metal surface caused by vibration or chattering have a high acid content. Application of lubricating
against another part. A fretted steel surface may oil or corrosion-preventive mixture will not neces-
appear dull, scuffed or corroded. This depends on sarily stop corrosion from this cause.
length of time subject to the action, dissimilarity
and link of contacting metal and presence or
absence of moisture. 9-3. VISUAL INSPECTION: All parts should be
inspected visually under good light for surface
g. GALLING: Excessive friction between two damage such as nicks, dents, deep scratches, visible
metals resulting in particles of the softer. metal cracks, distortion, burned areas, pitting, pick-up of
being torn away and "welded" to the harder metal. foreign metal and removal of enamel coating.
Visual inspection should also determine the need
h. INDENTATION: Dents or depressions in a for further cleaning of obscure areas. Inspect all
surface caused by severe blows. studs for possible bending, looseness or partial
removal. Inspect all threaded parts for nicks and
i. OXIDATIONS: Chemical combining of a other damage to the screw threads. After visual
metal with atmospheric oxygen. Aluminum oxide inspection the engine parts should be in three
forms a tough, hard film and protects the surface groups: apparently serviceable parts, repairable
from further decomposition. However, iron oxides parts and parts to be discarded.
A-9- 1
9-4. MAGNETIC PARTICLE INSPECTION: mination of running clearance, refer to Table of
Inspection by the Magnaflux method must be Limits, Chapter B and to Limits and Lubrication
conducted on all ferrous parts listed in Table 7, Chart to locate the reference number of each fit
and in accordance with the methods and data and the acceptable limits assigned to it. Limits
before dimensional inspection. The Magnaglow under the column heading "New Parts" are
method is recommended whenever the necesary manufacturing limits. All running clearances in this
equipment is available. This method employs column apply to mating parts, both of which are
magnetic particles coated with a fluorescent new. The low limit applies in all instances. Such
organic material which may be illuminated with clearances are allowed to increase with wear to, but
"black light", as in Zyglo process, to amplify weak not beyond, the values in the column headed
indications. If a crankshaft is doubtful after "Serviceable limit". All press and shrink fits must
circular magnetization and inspection, demagnetize be maintained as specified in the "New Parts"
and remagnetize it longitudinally for further column when the inserted member is replaced.
inspection. Oversize parts are supplied, in some instances, to
permit conformity to this requirement.
NOTE ... Before magnetic particle inspection,
piston pins and valve rocker shafts must be c. ORIGINAL DIMENSIONS. Although com-
polished with crocus cloth. parative measurements of mating parts will deter-
mine the serviceability of the fit, it is not always
CA UTION... Before magnetic inspection of any easy to determine which part has worn the most.
part, plug small holes leading to obscure cavities In some instances (e.g., main journals in new
with tight-fitting wood plugs or with a hard grease bearing inserts), accurate measurements of fit are
which is soluble in lubricating oil to prevent not possible. While no limits of wear on critical
particles from lodging in places from which they dimensions have been assigned to specific parts in
would be difficult to remove and which places are most instances, it is helpful in estimating wear to
not subject to visual inspection. After magnetic know the original dimensions. Table 6 lists manu-
particle inspection, remove all such plugs and clean facturing limits on important dimensions of new
the part thoroughly in solvent; then dry with parts and should be consulted when the serviceability
compressed air. Check for complete of a specific part is in doubt.
demagnetization.
9-7. PROTECTIVE COATING. The manu-
9-5. FLUORESCENT PARTICLE IN- facturer protects all aluminum alloy castings, sheet
SPECTION: This process, commonly known under metal and tubing from corrosion by treating all
the trade name of "Zyglo", is recommended for surfaces of the parts with "Alodine 1200"
inspecting aluminum alloy parts for invisible (American Paint and Chemical Co., Ambler,
cracks. The standard operating techniques for the Penn.).
process are applicable.
9-8. APPLICATION OF "ALODINE 1200". In
9-6. DIMENSIONAL INSPECTION. the event the original finish of an aluminum
part has deteriorated or been removed, the part
a. INSTRUMENTS. Areas of running parts may be"Alodized" as described in "Alodine"
and bushings subject to wear should be inspected manufacturers Technical Service Data Sheet No.
for serviceable fit with mating parts by compara- AL-1200-D. Wrought or die cast (smooth surface)
tive linear measurements and alignment measure- parts, such as valve rocker covers and intake tubes,
ments. Use standard pattern precision measuring are tumble blasted prior to machining, if any, to
instruments such as micrometer calipers, tele- roughen surface before treatment. Such treatment
scoping gauges and dial indicators. The use of a should not be employed in overhaul work on parts
dial-type cylinder bore gauge is recommended in with machined surfaces. "Alodine" unlike enamel
preference to other tools not specifically designed or primer will not peel off to contaminate engine
for this purpose. lubricating oil; therefore, corrosion protection can
be afforded to all interior aluminum surfaces and
b. DIMENSIONAL LIMITS. After compara- parts. If an enamel coating is required for a part
tive measurements of mating parts and deter- previously treated with "Alodine", application of a
A-9-2
primer before painting is not necessary. Magnesium parts will be pickled and primed before
"Alodizing" will be performed after all machining painting, then baked with infrared equipment for
and/or repair operations have been completed. The 15 minutes at 2750 - 285 F. following each coat of
surface color of an "Alodized" part may vary from enamel.
light gold to dark brown. When a part is treated
with "Alodine 1200" the thickness of the film, or NOTE . If a part that was originally "Alodized"
..
build up, on the mating or bearing surfaces is so is to be refinished with enamel, it will not be
slight that the effect on dimensional tolerances is necessary to apply zinc chromate primer except to
negligible. the surface areas completely stripped of
"Alodine".
9-9. REPAIR OF "ALODIZED" SURFACES.
If "Alodized" parts have been remachined, rubbed CA UTION ... Before application of primer and
with abrasives or scratched in handling so as to enamel to a part, carefully mask all connection
expose areas of bare aluminum, the surface may be joints and mating surfaces. No primer or enamel is
repaired by local application of "Alodine" solution permissible on interior surfaces of any parts con-
in the following steps: tacted by engine lubricatingoil after assembly.
a. Clean bare area thoroughly with carbon

tetrachloride. Do not, under any circumstances, 9-11. SPECIFIC INSPECTIONS.
use an oil base solvent or strong alkaline cleaner.
9-12. CRANKCASE.
b. Mix a small quantity of hot water
(180 F.) with 1-1/2 to 2 ounces of "Alodine a. All GTSIO-520 models incorporate two (2)
1200" powder to form a paste, then gradually P/N 639418-3 and four (4) P/N 639418-4 studs
dilute with hot water until a solution of one gallon installed as shown in Figure A-4-2 1.
is attained. This solution is to be adjusted by
addition of nitric acid to a PH value of 1.5 to 1.7. The following categories will have to be considered
if and when it becomes necessary to replace studs
c. Apply solution with a rubber set paint in crankcases in the field.
brush in such a manner that solution flows over
bare area. Allow solution to remain on the part 1. Replacing a stud in a crankcase which
from one to five minutes or until color of the new originally had an interference fit and it has either
film is approximately the same as original. backed out during disassembly, suffered thread
damage or for other permissible reasons.
d. Flush part with clear water and dry with
warm air current. Do not air blast or rub with cloth 2. Replacing a stud in a crankcase which
to dry new film area. If color is too light, repeat originally was fitted with Loctite and has backed
step "c" until desired color is obtained. out during disassembly.
NOTE. ... If "Alodine" does not adhere to metal, Category (1) requires that the hole be clean and
a more severe cleaning method must be used. A substantially free of the original National Oil Seal
solution of 12 to 16 ounces of Oakite No. 61, or compound. If the stud is in good condition after
equal, per one gallon of water is preferred. Apply cleaning, it should be coated with Stud-loc and
and remove the solution with caution because an reinstalled at the proper driven height and allowed
alkaline cleaner of this type will remove any to set before installing the cylinder (approximately
"Alodine" film previously applied. Remove clean- 2 hours). If the stud is not reusable, a stud of
ing solution thoroughly with plenty of hot water identical size should be selected - e.g. If stud is
and vigorous brushing. standard size, replace with standard of same part
number. If stud is oversize, replace with same
9-10. ENAMEL COATINGS. Ferrous parts when oversize. The idea here is to achieve a "class 3"
painted with gold enamel will be baked with type of fit as opposed to an interference fit. A new
infrared equipment for 15 minutes at 275 - "class 3" stud is not suitable for this application
2850 F. following application of each coat. since it would be excessively loose.
A-9-3
Category (2) requires that the old stud be recoated or loose in prop drive gear. Use the next largest
with Stud-loc and reinstalled and allowed to set up oversize replacement sleeve.
(2 hours). It is not necessary to clean out the old
Loctite. The hole and stud should be free of oil 9-14. CRANKSHAFT AND COUNTERWEIGHT
and dirt. Oversize studs are not planned at the BUSHINGS.
present time so if the old stud is not suitable for
reuse, a new "class 3 " stud should be used. a. Excessive localized brinelling of the crank-
shaft damper pin bushings can affect propeller
b. All of the cylinder base nuts should be blade tip stresses. It is, therefore, recommended
replaced if any nut was loose at disassembly, if any that at each normal major overhaul the pin
of the attaching studs are bent, even slightly, or if bushings be inspected and replaced as required.
there is definite evidence that a cylinder was loose This applies to both the dampener bushings and
at any time. Any of these conditions could have the crankshaft blade bushings.
been caused by reversal of stress which fatigued the
studs and thru bolts installed on the cylinder pad. b. Inspect in the following manner: Measure
Test for bent studs with a toolmaker's square. the inside diameter of the bushing across points A,
When inspecting for casting cracks pay particular B and C. Take the average of A and B and deduct
attention to areas on and adjacent to the cylinder this from C. If the difference exceeds 0.001 inch
mount pads, tappet guides, bottom flange and then the bushing should be replaced.
bearing bosses. Look for nicks on machined sur-
faces and scoring in shaft bearings and the shaft- 1. The C measurement should be the point of
gear bushing. The castings must be clamped maximum diameter which is generally a point
together at all attaching points before dimensional perpendicular to the lengthwise centerline of the
inspection of camshaft bearings. crankshaft.
NOTE . .. If camshaft bearings are excessively 2. Measurements A and B should be taken at

worn, the crankcase may be line bored for a 0.020 points approximately 60' either side of point C.
inch oversize camshaft.
3. After removing the bushings from the
9-13. CRANKSHAFT & PROPELLER DRIVE crankshaft blades, measure the inside diameters of
SHAFT. In addition to magnetic particle, visual the holes. Select a replacement bushing which will
and dimensional inspection, the shaft should be give an interference fit of 0.001 inch to 0.00 3 inch
mounted on matched vee blocks on a surface plate for the crankshaft blade holes. Replacement bush-
(supporting the front and rear main journals) and ings for the counterweight must be with standard
rotated under a dial indicator placed to bear on the size bushings.
center main journal in order to detect excessive
bending. This is of particular importance if the c. Replacement bushings are available in
aircraft has been involved in an accident resulting standard, 0.0015, 0.003 and 0.005 inch oversizes
in a broken or bent propeller (Refer to Table of on the outside diameter. Only the crankshaft blade
Limits for limits of "run-out" at the center bushings may be replaced with oversize bushings.
journal.) The propeller driveshaft is also mounted
on matched vee blocks in the same manner as the d. A special tool for removing and replacing
crankshaft. Supporting the driveshaft on the two these bushings has been developed by Borroughs
bearing surfaces, mount the dial indicator to bear Tool and Equipment Corporation, 2429 North
directly on top of the bearing surface. After the Burdick Street, Kalamazoo, Michigan. We re-
bearings are checked for run-out, leave the drive- commend that this tool only be used for these
shaft in the vee blocks and check the oil seal operations. Removing and replacing bushings with
bearing surface, gear, propeller flange and all points makeshift tools and methods can result in irrepar-
of importance in accordance with the Table of able damage to the crankshaft and/or dampeners.
Limits. If it is necessary to replace the oil transfer
tube, the hole must be reamed to obtain an e. The number of this tool is Borroughs' Part
interference fit of 0.0005T to 0.0025T. Criteria for No. 4965. It should be ordered directly from
replacement will be transfer tube hole out of limits Borroughs Tool and Equipment Corporation.
A-9-4 June 1980

f. Counterweight pins are identified by dash cleaning, including the oil relief holes in the third
numbers stamped in one end. Because the damper ring groove. it is not necessary to remove light
order is controlled by the pin diameter, it is scores or discoloration from the exterior surfaces,
imperative that the pin with the correct stamp be and it is not advisable to use abrasive (including
properly identified and used. crocus cloth) on the skirt, since the cam-ground
contour should not be altered. If the piston is
9-15. CAMSHAFT. Inspect the lobes for scoring, dimensionally serviceable in other respects and
corrosion and overheating, and the lobes for pitting apparently sound, measure side clearance of new
at the toes and evidence of overheating or unusual rings (after measuring their gaps while squared in
wear. cylinder barrel). Install the rings in their respective
grooves in accordance with the piston in use (five
9-16. CONNECTING RODS. Use a telescoping ring, four ring or four ring with steel insert top
gauge and an outside micrometer caliper to groove). Do not intermix piston types. Install with
measure all worn bushings and locally replaced part numbers toward the piston head and check
bushings. If a bushing was replaced locally, it is side clearance as ilsrtdin Fig. A-4-22. The gaps
also necessary to check its alignment with the big of rings should be measured in the barrel first so
end bearing seat. The simplest method in making that those selected may be left in the piston
alignment measurements requires a push fit arbor, grooves, if the grooves are not excessively worn or
preferably at least eight inches long, for the distorted. When installing rings, take care not to
bushing bore and another for the bearing Seat, a allow their sharp ends to scratch the piston lands.
surface plate, two matched vee blocks and two If the cylinder barrel has not been ground oversize
blocks of ground flat steel stock of equal height. and fits the piston within the allowable clearance
To measure twist, insert the arbors into the rod limit, it is permissible to install either standard or
bores; then lay the big end arbor in the vee blocks 0.005 inch oversize rings, whichever have the
on the surface plate, and place the ground steel seiidgap. The gap is measured with the ring
blocks under the end of the bushing arbor at a pushed up by the piston head to a point in line
measured distance apart. A feeler gauge may be with the base flange.
used to detect any clearance at either end under
the bushing arbor. This, divided by the separation 9-19. CYLINDERS. Measure the barrel bore near
of the blocks in inches, will give the twist per inch the top of the ring travel limit, at the 5-3/4 inch
of length. (Refer to Fig. A-4-29). To measure station from the open end in the thrust direction
bushing and bearing convergence, mount a dial and at right angles to that in order to detect
indicator on a surface gauge, and swing the rod out-of-roundness and wear-in taper. There should
around the big end arbor to the vertical position be little or no wear at the open end. Look for bent
against a firm stop. Pass the indicator over the barrel fins and broken head fins. Barrel fins can be
bushing arbor at points an exact number of inches straightened if not badly bent or cracked. A
apart. The difference in readings at the two ends, reduction of not over 10% in area of head due to
divided by the distance between points of measure- breakage is allowable. Look for cracked head fins,
ments, again give the misalignment per inch, as and rectify any radial crack by drilling a vee notch
specified in Figure A-4-29. to remove it. If a radial crack extends to the root
of a fin it may have penetrated the wall; hence, the
9-17. GEARS. Inspect gear teeth for signs of cylinder should be rejected. If the cylinder base
overheating and excessive wear. Normal wear pro- nuts were loose at disassembly, or if the base studs
duces a fine polish on the tooth thrust faces. were loose or bent, test the machined side of the
Alteration of the tooth profiles, score marks and cylinder flange for bending, which is cause for
pitting are sufficient cause for rejection. rejection. Measure valve guides for wear and look
for scoring in their bores. Valve seats should be
9-18. PISTONS AND RINGS. Inspect the skirt inspected after refacing to make sure that their
for long, deep scores which indicate overheating outside diameters are still less than the valve head
and are sufficient cause for rejection. If a tele- diameters. Exhaust valves should be checked for
scoping gauge is used in measuring the pin bore, do warpage before refacing. All valves should be
not allow the spring pin to expand rapidly so as to measured in length if the stem tips were ground.
strike the wall hard. Inspect visually for thorough Inspect the spark plug hole and intake flange screw
June 1980 A-9-5

hole helical coil inserts for looseness, deformation index finger and release it quickly. Compression of
and position. The outer ends should lie in the first air in cylinder should make plunger kick back
full thread of the tapped hole in which they are instantly. if plunger does not return fully, either it
installed. The spark plug hole helical coil has teeth is excessively worn or check valve is leaking. To
at the outer end which are forced into the head check for leaking valve, repeat compression test
metal and should not be visible. If there was an while plugging end of oil inlet tube with other
evdence of overheating of cylinder or piston, hand. If plunger still does not kick back promptly,
check as well as possible for turning of the head in it and the cylinder are excessively worn. If it does
relation to the barrel flange. Do not be misled by not kick back on the second test, either check
findings of heavy discoloration or the appearance valve seat is worn and leaking or it is dirty. Clean
of a seepage at the cylinder head and barrel cylinder again and repeat first test (tube open). If
attachment area. Security between the cylinder plunger still does not kick back, valve is defective.
head and barrel is dependent on the metal to metal Any unit failing to pass this rough check must be
contact of the cylinder barrel top threads and discarded. Discard both plunger and cylinder, since
threads within the head shoulder. Therefore, both these parts are selectively fitted and are not
new and rebarreled cylinders may exhibit dark interchangable.
stains in this area sometime after installation. This
is not cause for removal of the cylinder. It is
generally due to the emission of thread lubricant 9-21. INTAKE TUBES. Inspect intake tubes for
used for assembly of the head to barrel. Also, it distortion, cracks and out-of-roundness. All other
could be due to a slight gas leakage which usually types of damage will require replacement of the
stops of its own accord when the gap fills with part.
carbon while in service. Neither condition is
hazardous or detrimental to engine performance or 9-22. LUBRICATION SYSTEM. Visually inspect
operation. Only confirmed leakage exceeding the all parts of the system in accordance with
above conditions should be reason for rejection of instructions.
cylinders in service. Due to the design of the
cylinders, a persistant leak of actual oil (not sealing 9-23. FUEL INJECTION SYSTEM. Inspection of
compound) may indicate that the required pre-load the components and parts of this system is limited
at the head to barrel junction has been relieved. strictly to visual for evidences of damage or
This condition should require further investigation deterioration. Further disassembly of the fuel
for possible cylinder replacement. injection system is not recommended unless proper
flow test equipment is available. For complete
9-20. HYDRAULIC VALVE LIFTERS. During overhaul instructions, see Fuel Injection Systems
examination of each part, look for sludge and Overhaul Manual and Parts Catalog, Form
carbon residues. Also check for obstructed oil X-30091.
holes. Inspect face of cam follower on body for
any type of damage and look for deep scoring and 9-24. IGNITION SYSTEM. Teledyne Continental.
corrosion on exterior of tubular portion. Discard Motors recommends replacement of the complete
any lifter body which exhibits any of these faults- ignition harness at every engine overhaul. For more
To test roughly for excessive diametrical clearance detailed information pertaining to the ignition
between hydraulic unit plunger and cylinder and to harness, magnetos and/or starting vibrator, refer to
check valve wear in cylinder, start dry plunger into the Bendix Corporation, Electrical Components
dry cylinder. While holding cylinder between Division, Maintenance and Operation Instructions,
thumb and middle finger, depress plunger with Form L-526-2.
A-9-6 June 1980

10-1. CASTINGS. Remove the raised edges of power-driven installing tools, tang break-off tools,
nicks in machined surfaces with a hard Arkansas special taps and plug gauges. A tap drill bulletin is
stone. Unobstructed flat surfaces, such as valve also available from the manufacturer. Helical coil
rocker cover flanges, may be returned to true inserts arc available in both National Coarse and
flatness by lapping if a true lap plate is available. National Fine series in lengths equal to 1, 1-1/2
Use fine grade lapping compound and move the and 2 times nominal diameter and in pipe thread
casting in a figure 8 stroke without rocking it. sizes. They are made of either carbon steel,
phosper bronze or stainless steel, as specified by
10-2. STUD REPLACEMENT. Remove damaged part number. They are supplied with or without a
whole studs with a standard pattern stud remover notch above the driving tang. The notch is pro-
or a small pipe wrench, turning slowly to avoid vided to facilitate breaking off the tang in open
heating the casting. Remove broken studs which holes.
cannot be gripped by drilling on center to the
correct diameter for unscrewing them with a a. Helical coil inserts are helical coils of wire
splined stud extractor. (Splined extractors and with a diamond-shaped cross-section forming both
drills are usually sold in sets). Examine the coarse a male and a female thread. The diameter of the
thread end of the damaged stud before discarding insert, when compressed into a special tapped hole
it to determine its size. Standard studs have no at the widest part of the wire (between male and
marking. For oversize stud identification refer to female threads), is equal to the nominal screw size.
Table 8. Clean the casting tapped hole with solvent The special finishing taps size the casting hole so
and blow dry with compressed air; then that the pitch diameter of the female thread of the
examine the thread. If it is not torn install the next installed insert conforms to class 3 fit with
larger oversize stud. If the old stud was of the standard bolt threads or class 4 (tight) fit with
maximum oversize, or if the thread is damaged, the standard-size studs. The difference in fit is due to a
hole may be tapped and a helical coil insert difference in pitch diameters of bolts and studs, so
installed for a standard-size stud. Coat the new that only one set of helical coil special taps is
stud's coarse thread with Alcoa thread lube if the required for installation of these inserts in both
hole is blind or with National Oil Seal compound if bolt holes and stud holes. Tap drilling depths and
the hole goes through to a cavity subject to oil tapping depth for helical coil inserts to be installed
spray. It is advisable to drive the new stud with a in blind holes should conform to the
tee handle stud driver. Turn it in slowly, and recommendations relative to inserts of length equal
compare the estimated torque values listed in the to 2 times nominal diameter, as tabulated in the
Table of Limits. Drive the stud in until it projects a manufacturer's Bulletin No. 650-R. Helical coil tap
distance equal to the appropriate "Setting Height" drills and special taps must be run in perpendicular
listed in Table 9. to the machined surface of the casting. Drilling
should be done in a drill press after the casting is
10-3. HELICAL COIL INSERT INSTALL- firmly supported and clamped and alignment
ATION. Bronze helical coil inserts are installed at checked. The tap will tend to follow the drilled
the factory in four tapped holes of each crankcase hole. For drilling and tapping aluminum alloy
bottom flange, in three holes in the left crankcase castings use a lubricant made by mixing one part
parting flange, two in the right crankcase parting lard oil with two parts kerosene to prevent
flange and in four bolt holes at each cylinder head overheating of the metal and tearing of the thread.
intake port flange. Stainless steel helical coil inserts
of special design are installed in all spark plug b. To remove a damaged helical coil insert use
holes. Any of these inserts may be replaced, if the proper size of extractor tool for the nominal
damaged, with the aid of tools available through thread size. Tap it into the insert so that the sharp
Authorized Distributors of the Heli-Coil edges get a good "bite"; then turn the tool to the
Corporation, Danbury, Connecticut. The manu- left, and back out the helical coil until it is free. To
facturer's Bulletin No. 650-R lists both manual and install a new insert in a properly tapped hole (after
A- 10-1
blowing out all liquid and chips), slide it over the expanding tool threaded end with Alcoa thread
slotted end of the driving mandrel of the proper lube or a mixture of white lead and oil. Screw it
size of installing tool and engage the driving tang into the new insert until its final thread forces the
(bend end) of the helical coil in the mandrel slot; teeth firmly into the cylinder head metal. (See
then wind the insert slowly into the tapped hole. Fig. A4-26)
(See Fig.A4-24) The outer end of the insert should
lie just within the first full thread of the hole.
Break off the driving rang of a notched helical coil c. VALVES GUIDES . If the valve guides are
by bending back and forth across the hole with to be replaced, the new guides must be installed so
long-nose pliers or with a special tang break-off that the valve stem hole is accurately square and
tool. aligned with the valve seat. When pressing or
driving out a worn guide, the cylinder assembly
10-4. CYLINDERS. should be firmly supported in the inverted position
with space below to allow the guide to drop out. The
a. FIN REPAIRS. Straighten slightly-bent driving tool should pilot inside the guide and drive
barrel fins with long-nose pliers. File to smooth the on its inner end. All carbon must be removed from
edges of broken head fins, if it becomes necessary the guide's inner end. If the cylinder head hole is not
to cut out a vee notch to stop a head fin crack, a scored or enlarged, a standard size guide may be
slotted drill bushing to fit over the fin and a 3/16 installed as a replacement. If the head hole is rough,
inch twist drill may be used to cut the notch. Its it must be broached or reamed to a diameter smaller
apex must be rounded and the edges should also be than the next larger oversize guide by the amount of
rounded. If such repairs and previous breakage interference ("T") specified in Table of Limits.
have removed as much as 10% of the total head fin Valve guides are supplied in oversizes of 0.005,
area, the cylinder assembly has reached the limit of 0.010, 0.015, 0.020 and 0.030 inch. The cylinder
such repair. assembly must be supported firmly while the new
guide is driven or pressed into place with a driver
b. SPARK PLUG HOLE HELICAL COIL which fits over its end and bears on the filleted
INSERTS. Before attempting to back out a flange. Driving on the guide end will spread it.
damaged insert, use a sharp pointed tool to pry the Before installing a new guide, dip the end to be
teeth at outer end away from the cylinder head inserted in engine lubricating oil. The flat side of the
metal. Tap a helical coil extracting tool into the guide flange must go against the cylinder head.
insert until it has a good bite. (See Fig. A4-27) Watch for peeling of bronze and correct
Place a new helical coil in the cut-our side of the misalignment which causes it. It is recommended
installing tool sleeve with its driving tang toward that the valve guide be chilled in dry ice and the
the threaded end. Engage the tang with the slotted cylinder assembly heated to 500-550 F. before
end of the driving mandrel and wind the insert into installation. Current production and replacement
the sleeve thread, thus compressing it. Hold the guides are prefinished and no reaming is required.
sleeve so that the helical coil can be seen through During the installation process some of the
the slot in the threaded end, and turn the mandrel aluminum bronze intake guides used early in the
crank until the insert starts into the cylinder head program were reduced in diameter beyond the
hole. If the sleeve is then not in contact with the required limits. A change to the guide was made to
head surface, grip sleeve and mandrel and turn eliminate that occurrence but some of those guides
until the sleeve touches lightly. (See Fig. A4-25) may still be on dealer shelves. It is, of course,
Wind the helical coil into the cylinder head until its permissible to ream them to size.
toothed end lies just within the first full thread.
The teeth should be in position to enter the
depressions made by the original insert. If driven
too far the insert will emerge in the combustion
chamber and will have to be wound on through. d. VALVE AND VALVE SEAT REFACING..
When the helical coil is in correct position, use Numerous grinding machines are marketed for
long-nose pliers to bend the driving tang back and these purposes. Operating instructions are furnish-
forth across the hole until it breaks off at the ed with each machine and need not be repeated
notch. Coat a Heli-Coil Corporation No. 520-2 here, except that certain precautions must be
A-10-2 June 1980

observed. These are: ring which will allow the old bushing to pass
through. Press the new bushing in flush with the
1. Use only soft stones on these hard alloy rocker hub after dipping it in clean lubricating oil.
metals to avoid overheating and surface roughness. Ream the new bushing to the specified diameter. It
is advisable to plug the oil holes with beeswax
2. Keep stones trued to angles specified in before reaming. Be sure to remove the wax after
Table of Limits. reaming. Lightly break the sharp edge at each end.
3. Use the coolant system at all times when g. PISTON PIN BUSHING REPLACEMENT.
grinding. The connecting rod does not need to be heated for
this operation. Press out the old bushing in an
4. Replace chucks and pilots whenever results arbor press, using a drift only slightly smaller than
indicate excessive wear. the bushing O.D. Make sure that the rod bore is
smooth. Dip the new bushing in engine lubricating
5. Do not grind seats more than a few seconds oil before placing it in position, and locate the split
without lifting the stone. Keep the grinding head as illustrated in fig.A-4-29.(The position number is
of the valve-facing machine in constant motion stamped on the rod and cap bosses on the far side.)
back and forth across the valve face without Ream or bore the new bushing to the specified
running off the edges. diameter and check alignment as described in
paragraph 9-16. The center-to-center distance given
6. Break sharp edges at the outside of the in fig.A-4-29 will be held automatically if the bore is
valve faces with a hard Arkansas stone or a fine centered in the new bushing.
India stone. The face must never run into the
rounded edge of the head. Discard valves which 10-5. CRANKSHAFT ASSEMBLY.
must be ground to this condition to clean up.
a. Lightly scored crankpins and journals
7. After the valve seat has been ground, the may be smoothed with a hard Arkansas stone. Do
concentricity, angle and angular relationship of the not use a coarser abrasive. Do not attempt to
seat to the valve guide may be determined by the remove deep scoring or indications of overheating
use of a blueing gauge. Coat the cone surface with which render the crankshaft unserviceable. Remove
a very thin film of Prussian blue, oil base pigment, the upstanding edges of small nicks on softer
and insert the gauge end into the valve guide until surfaces with a hard Arkansas stone. Polish crank-
the cone surface can be rotated in contact with the pins and main journals with long strips of crocus
valve seat. The tool should have a flat, marking the cloth, preferably while the shaft is rotated about
limiting diameter of the seat. If regrinding has 100 RPM in a lathe.
excessively enlarged the seat, it may be reduced
once only with a stone which makes an angle of 68 b. Due to the fact that No. 631871 gears are
- 78 with the stem axis. shrunk fit to the crankshaft, it may be necessary to
dip the gear in oil heated to 300 F. before removal
e. CYLINDER WALLS. Glazed cylinder walls can be accomplished. These operations should
will not seat new chromefaced piston rings quickly. precede Magnflux inspection.
therefore, they should be roughened by honing
with No. 180-220 grit stones in a spring-loaded c. Hardened steel bushings in the crankshaft
honing head. The fine scratches produced should blades and in the counter-weights may be removed
be crossed and those running in each direction and replaced if excessively worn. (See Fig. A-4-30)
should form an angle of 35 - 55 with the end of It may be necessary to chill the old bushings to
the barrel. free them. New bushings must be chilled, before
installation, with a suitable drift; also, the holes
f. VALVE ROCKERS. Worn bushings may be must be smooth. No finishing operation is required
driven out with a suitable drift. If properly for the new bushings, since they are made to final
designed, the same tool may be used to drive in dimensions. They must be driven in to the same
new bushings. The rocker must be supported on a positions as the original parts.
A-10-3
NOTE ... Crankpins and crankshaft main journals CA UTION... Before boring a new bushing, plug
may be reground to the allowable 0.010 inch its oil holes with beeswax to exclude chips from
undersize. the adapter oil groove. Be sure to remove this wax
completely after the operation.
CA UTION ... Crankshaft counterweights are
matched in pairs with a maximum weight variation In most instances the old seal may be
of 2 grams. The complete crankshaft and counter- driven out with a 1/8 inch diameter pin punch
weights assembly is dynamically balanced. As a inserted through the four oblique oil holes in
result, if either counterweight is damaged, it will be the bushing boss alternately. If the seal is too
necessary to discard both on that cheek and to tight for that method, drill and tap two opposite
procure a matched pair for replacement. machine screw holes in the exposed flange of the
seal case to match two screw clearance holes in a
d. Table 11 is a listing of crankshafts and pressure plate which can be laid on the adapter
crankcases enumerating the correct positioning of studs. Run nuts on two long machine screws; then
the crankshafts, counterweights, pins, connecting insert the screws through the pressure plate holes,
rods and bearings. and screw them into the holes tapped in the seal.
To avoid unnecessary stoning of the seal bore,
10-6. IDLER GEAR. Replacement of excessively tighten the nuts against the plate to pull the seal
worn idler gear bushings is not recommended. A squarely from its recess. Smooth any scores in the
special fixture is required to hold the gear during vacant adapter counterbore. Coat the outside
the boring operation, in order to maintain the diameter of a new oil seal with Lubriplate, and
necessary concentricity of the bushing hole and the press it into the adapter with an arbor press and a
gear pitch circle. flat end block of 1-3/8 dia. x 1-1/4 inch length.
10-7. MAGNETO AND ACCESSORY DRIVE 10-8. TACHOMETER DRIVE HOUSING.

ADAPTER ASSEMBLY. If the magneto and Remove the oil seal with a suitable oil seal puller.
accessory drive adapter bushing must be replaced, If the housing counterbore is scored, smooth it
it may be driven out with a 0.92 inch diameter with crocus cloth. Spread a film of Lubriplate
drift while the adapter boss is supported on a 1.25 grease on the outside diameter of a new seal. Then
inch I. D. ring. However, this procedure involves press the seal squarely into the housing with its lip
some chance of scoring the adapter bore. A safer pointed outward, facing the oil source.
procedure is to turn down the bushing flange to
the body diameter (0.942 inch) and to bore out 10-9. STARTER DRIVE ADAPTER. The clutch
the bushing to a thin shell which can be collapsed. spring sleeve is shrunk and doweled in the housing.
if this method is used, take care not to cut into the If it is necessary to remove the needle bearing in
end of the adapter boss or to mark the adapter the adapter, a removing driver may be made similar
bore. Press in a new bushing with an arbor press to the driver illustrated in fig. A4-3 1.
after dipping it in clean engine lubricating oil. The
rear pad of the adapter, rather than the studs, 10-10. OIL PUMP ASSEMBLY. Except for ston-
should be supported on a parallel block and a flat ing down nicks on parting flanges and replacement
block should be used to exert pressure, unless the of studs and worn parts, no repairs to the pump
arbor has a perfect end. Ream or bore the bushing assembly are possible. The pump driven gear shaft
to the specified diameter then face the flange until is pressed into the pump housing and cannot be
it projects forward 1.454 inch - 1.458 inch from replaced successfully. The pump gear chamber
the adapter parting surface. Chamfer the bore at must not be enlarged. If it is scored, the housing
the flange end 1/16 inch deep on a 45 angle, and must be discarded. Heavy scoring on the gear
slightly break sharp edges at both ends. The contact area of the tachometer drive and pump
bushing hole must be concentric with the adapter cover renders this part unserviceable, unless the
pilot shoulder within 0.002 inch and square with parting surface can be lapped smooth and perfectly
the parting surface within 0.002 inch per inch of flat.
length. Its flange thrust face must be parallel to the
parting surface within 0.002 inch (full indicator 10-1 1. IGNITION CABLES. Normally, all ignition
reading). cable assemblies or harness assemblies should be
A-10-4
replaced at each overhaul. If the high tension 10-12. 100% REPLACEMENT PARTS AT
outlet plates are in good condition, new cable NORMAL MAJOR OVERHAUL. It is
assemblies and grommets may be installed on recommended that the following parts be replaced
them. The cable ends are secured to the grommet 100 percent during overhaul regardless of condition:
of each harness with a brass washer and a cable
piercing screw, installed as in the original assembly. Crankshaft Gear &
If only the cable assemblies and grommets are to Valve Springs
be replaced, leave the cable clamping bracket on Hydraulic Hoses
the original cables of each harness; detach all cables Rubber Hoses
from the high tension outlet plate by removing the Oil Seals
cable piercing screws from their ends in the plate Gaskets & Packings
grommet. When the coupling nuts are unscrewed, Circlips, Lock Plates &
the cables may be withdrawn and the grommet Retaining Rings
removed from the plate. Observe the "I" mark on Piston Rings
the exterior side of each outlet plate adjacent to Valve Keepers
the No.1 cable outlet hole. Refer to fig.A4-3 2 and Bearings - Main & Rod
observe th at the numerals appearing at magneto Rubber Drive Bushings
ends of the high tension cables correspond to the Exhaust Valves
consecutive order of outlet plate cable holes; while R otocaps
the relative positions of spark plug elbows indicate Piston Pins
the installed positions of the cables. Install cable Needle Bearings
assemblies (4 thru 15,Fig.A4-32)in the indicated Woodruff Keys
positions in the two outlet plate and grommet Rocker Arm & Conn Rod
assemblies (1 and 3). Start with the proper No. 1 Bushings
cable assembly in the marked hole of each plate,
and proceed in consecutive order around the
plates. As each cable is inserted through the outlet
plate (1), it must pass through a ferrule (2). The
cable will then pass through the grommet (3) and
into the eyelet (23). When all cables have been SPECIAL NOTES: . .. If for any reason lifters are
attached to the two outlet plates, locate a clamping removed for inspection before the overhaul period
bracket (24) on the proper cables of each harness has been reached, they must be placed back in the
in the same position as on the original cables. same location from which they were removed.
Parts indexed 25 through 36,45 and 46 will be
installed at final assembly.This group should be Replace all part number 631402 lifters with part
collected and ready for installation.Parts indexed number 628488 on intake side and 641709 on the
37 through 44 are installed on the aircraft ignition exhaust side at the next major overhaul, top
switch wires. overhaul or earlier at owner's discretion.
June 1980 A-10-5/A-10-6

SECTION XI
ASSEMBLY OF SUBASSEMBLIES
11-1. NEW PARTS. Parts which require pro- 11-4. LUBRICATION. Immediately after final
tection from atmospheric dust and moisture are cleaning and before installation, coat all bare steel
wrapped or boxed individually or in sets. These surfaces and journals with clean engine lubricating
parts should not be installed at this time. This is oil, except where special lubricants are mentioned
especially true of precision bearing inserts and in the text. In some instances where gears and
antifriction bearings. Check other new parts on other running parts are accessible after assembly in
receipt for damage occurred in transit. Refer to the a housing, additional oil should be applied to
Section IV of the parts catalog, Form X-30046A, assure full coverage. Before installing tapered pipe
for part numbers of the complete gasket set, main plugs or straight thread plugs, and to prevent
bearing set, piston ring set and tubes of lightweight seizure and leakage of oil, coat the first three male
Tite-Seal gasket paste. All of which should be on threads with Parker Fuelube No. 44 sealing lubri-
hand when work is started. Use only new split cant, (Parker Appliance, Co., 17325 Euclid Ave.,
lock-washers, tab washers, cotter pins and anneal- Cleveland, Ohio). This compound is fuel and oil
ed, corrosion-resistant lock-wire. resistant and has good lubricating properties. It
may be used also to coat rubber-asbestos gaskets
before installation to assure a perfect seal and to
11-2. TIGHTENING TORQUES. The accuracy counteract the permanent "set" caused by com-
of any torque-indicating wrench depends on a pression. Lubriplate lubricants mentioned in the
smooth application of force. Do not back up a text are distributed by dealers in all principal cities.
nut or bolt and leave it in that condition. If a part See Table of Lubricants, Table 12.
is accidentally tightened too much,loosen it and
retighten to a value within the specified limits. If a 11-5. OIL PUMP ASSEMBLY (See Figure A-4-16)
nut slot must be aligned with a cotter pin hole,
tighten the nut to the minimum specified torque, a. Install new studs (6) if removed for
and check for alignment. If necessary, tighten replacement. Install plug (7).
further until alignment is achieved or the
maximum allowable torque reached, whichever b. Install by-pass valve assembly (18 thru 21)
occurs first. If the alignment cannot be obtained using new gasket (20). Install adjusting screw (1 3)
within allowable torque limits substitute another in housing (15) until 13/16 inch of screw shows
serviceable part and tighten it in the same manner above housing. Secure with copper washer (16) and
as before. If a cotter pin hole in a stud lies beyond nut (17). Install new gasket (14), washer (12),
the nut slots when the nut has been tightened spring (1 1) and seat (1 0) onto adjusting screw and
correctly, then either the stud has been improperly assemble into housing (5).
installed or has backed out, or the attached part
has been reduced in thickness, or either the nut or c. Slide new gasket (43)over oil filter plug (44)
its washer is not the correct part for that location. and insert plug into its chamber in pump housing.
The situation must be corrected by whatever Tighten plug by hand only.
replacement is indicated by inspection.
d. Install pump driver and driven gears (22,
NOTE .. . Tightening torque limits specified in 8) in pump housing. Spread a thin but continuous
Chapter B are based on oiled threads but are not film of No. 3 Aviation Permatex on scavenge pump
applicable when special thread lubricant is applied. housing flange. Lay lengths of No. 50 silk thread
on flange. Thread should be on inside of stud holes
11-3. FINAL CLEANING. Immediately before but never on the edge. Install turbo scavenge pump
assembling a group of parts they should be washed housing (26) over drive gear shaft and onto studs
in, or sprayed with, a clean solvent and dried with (6) ; then install Woodruff key (25) into driver
dry compressed air. gearshaft. Slide turbo scavenge pump driven gear
A-11-1
(30) onto shaft (22); then slide driver gear (29) e. Compress and install retaining ring (27) in
over shaft and key. cover (23). Press in ball bearing (32) and new oil
seal (26) with seal lip toward retaining ring.
NOTE ... Pump gears must turn freely at final
engine assembly conditions. f. Install gasket (28) and cover assembly (23,
26, 27, 32) on adapter and secure with attaching
e. Slide scavenge pump cover (3 5), with new parts (20, 21, 22). Install "O" ring (25), spacer
oil seal (36) installed, over the two studs (6) and (24) and Woodruff key (19); then place torsional
attach to oil pump housing with two sets of damper (18) over shaft and key. Attach with
attaching parts (3 2, 3 3, 34). washer (17) and nut (16). Torque nut to 180-220
foot pounds. Install spring (15), key (14) and
f. Apply a thin coat of Tite-Seal gasket retaining ring (1 3).
compound to each side of tachometer cover gasket
(38). Install gasket and tachometer drive pad cover 11-7. CYLINDERS. (See Fig. A4-17). Assembly
(39) and secure with attaching parts (40, 4 1,42). parts to make up each of the six cylinder and valve
assemblies in the manner outlined below. Each
NOTE .. . The pump cover (35) must be removed cylinder should have a different position number
during final assembly. The oil filter plug (44) can (1 through 6) stamped on the edge of its base
best be tightened after oil pump is installed on the flange, which will be on top when installed. These
engine. numbers should be found on original cylinders, but
they must be stamped on new parts. After
11-6. STARTER ADAPTER ASSEMBLY (See assembly, cylinders should be laid on the bench in
Figure A-4-15). a row in the order of position numbers, and the
piston, pin and ring assemblies should be laid in
a. Install needle bearing (43) into adapter front of them in the same order. Piston position
(29). numbers are stamped on the rims of their heads on
the side which is to go toward the propeller. The
b. Install bearing (41) on worm drive shaft part number is stamped on the rim at right angles
(42); then install Woodruff key (40), worm gear to the pin hole and should be on top when
(39) and bushing (38). Align bushing and shaft installed. Mark new pistons accordingly.
holes; then install a new pin (37). Insert worm gear
and shaft assembly into adapter and needle bear- a. Spread a film of Lubriplate No. 707 grease
ing. Install retaining ring (36). on valve stems (29, 30) and insert them into
cylinders to which they have been lapped. Grasp
c. Place depressed end of clutch spring (30) valve stems and lift cylinder onto a post which will
over knurled end of worm wheel (3 1). Push spring support valve heads. Clamp cylinder base flange to
away from depressed end sideways; work end coil prevent it from rising. Again apply Lubriplate No.
over drum and push spring inward until depressed 707 to valve stems.
end snaps into gear hub groove. Position spring on
gear so screw notch is aligned with screw hole in b. Place valve spring retainers (28) over valve
gear hub. Install tab washer (35) and retaining guides (48), cupped side up. Install inner and outer
screw (34). valve springs (26,27)per instructions in Fig. A-4-34.
Also install outer retainer (25) and rotor (24).
d. Lubricate spring, sleeve and shaftgear Using the same type of spring compressor as for
liberally with clean oil. Press worm wheel spring disassembly, compress, in turn, the sets of springs
assembly and spacer (33) onto shaftgear (12). and insert the stem keys. The springs should be
Install shaftgear (12). Install shaftgear and clutch depressed only enough to admit the keys to the
assembly into adapter (29). Adapter should be held stem grooves. If they drop too far the keys may be
in such manner that sleeve faces downward. Bear cocked. This condition could cause them to nick
down on worm wheel (3 1) while turning the stems when the springs are released. Make sure
counterclockwise, thus winding up spring to start the keys are properly seated before releasing
into adapter sleeve. Make certain worm wheel and pressure on springs. Do not allow the compressing
worm gear teeth are aligned. tool to cock the outer retainer so as to contact the
A-1 1-2
stems, since they can cause score marks. Remove a. Lay crankshaft on two notched 2 by 4 inch
cylinder from fixture and set it upright on a bench. wood blocks. Locate blocks under front and rear
Strike the end of each valve stem sharply with a journals.
rawhide mallet to assure correct seat of stem keys.
b. Lay out connecting rods, caps, bolts and
c. Lay all cylinders upside down on the nuts (2, 3, 4, 5) opposite crankpins in accordance
bench. They should be resting on the sloped head with position number stamped on bolt bosses.
fins. Place a new base packing on the skirt of each Start with No. 1 at the end opposite the flange and
cylinder and put it against the flange. Make sure proceed in numerical order. Obtain a set of 12 new
that none are twisted. Coat cylinder bore walls crankpin bearing inserts and make sure they are
thoroughly with Lubriplate No. 2, Sunoco Way oil throughly clean. Snap an insert into each rod and
or castor oil.
each cap so that their ends project the same small
distance.
d. Install baffle on cylinder as shown in
Fig. A-4-37 Insert spring in hole in baffle and push c. Lubricate and install each rod and cap with
through cylinder fins. Use another spring, or a position numbers on top when odd-numbered rods
hook fashioned from stiff wire, and hook onto are extended to the right and even numbers to the
spring. Pull spring hook end over fin as shown. left. Attach them with special bolts (3) and slotted
nuts (2). Tighten nuts to specified torque and
11-8. PISTON AND RING ASSEMBLIES (See
secure each with a cotter pin(1). Bend one leg of
Figure A4-17). each pin down snug against the nut flat; the other
leg of each pin will be bent against the bolt end.
a. Lubricate pistons (32), rings (33 thru 37)
as applicable and pins (31) liberally with clean d. Attach six third order counterweights ( 12) to
engine oil. crankcheeks with two pins (10) each and install
retaining plates and rings (8, 9). Install retaining
b. When installing five ring pistons, position plate and retaining ring with the flat or rough side of
the first, third and fifth ring gaps toward the top of the retaining ring to the outside.
the piston. Position the second and fourth rings so
that the gaps are 180 apart from the first, third e. Heat crankshaft gear (15) to 300F; align
and fifth ring gaps. When installing four ring gear dowel hole with crankshaft dowel (40) and
pistons position the first and third ring gaps on top tap gear onto crankshaft. Attach gear to shaft with
of the piston. Position the second and fourth ring six screws (1 3). Tighten screws to specified torque
gaps 180 apart from the first and third ring gaps. and secure with lockwire.
CA UTION.. Do not intermix piston types in any f. Attach alternator drive gear (23) to prop
one engine. shaft drive gear (19) with tab lock plate (22) and
four screws (21); tighten to torque specified. If the
11-9. PUSH ROD HOUSINGS (See Figure A4-17) alternator gear has timing marks, it should be
installed in such a manner that the TC mark lines
a. Install "O" ring (17) on cylinder end of up with crankshaft No. 2 throw when at TDC as
housing (14). shown in Fig. A-4-40. Install propeller drive gear
quill shaft (20) into crankshaft making sure split
b. Install spring (15), washer (16), packing end of quill shaft is aligned with oil tube in
(18) onto crankcase end of housing (14). crankshaft. Line milled tooth up with oil hole in
crankshaft bearing journal. Slide propeller drive
c. Lay two housings with each cylinder. shaft gear (1 9) over quill shaft. Install plate (18)
and secure with two screws (17); then install
retaining ring (16). It is necessary that the prick
punch mark of the reduction gear fall between the
11-10. CRANKSHAFT AND CONNECTING ROD prick punch marks of the quill shaft as shown in
(See Figure A-4-20). Figure A-4-40.
June1980 A-11-3
g. Attach idler accessory drive gear (3 5) to 11-14. FUEL INJECTION CONTROL AND AIR
idler gear (37) with four screws (34) and tighten to THROTTLE BODY ASSEMBLY (See Figure
torque specified. Secure screws with lockwire. A-4-44).
CA UTIO N. . . Use only a fuel soluble thread lubri-

11-1 1. CAMSHAFT (See Figure A4-19).
cant on any injector system connection fitting.
a. Install woodruff key(3) in front end of cam-
CA UTION. .. The fuel injection equipment is
shaft(7) and install bevel gear (2).
calibrated with plugs and fittings intact. Removal
b. Install gears (5,6) on camshaft and secure with of these parts could allow small metal shavings to
four screws (4). Secure screws with lockwire. become lodged in the equipment causing mal-
function.
11-12. ALTERNATOR ASSEMBLY (See Figure
a. Assemble fuel pressure regulator assembly
A-4-13).
(20) and bracket (16) to air throttle body (54)
using attaching parts (14, 15). Connect tube
a. Install Woodruff key (8) in alternator shaft; assembly (23) and parts (6 thru 13), in order
then slide driven gear assembly (10 thru 13) onto shown, to regulator assembly.
shaft. Install washer (9), nut (7) and torque to
limit specified; then secure with cotter pin (6). b. Install gasket (50) and controller assembly
(49) onto air throttle body (54) using attaching
NOTE . .. Washer (9) installed with bearing surface parts (47, 48).
(copper colored) against gear assembly.
c. Attach adapter (42) and retainer (43) to
11-13. CRANKCASE (See Figure A4-18). shroud. Install shroud assembly (41, 42, 43),
control assembly (46) and shroud (44) to air
a. Replace any pipe plugs removed during throttle body using tab washer (40), screw (39),
speed washer (38) and sheet metal screw (37).
previous operations.
Bend ear of tab washer to flat side of hex head on
screw.
b. Coat gasket (48) on both sides with a thin
film of Tite-Seal compound and slide over governor d. Install rod and link assemblies (2.7 thru 31)
mount pad studs. Attach governor pad cover (47) and (32 thru 36), in order shown, with attaching
with four sets of attaching parts (43, 44, 45, 46). parts (24, 25, 26). Final adjustment of rod linkage
will be established at final assembly.
c. If engine mount brackets were removed,
reinstall them and their attaching parts. 11-1 5. OIL COOLER (See Figure A-4-14).
d. Turn both crankcase halves open side up. If a. Install elbow (15) so that open end faces
squirt nozzle (142) was removed, reinstall them. the rear of the engine.
Lubricate all camshaft bearings and main bearing
inserts. Install main bearings so that bearing ends b. Install oil temperature control valve (18)
project equally. and reducer bushing(1 9).
A-11-4
SECTION XII
FINAL ASSEMBLY
12-1. GENERAL INSTRUCTIONS. d. Install mount brackets on the left
crankcase and attach assembly to engine stand.
a. LUBRICATION. Apply clean engine lubri- Place a support under the casting.
cating oil liberally to all bare steel surfaces,
journals, bearings and bushings, before and/or after 12-3. CRANKSHAFT ASSEMBLY.
installation, depending on accessibility, except
where special lubricants are mentioned. a. Lift crankshaft by No. 1 connecting rod
and crankshaft gear, while a second person lifts by
b. TIGHTENING TORQUES. See Table of No. 3 and 5 connecting rods. Lower the assembly
Tightening Torques, Chapter B and instructions in into the left crankcase bearings. The connecting
paragraph 11-2 rod position numbers should automatically be
toward crankcase upper flange if properly installed.
c. CLEARANCES. Wherever possible,
measure clearances of running parts as they b. Rotate crankshaft assembly in crankcase
are installed. When end clearances, side clearances two or three times to check freedom of movement.
Refer to Table of Limits, Chapter B, for proper
and backlashes cannot be measured with normal
clearance.
thickness gauges due to inaccessible position of the
parts, test for binding and excessive looseness as 124. CAMSHAFT ASSEMBLY.
well as possible by use of a dial indicator or by
moving the running part. a. Insert the governor-driven gear into its
bearing.
d. COVERS. Unless the atmosphere is
unusually free of dust and airborn grit, it is b. Slide the governor driver gear onto the
advisable to cover openings as soon as possible and front end of the camshaft. Lay the camshaft
to cover assemblies and the partial engine assembly assembly in its bearings in the left case. Mesh the
whenever they are not in the process of being spur gear teeth with those of the crankshaft gear,
assembled. Cover all openings into which small so that the timing marks will align as illustrated in
parts might be dropped. Fig.A4-3 5.Also turn the governor driven gear to
mesh it with the driver gear.
12-2. CRANKCASE (See Figure A4-18).
12-5. PROPELLER SHAFT (See Figure A4-20,
a. Nicks or scratches should have been A-4-41, A4-42)
detected and removed from parting surfaces of
both crankcase halves during inspection procedure. a. Make certain the oil transfer sleeve (28),
Check for any metal chips or foreign objects transfer tube (29) and sleeve assembly (30) are
clogging bolt holes, oil holes and passages. installed in the propeller drive shaft. Place a new
"O" ring (31) on the sleeve assembly. Install the
propeller drive shaft assembly in the left crankcase.
b. Install bearings and/or any plugs which Scribe line on propeller flange must be on split line
may have been removed for crankcase cleaning. of case. Make certain the right angle tube of the
sleeve assembly enters the crankcase bore properly
and that the oil seal enters its recess in the crank-
c. Make sure that oil hole in bearing lines up case. Lubricate thrust washers with Gredag No. 44
with corresponding oil hole in crankcase. Lubricate grease. Slide plain half of thrust washer into left
all main bearing inserts, camshaft bearing surfaces crankcase. Place pinned half thrust washer on edges
and needle bearings with clean engine lubricating of plain washer; then rotate both until pin lies in
oil crankcase notch.
A- 12-1
b. Installing the propeller shaft oil seal is most b. Measure camshaft and crankshaft end
easily performed with the propeller drive shaft clearances at either end of their rear bearings.
installed in the crankcase. Make sure there are no Clearances must not exceed those specified in the
sharp edges or nicks on the flange. Table of Limits, Chapter B.
c. Remove spring (26) and reinforcing ring c. Place the idler gear in the left crankcase.
(25) from new oil seal (24). Unhook the spring Apply clean engine lubricating oil liberally to all
ends using an unwinding motion. Wrap spring bare steel surfaces, journals, bearings and bushings.
around shaft in seal area. Turn spring ends in
unwinding direction; then join and allow one end d. Spread a thin but continuous film of No. 3
to wind into the other end. Aviation Permatex on left crankcase parting flange.
Take care that Permatex does not get on any other
d. Oil propeller flange, shaft and I. D. of seal part. Lay lengths of No. 50 silk thread on parting
liberally with Sunoco Way Oil. flange. Thread should be on inside of bolt holes
but never on the edge. Stand No. 1, 3 and 5
e. Squeeze oil seal until egg-shaped and start connecting rods upright.
seal over bottom of propeller flange, grooved side
to the rear. Work seal carefully upward over flange. e. Carefully lower the right crankcase half
Exercise care to prevent damage to seal lip. onto the left crankcase half.
NOTE .. . Placing a lightly oiled plastic bag over NOTE . . . Unwanted stesses in the crankcase
the prop flange will help protect the seal lip. Also, could be induced by improper sequence of attach-
a special tool for stretching the seal over the prop ing hardware when first fastening crankcase halves
flange is available from Borroughs Tool and Equip- together. It is suggested that the torqueing
ment Company, 2429 North Burdick Street, sequence illustrated in Fig.A4-38 be followed to
Kalamazoo, Michigan 49007. help eliminate this possibility.
f. After seal is in place, wipe oil from seal and f. Apply a film of Tite-Seal compound to
shaft. Seal must be dry before final crankcase both sides of gasket (29). Hold idler gear in
installation. place, then install gasket (29), idler gear support
pin (28) and two sets of attaching parts (26, 27).
CA UTION. ... No sealing cement or compound is Install gasket (25),needle bearing housing assembly
to be used. (23, 24) and two sets of attaching parts (20, 21,
22). Do not tighten the four sets of attaching parts
g. Install reinforcing ring. Work O.D.. of seal at this time.
over ring to insure snug fit. install spring in cavity
in seal. g. Install "O" rings (143) on thru bolts. Install
two thru bolts (120),one above and one below the
propeller shaft. Install two thru. bolts (121), one
h. Using thumb pressure, force seal into immediately to the rear of the crankcase breather
counterbore. and the second at the crankcase nose below the
crankshaft. Install four thru bolts. (122) in front
12-6. CRANKCASE REASSEMBLY. (See Figure crankshaft bearing area. Install eight thru bolts
A4-18). (123) in the vacant holes of the cylinder mount
pads. Install three thru bolts (124) in the front
a. Using a feeler gauge, measure propeller three holes below the camshaft level. Install
shaft end clearance at either end of front bearing one thru bolt (125) in the rear hole below the
with shaft pushed toward end where measurement camshaft level. Install washers (39) and bolts (38)
is to be made. Measure distance from rear face of in the two bolt holes inside the alternator mount
rear thrust washer over propeller shaft oil slinger. pad bore. Tap all thru bolts to a centered position
These clearances must not exceed the limits with a non-marring hammer. Install eighteen sets of
specified in the Table of Limits, Chapter B. If the attaching parts on thru. bolts (120, 121, 124, 125,
clearances are excessive, replace the thrust washers. 38). Install four sets of attaching parts on two rear
A-12-2
bolts (123) projecting from the left crankcase and n. After cylinders and their attaching parts are
the two thru bolts projecting from the right installed, tighten the crankcase attaching parts to
crankcase at the rear of the alternator mount pad. the torques specified in the Table of Tightening
Do not tighten attaching parts at this time. Torques, Chapter B, and to the torquing procedure
in Figure A-4-38.
h. Install one set of attaching parts (35, 36,
37) at crankcase nose below camshaft level. Install 12-7. CYLINDERS (See Figure A-4-17).
two sets of attaching parts (68, 69, 70) from left
side and one set each (30, 31, 32) and (33, 34) NOTE... CHROME PLATING OF CYLINDERS.
from right side in rear edge of crankcase. Install According to the field service experience
four sets of attaching parts (53, 54, 55, 56, 57), accumulated by Teledyne Continental Motors and
one set above the camshaft and three sets adjacent FAA Malfunctions and Defect Reports, the
to and in front of the crankcase breather, in the practice of chroming the cylinders definitely
crankcase parting flange. affects their reliability.
i. Install parting flange attaching parts (91, As a result, Teledyne Continental Motors has no
92, 93, 97). Secure the front lifting eye (64) with alternative but to strongly recommend that the
attaching parts (58, 59, 60, 61, 62, 63). Rear practice of installing such cylinders on GTSIO-520
lifting eyes (99, 100) will be installed with the engines be discontinued.
accessory adapters.
a. Before installing each cylinder and piston,
j. Position the manifold valve (90) on the rotate crankshaft to place connecting rod in its
third and fourth holes, in front of bolt (94) or outermost position.
(97). Secure the manifold valve with two sets of
attaching parts (86, 87, 88, 89). Install four sets of b. Dip piston pin (3 1) in castor oil before
attaching parts (81, 82, 83, 84, 85) in the installing in piston and connecting rod. Lubricate
remaining vacant holes of the crankcase upper all cylinder head studs before installation of
parting flange. cylinder assemblies to crankcase.
k. Install engine mount brackets to right c. Make sure the piston ring gaps are properly
crankcase half. Secure to engine stand, but leave positioned. Place the piston over the connecting
attachments loose enough to allow necessary rod with the position number on its head forward,
adjustments. Rotate crankcase on engine stand to and push the pin through until it is centered.
an upright position. Lubricate rings and piston liberally before com-
pressing rings.
l. Apply a film of Tite-Seal compound to
both sides of gasket (10). Place the gasket (10) and d. Hang a piston ring compressor on the
oil filler neck (9) on the crankcase boss and install piston skirt. Holding the cylinder in left arm,
one screw (3). Place a new packing (5) on the oil center the compressor over the piston rings and
gauge tube assembly (4). Insert the tube end into compress them fully. Push the cylinder onto the
the crankcase bore, between No. 4 and 6 cylinder piston, forcing the compressor off the piston.
pads at the crankcase-to-oil sump parting flange.
Install two screws (3) to secure the tube assembly e. Remove the ring compressor and start the
and filler neck to the crankcase. After tightening cylinder base flange onto the hold down studs.
screws, secure their heads together with lockwire. Make sure the base flange packing ring is in place
Make certain the retaining ring (6) is installed on and not twisted. Seat cylinder barrel flange on
the tube assembly. Do not install the oil gauge rod crankcase cylinder pad. Install, but do not tighten,
assembly (1, 2) at this time. Install the gasket (8) attaching parts (19, 20).
and oil filler cap assembly (7).
f. Install pistons and cylinders in any desired
m. Apply a film of Tite-Seal compound on order. In order to minimize turning of the crank-
gasket (15) and install with cover (14). Secure with shaft and to prevent excessive unbalance, it is
four sets of attaching parts (11, 12, 13). suggested that Nos. 4 and 5 be installed first. Turn
A- 12-3
the crankshaft for Nos. 2 and 3 and install the studs.
assemblies. Then turn the shaft for 1 and 6 and
install the last two assemblies. b. Install adapter assembly and secure with
two sets of attaching parts (5, 6, 7), one set of
g. As soon as a cylinder has been installed, attaching parts (6, 7, 8) and two sets of attaching
attach it first with the upper four nuts, then with parts (7, 9, 10).
the lower four. Tighten these moderately.
12-10. ALTERNATOR ASSEMBLY (See Figure
h. After installing all pistons and cylinders in A4-13).
like manner as outlined in previous steps, torque
according to the sequence shown in fig.A4-38 to a. Coat gasket (5) on both sides with a film of
the value given in Chapter B. Tite-Seal compound.
i. Turn overhaul test stand so that the engine b. Install gasket and alternator (4); secure
is in inverted position. Lubricate the exterior with four sets of attaching parts (1, 2, 3).
surface of valve lifter with clean lubricating oil and
install in crankcase bores. Insert the spring loaded c. The gear driven alternators used on the
end of the pushrod housing into crankcase bore GTSIO-520 engines are equipped with a drive
and compress spring until opposite end will slide coupling which has a spring assembly to help
into cylinder head flange hole. Insert two pushrods absorb torsional vibrations. This spring is wound in
(13), for each cylinder, into the housings. the opposite direction for the geared engines as
compared to the direct drive engine.
Turn crankshaft until both pshosaet
their lowest position. Lubricate the rocker shafts The proper installation of the coupling is
(8) with clean engine oil, then insert into rocker important and special attention should be given to
arms (11). Install thin washer (51). Center rocker the following items.
arm on valve stem and snug down inboard retainer.
Tighten both to specified torque. Remove shipping spacer and washer from the
alternator shaft and discard, if installed.
NOTE . . . When installing retainers (12), side
clearance between retainers and rocker arms should
be 0.005 to 0.035 inch. See Fig. A-4-36. WARNING . . . Installation of the drive coupling
assembly on the alternator shaft with the shipping
k. Coat both sides of gaskets (5) with Tite- washer in place will cause interference with the
Seal compound. Install gaskets and covers (4, 5), face gear on the crankshaft and will result in
Secure with five sets of attaching parts (1, 2, 3). damage to the engine and alternator.
12-8. OIL PUMP (See Figure A-4-16). Install Woodruff key, coupling assembly and
washer. The washer is a special thrust washer and
a. Coat gasket (1) on both sides with a film of must be installed with the bearing surface (copper
Tite-Seal compound and slide gasket over mount- color) toward the alternator. Install nut and
ing studs. Slide oil pump assembly over studs and tihten to 400 inch pounds torque. If slots of nut
secure with nine sets of attaching parts (2, 3,4). do not align with cotter pin hole in alternator
shaft, the nut may be tightened further but not to
b. Torque oil pump to specified limits; then exceed 500 inch pounds. Do not back off on nut
torque pipe plug (7) , filter screen plug (44)and to align holes. Install cotter pin as shown to insure
check all housings and attaching parts making sure clearance when alternator is installed in engine.
they are adequately secured. Insure that the alternator slips into the crankcase
without binding and that the mounting flange is
12-9. STARTER ADAPTER (See Figure A-4-15). properly seated against the crankcase before
torquing the four (4) mounting nuts. Do not force
a. Coat gasket (1 1) on both sides with a film the alternator into position as damage to the
of Tite-Seal compound and install it on crankcase alternator and drive gears could result.
A-12-4 June1980
If there is stud interference with the mounting lug 12-13. OiL. SUMP (See Figure A-4-12).
holes while mounting the alternators, do not force
the alternator over the studs. Doing so could a. Make certain engine is securely mounted to
precipitate mount lug failure due to the resulting stand bed; then turn engine upside down.
preload. If interference exists, it is permissible to
enlarge the mount lug stud holes by drilling or b. Coat both sides of gasket (12) with a film
reaming (as necessary) up to a maximum diameter of Tite-Seal compound and install on suction tube
of .387. Standard hole size is .337 - .347. (11). Install oil suction tube and secure with two
sets of attaching parts (9, 10). Secure oil suction
Care must be taken during installation to assure tube supports with two screws (8).
that the alternator pilot enters the crankcase pilot
bore squarely. Forcing entry with the attaching c. Coat both sides of gasket (7) with Tite-Seal
nuts may prestress the lugs to cause cracking and compound and lay in position on sump flange of
failure. crankcase. Install oil sump (6) and secure with
attaching parts (3, 4, 5).
With the alternator pilot properly engaged in the
pilot bore, run the attaching nuts up to the lug d. Make certain drain plug (2) is tight and
contact surfaces evenly and snug. Torque the nuts safety.
to 150-180 in. lbs. in diagonally opposite pairs.
12-1 1. OIL COOLER (See Figure A-4-14).

12-14. INDUCTION SYSTEM, GTSIO-520
a. Coat gasket (14) on both sides with a film
of Tite-Seal compound and install on crankcase a. Turn engine stand bed to put engine in
studs. upright position.
b. Install plain washer (1 1) and "O" ring (10) b. Install copper washer on base threads of
onto bolt (12). Install into the right crankcase nozzle assembly. Lube threads and install nozzle
through the left crankcase. Install "O" ring (9) and assembly in cylinder. Torque to specified value.
plain washer (8) onto projecting threaded end of Lube nozzle "O" rings and slide sleeve over nozzle
bolt. Install plain washer (7) onto stud adjacent to and seat; install rubber washer and plain washer
bolt (12). over top of nozzle and seat on sleeve. Connect fuel
discharge tubes. Install a clamp over each fuel
c. Install oil cooler assembly onto mounting discharge tube and insert spring legs of clamp into
studs while being careful not to push bolt (12) bracket.
back into crankcase. Secure the oil cooler with
four sets of attaching parts (1, 2, 3) and one set (4, c. Place a new gasket on the intake port
5, 6). flange of each cylinder. Install flange over intake
tube and secure finger tight with attaching parts.
12-12. MAGNETO AND ACCESSORY DRIVE Install clamps and hoses on tubes. Locate intake
ADAPTER (See Figure A-4-11). manifold assembly and adjust hoses to proper
position. Secure hose clamps and tighten intake
a. Place two new gaskets (13) on the two tube flange attaching parts to specified torque.
upper four stud mount pads at the rear of the
crankcase so that oil holes in gaskets are aligned d. Lubricate seal with Gredag No. 44 and
with crankcase oil outlet holes. install intercooler. Secure to intake manifold
assembly with screw, and washer. Secure to
b. Install two adapter assemblies (12) with oil bracket with insulator, sleeve, plain washer and
holes aligned with crankcase oil outlet holes. Make bolt.
certain that adapter with studs on the adapter pad,
is positioned on the 1-3-5 crankcase. Attach both e. Place seal on nozzle sleeve opening of air
adapters to crankcase with plain washers, lock- fuel nozzle tubes. Connect air fuel nozzle tubes to
washers and nuts (6, 7, 8, 9, 10, 1 1). nozzle sleeves. Install tubes and junction box.
A- 12-5
f. At this time it is most convenient to hook thumb. No. 1 cylinder is coming up on the
up crankcase breather hoses. (Refer to Fig. A-4-18) compression stroke.
Slide four clamps (16) onto hoses (17, 18). Slide
one end of hose (18) onto breather tube of oil b. Remove plug (1 17, Figure A-4-18) from
filler neck assembly (9) and the other end onto crankcase between fuel manifold valve and No. 6
breather tee (19). Attach hose (17) to breather tee cylinder. Rotate the crankshaft slowly and observe
(19) and to breather tube (138). Make certain the timing mark on the No. 8 crankshaft cheek.
clamps are in position to secure the hose ends. When the mark is centered with the indicator pin,
the No. 1 piston is at the correct position
12-15. FUEL INJECTION SYSTEM according to model.
a. Lubricate fuel pump drive gear assembly c. If the plug is located in front of No. 6
and install into crankcase. Install coupling in drive cylinder, remove it and observe the timing mark on
gear. the alternator drive gear as the crankshaft is
centered in the viewing hole, the No. 1 piston is at
b. Coat both sides of gaskets with a film of the correct position.
Tite-Seal compound; then install gasket on mount-
ing studs and slide fuel pump adapter over studs. 12-18. MAGNETOS.
Install gasket, then install fuel pump and secure
with four sets of attaching parts. a. Remove inspection hole plugs from magnetos.
c. If removed, install grommets in fuel pump b. Turn magneto coupling until the pointed
shroud. Install shroud onto fuel pump and secure chamferred tooth on the distributor gear is approxi-
with attaching parts. mately centered in the inspection hole.
12-16. MAGNETO DRIVE GEARS (See Figure c. Without turning the impulse coupling, hold
the magneto in near horizontal position it will
A-4-1 1).
occupy and see that the coupling slot in the driver
gear aligns with impulse coupling lugs on the
a. Insert one presssed steel retainer (18) into magneto. If coupling lugs and gear coupling will
each gear hub slot.
not align, pull coupling drive gear just far enough
to rotate teeth and reset at correct angle to match
b. Cover each of the four new rubber bushings impulse coupling.
with a film of Gredag No. 44 and insert two
bushings (17) into each retainer, rounded long CA UTION.. .Do not pull coupling drive gear out
edges first. of oil seal.
c. Turn the crankshaft to the No. 1 cylinder d. Place a new gasket on the flange of each mag-
advanced firing position. Lubricate each magneto neto. Install magnetos carefully so drive coupling
drive gear shaft and teeth (16) and insert into bush- lugs mate with slots of drive bushings. Install and
ings (14). Rotate the gearshafts when they are snug down four sets of attaching parts. Tighten
carefully pushed through the bushings and oil seals only enough to permit turning the magneto for
so as not to damage or reverse the seal lip. Mesh final timing, without looseness.
the magneto drive gears and idler gear to the
e. Connect one red lead from the timing light
approximate position they will occupy. These
to a test lead installed in the "switch" terminal
positions will vary slightly due to differences in
on the breaker cover of each magneto and the
magneto and gears. black lead to any bare metal part of the engine.
12-17. PLACING CRANKSHAFT IN TIMING f. Both timing lights should be on. Tap the
POSITION. right magneto up, with a non-marring hammer,
unil the light goes out. Tap the left magneto
a. Plug one spark plug hole of No. 1 cylinder. down until the light goes out. When the light goes
Place a thumb over the other spark plug hole and out, the points are just opening. Secure the mag-
turn crankshaft until a pressure is felt on the netos.
A- 12-6
g. Turn the crankshaft back a few degrees and d. Install ignition harness assembly. Insert ter-
tap it in the direction of rotation until the timing minals into plugs and connect elbows to spark
marks are aligned. Both timing lights should go plugs. Make certain that conduits are not kinked or
out at the same instant that the timing mark on interferring with some other part.
the crankshaft cheek aligns with the timing pin
indicator. e. Attach cables to brackets with clamps. Tight-
en all coupling nuts.
h. If the timing lights do not go out at the same
time, loosen the magneto that is late or early and 12-20. FUEL LINES.
repeat the process.
a. Make sure that all nozzles have been installed
12-19. IGNITION HARNESS. and properly tightened.
a. The high tension cable outlet plates can be b. Snap fuel discharge tube retaining clamps into
attached to either magneto in only one position. brackets and secure tubes in clamps.
The shortest ignition cable is for No. 1 upper spark
plug and identifies the proper assembly for the c. Connect tubes to respective nozzles and mani-
right magneto. Notice the "1" on the outlet plates fold valve fittings.
next to the No. 1 cylinder cable outlet holes.
12-21. FINAL PARTS.
b. Attach each cable outlet plate to its magneto.
a. Unless optional accessories are to be installed
c. Install spark plugs and gaskets in cylinders. on the mount pads behind the magneto drive gears
before the test run, install gaskets and covers. At-
Tighten to torque specified in Section VII.
tach the covers with four plain washers, lockwashers
and plain hex nuts.
NOTE . . . Before final installation, coat spark plug b. Install timing inspection plug and gasket (1 17,
18 mm threads with a film of thread lubricant. 118, Figure A-4-18).
MARCH 1981 A-12-7/A-12-8

SECTION XIII
REPAIR AND TESTING
OF ACCESSORIES
13-1. HYDRAULIC VALVE TAPPETS. Select a d. Insert a finger into the plunger, and with-
clean bench space in a location where there is draw the attached spring and check valve assembly.
adequate light and a minimum of air circulation If the socket was not held out against the snap
and air-borne dust. If the bench top is wood or ring, the plunger will be stuck tightly in the body.
metal, spread over it a clean sheet of heavy brown This may be due to the formation of a ring of hard
wrapping paper. A bench covered with linoleum or carbon around the upper oil groove. It may be
tempered masonite is preferable. In any event, the possibl to scrape off such a deposit with a
work surface should be absolutely clean. If the blunt-edge knife, holding the plunger fully down in
volume of tappet work permits, it will be advisable the body. If so, the carbon should be blown out
to provide a rack of varnished wood or of sheet with a watchmaker's blowgun or a small rubber
aluminum to hold the parts while they are ball-type syringe as it is scraped loose. if such an
disassembled. If such a rack is not available, the obstruction cannot be removed, or if the plunger is
disassembled parts of each tappet should be placed seized by score marks, the entire assembly must be
in a row on the clean work surface so as to avoid discarded.
interchanging them between assemblies.
Particularly, it is essential that bodies, sockets and e. After removing the plunger, detach the
plungers, be kept in original relationship, since spring by turning it so as to unwind it while pulling
they are selectively fitted to obtain the specified outward. Sometimes the spring will come off
"leak-down" rate (the rate at which oil escapes without twisting, but do not stretch it out of
past the plunger). Obtain a supply of cleaning shape.
solvent of a type which leaves no perceptible solid
residue when it evaporates. Cleaners Naptha and f. To remove the check valve cage from the
the various trade-named mineral spirit solvents edge of the plunger, use a very small screwdriver or
used in regular cleaning of engine parts will be a cotter pin inserted only far enough to pry against
satisfactory. The solvent must be previously the plunger shoulder just inside the cage slots. Do
unused, and the supply should be kept in a not flip the cage off; just loosen it; then lift it off
tightly-covered can. Pour out a sufficient quantity while the plunger stands on its open end. Take off
of solvent into a clean pan, such as a tinned cake the check valve spring and the valve plate.
pan, for use, and discard the working bath when-
ever it becomes discolored or contains an 13-3. CLEANING AND INSPECTION.
appreciable amount of sediment. No special tools
are required, though a new paint brush may be a. Clean the tappet parts individually in the
used to loosen sludge deposits. solvent, and inspect all oil grooves, oil holes and
corners for deposits. Each part must be thoroughly
13-2. DISASSEMBLY. clean, all oil holes unobstructed and all particles of
carbon and other foreign matter removed from all
a. Clean the assembled tappet, then stand it surfaces.
on its flat end.
b. Inspect the body for nicks, scores and
b. Use a small screwdriver carefully to pry the other roughness on all machined surfaces. Inspect
snap ring's flat sides inward, in turn, until the ends the cam follower face for pitting, radial scores and
are disengaged from the body groove. Hold down groove wear. The latter indicates that the tappet
the socket with a pushrod or other ball end tool did not rotate as it is intended to do. This may be
until the snap ring has been removed. due to excessive wear on the tapered toe of the
cam lobe. None of these defects may be allowed.
c. Invert the tappet, and catch the socket as it
drops out. c. Inspect the socket for scoring in the con-
A-13-1
cave area. If properly lubricated, the socket should valve is leaking, it will stop there. In order not to
wear to a mirror polish at the bottom. The size of obstruct the check-valve oil hole, use a screwdriver
the worn area is not a true indication of the extent to push down on the bottom of the plunger bore.
of wear, since there is some variation in pushrod Push only a short way, and release at once - a
ballend radius and hardness, as well as in socket tapping motion. The plunger should kick back
hardness. If the worn area is small in diameter it promptly due to the compression of trapped air
may appear to be rather deep. This, too, is under it. It may not come quite back to the
deceptive. Unless there is indication that wear has starting point, and by successive taps it can be
gone beneath the hard case depth, the socket will pushed eventually to the bottom as air slowly
be serviceable, unless it is rough. Inspect each of escapes around it, but the kick back should
the right-angle socket oil holes while aiming the indicate good compression. If it shows rapid
other at a strong light to check for restrictions. leakage, this may be due to dirt on the check valve
Remove any deposit with a 1/16 inch brass rod cut or seat or to irregularities in either part, or it may
square and flat on the end. be due to wear of the plunger. A second test for
valve leakage may be made by plugging the top of
d. Inspect the plunger exterior wall for scores the plunger either with the smallest finger or with a
and other roughness. (Do not attempt to smooth rubber cork into which a small screw has been
these surfaces. If they are rough the plunger is not driven and pushing the plunger in while plugging
repairable). Make sure that its side oil hole and the body oil holes by holding the body between
check-valve oil hole are clear. Inspect the check- thumb and forefinger. If the plunger resists inward
valve seat for nicks, pitting and scratches, using a and outward motion, indicating good compression
magnifying glass in good light. The seat must be and vacuum, respectively, then the check valve is
perfectly flat. not seating perfectly. In this event, clean the
sealing surfaces again and inspect for possible
e. Inspect the check-valve plate for bending scratches and other damage. If the valve cannot be
and roughness. It is possible to lap the valve made to seat perfectly, or if the second test
plate to restore perfect flatness; however, this is indicated excessive plunger wear, discard the entire
not usually an economical procedure. Inspect the tappet. On the other hand, if the first test
check-valve spring for distortion. It should stand produced a satisfactory kickback the unit should
about 1/4 inch high. Look for dirt in the valve operate well enough in the engine and, in the
cage, and see that it is not deformed so as to be absence of other kinds of damage to the parts, it
loose on the plunger shoulder. should be considered acceptable.
13-4. TESTING. Since proper leak-down past the 13-5. REASSEMBLY.

plunger and perfect seating of the check valve are
essential for maintenance of zero lash in the valve a. Coat the inside of the tappet body with
train, and since bodies and plungers are not only a film of clean engine lubricating oil. Stand it
interchangeable, it is essential to ascertain whether on its flat end.
the original body and plunger are worn too much
to operate satisfactorily and whether the check b. Stand the plunger on its open end. Lubri-
valve will seal perfectly. It is not necessary to cate the check-valve plate, and lay it on the seat at
determine the exact leak-down rate. A quick but the top of the plunger. Center it by eye. In the
sufficient check may be made immediately after center of the valve, stand the small valve spring.
cleaning the parts and without special equipment. Place the valve cage over the spring, push it down
For the first test assemble the plunger, check-valve onto the plunger shoulder. Use a screwdriver and a
plate, check-valve spring and cage (refer to para- small hammer or hand-tap the cage down firmly
graph 13-5). Do not install the large expanding against the plunger all around.
spring on the plunger. Stand the dry body on its
flat end, and start the dry plunger and valve C. Place the large expanding spring on over
assembly into its bore. The plunger will go in easily the valve cage. Lubricate the outside of the plunger
until its inner end has passed the lower body oil and the spring sparingly. Insert this assembly into
hole. Unless it is very badly worn or the check the body core, spring first.
A-13-2
d. Lubricate the socket. Place it, flat side steel plate and standard iron pipe fittings. The
down, on top of the plunger. Hold it inward below cleaning solution should enter through the normal
the body snap ring groove with a pushrod or other cooler outlet port (front in installed position). A
ball-end tool, and insert the ends of the snap ring filter must be interposed in the supply hose
into the groove, then with a screwdriver push the between the pump and the cooler. Circulate the
snap ring center curve into the groove. solution until the discharge appears clean the
pressure drop across the cooler has stabilized at the
e. Lubricate the outside of the body and its lowest value obtained. This may require 30
flat end with clean engine oil, but do not minutes or so.
squirt oil into the plunger or body oil holes. Store
assembled tappets under cover, or wrap them in 4. Flush the cooler core thoroughly with
waxed paper until ready for installation in the clean hot water, and drain it as completely as
engine. possible. Blow off the exterior with dry com-
pressed air.
13-6 OIL COOLER.
CA UTIO N... Use only an inhibited, mild alkaline
a. CLEANING. cleaning compound intended for cleaning alumi-
num parts. Strong alkaline ma terials intended for
1. Soak the assembly in a tank of mineral use on other metals will destroy the cooler by
spirit solvent or cleaners naptha to loosen and wash corrosive action. If such a compound has been used
out heavy sludge deposits and oil. in the circulating equipment it must be washed out
thoroughly before filling with the solution to be
2. Blow out the cooling fins and dry the pumped through the oil cooler. It is essential that
exterior with a jet of dry compressed air after all alkaline material be removed from all exterior
draining the cooler. and interior surfaces of the cooler. Residues left
inside the core will react with acids in the engine
3. For a final cleaning operation, a tank of at oil to form soap, and this will cause violent
least 10 gallons capacity with a solution-circulating foaming in the oil system.
pump system of approximately 35 gallons per
minute delivery at 75 - 150 p.s.i. pressure should After a cleaning operation, empty the solution
be used to circulate through the cooler core a filter, and examine the filtering element for
solution of an inhibited, mild alkaline cleaning metallic particles. If any significant volume of such
compound, such as Oakite No. 61 (6 oz. Oakite per particles is found, the cooler from which they
gallon water) maintained at a temperature between came should be destroyed, since there is no way of
160F. and 180F. A pressure gauge should be determining when all such particles have been
installed in the supply line and another in the removed.
return line to measure the pressure drop through
the cooler. The pressure drop will decrease, i.e., the b. INSPECTION.
gauge readings will come closer together as the
solid deposits are flushed out. An adapter for 1. Look for obstructions between the air fins.
attachment of the hoses must be made locally and
sealed to the cooler mount flange with a gasket and 2. Inspect the flat tubes, fins and headers for
three bolts, washers and nuts. The adapter may dents and bending. The assembly is allowed to be
incorporate the two gauges. It may be made of out of square 1/16 inch per foot in any direction.
MARCH 1981 A-13-3

Any distortion will indicate the possibility of 6. Remove all traces of welding flux by
cracks and broken jit.Fins must not be bent so wiping all accessible areas with a clean cloth wet
as to restrict the cooling air flow. with hot water; then scrub with a stiff bristle brush
and hot water, and wipe again with a wet, hot
3. Inspect the mounting surface for deep cloth. Flush all inaccessible areas thoroughly with
scratches and cracks which would cause oil leakage. hot water and dry with compressed air. Repeat the
flushing and drying operation several times.
4. To test for invisible leaks, block either oil
port with a gasket and adapter plate through which 7. Repeat the air test described in paragraph
compressed air may be introduced into the other I13-6B.
port and attach a compressed air hose to the
adapter inlet. The air line should be equipped with CA UTION ... All aluminum welding fluxes are
a pressure gauge and, between the gauge and the highly corrosive. Exercise care to prevent the flux
pump, a manual shutoff valve. Lower the cooler from entering the cooler core. Complete removal
into a water tank until it is completely immersed; of the flux residues is essentialfor the same reason.
then slowly open the air line valve until the
pressure has risen to 100 p.s.i. Close the valve, and 8. If a crack in the mounting surface was
watch for air bubbles escaping from the cooler, repaired by welding, the flatness of the surface
accompanied by a drop in guage reading. If must be restored by machining or by careful filing
necessary to maintain pressure, open the air line and lapping. Before machining or filing, plug the
valve long enough to locate the source of bubbles oil ports with a hard grease which is soluble in
at the cooler surface, and if the point is accessible, lubricating oil. Remove the plugs after machining
circle the leak with a crayon mark to identify or lapping and thorough cleaning.
points which may be repairable.
c. REPAIR. 13-7. TESTING. Seal the flushing adapter to the

cooler, and connect to a high pressure hose leading
1. Because of the welded constructions, through a valve to a source capable of supplying a
repairs are not recommended by the oil cooler low viscosity lubricating oil at a static pressure of
manufacturer; however, emergency repairs may be 200 p.s.i. Fill the cooler by circulating oil until all
made to stop leaks in accessible locations, such as air has been displaced. Then block the cooler, and
tube seams and header surfaces, when a new cooler apply a pressure of 200 p.s.i. Close the supply-line
is not available.Do not attempt to repair an oil valve, and allow the cooler to stand under this
cooler with blown or bulged tubes. pressure for 20 minutes, during which time there
should be no oil leakage, and the gauge pressure
2. Clean thoroughly the area surrounding the should remain constant.
crack or hole.
13-8. LUBRICATION. Following completion of
3. Apply a thin coat of a solution of Alcoa cleaning, testing and repair work, if any, and
No. 33 flux in water. pending installation of the cooler, flush the core
with clean, low viscosity lubricating oil at a
4. To repair tube leaks, heat the metal with an temperature of approximately 160'F. Drain out
acetylene torch equipped with a No. 3 tip, and the bulk of the flushing oil, leaving a coating on
apply Alcoa No. 716 welding wire 1/16 inch in the interior surfaces, and store the cooler in a
diameter. rightly-covered container.
5. To repair header leaks or mounting pad 13-9. ACCESSORIES. For overhaul instructions
cracks, heat the metal with an acetylene or and parts list relative to the starter, alternator and
hydrogen torch equipped with a No. 5 tip, and magnetos used on the GTSIO-520 series of engines
apply Alcoa No. 718 welding wire of 3/32 inch you are to forward your request to the address
diameter or Alcoa No. 43S welding rod. listed in Accessory Manufacturers.
A- 134
ACCESSORY MANUFACTURERS
Accessory Manufacturer Address Accessory Manufacturer Address
Starter Delco-Remy United Motors Service

General Motors Building Alternator Teledyne - Teledyne Continental Motors
Detroit, Michigan Crittenden P. 0. Box 90
Mobile, Alabama 36601
Prestolite The Presrolite Company
Division of Eltra Corp.
51 1 Hamilton Street
Toledo, Ohio 43601 Magnetos Bendix Bendix Electrical
Components Division
Alternator Delco-Remy United Motors Service Sidney, New York 13838
General Motors Building
Detroit, Michigan
Prestolite The Prestolite Company Slick Slick Electro, Inc.

Division of Ultra Corp. Rockford, Illinois 61 100
5 11 Hamilton Street
Toledo, Ohio 43601
June 1980 A-13-5/A-13-6

SECTION XIV
TESTING AFTER OVERHAUL
14-1. After each major overhaul, engine perform- least five feet above the cell floor so that the club
ance should be tested and new parts run-in while will not cause excessive air disturbance at floor
the engine is mounted on a rigid test stand, level. If the cell does not have a paved floor, the
preferably enclosed in cell of such design that ground under the stand, and for considerable
recirculating air is held to a minimum. The engine distance around it, should be treated to hold the
stand should be constructed in such a way as to Soil.
permit accessibility to all engine line and
instrument connections and to permit frequent
inspection of all points of possible leakage. All c. COOLING AIR SCOOP. In warm climates
tubes, wires, rods and cables used to connect it may be necessary to construct a scoop of
instruments and controls should be well supported, heavy gauge sheet metal to fit over the tops of all
yet of sufficient flexibility to permit them to be cylinders. It should have pads to seal it to the rear
moved out of the way during installation and cylinders and to all valve rocker covers, in order to
removal of the engine. direct an adequate flow of air downward through
the cylinder fins. It may be determined necessary
NOTE . .. You will find the test schedule etc. in to construct vanes to direct cooling air downward
the Difference Data Section for each lettered to the center cylinder and/or oil cooler. The
engine model. temperature of all cylinder heads should be
measured until uniformity within 50 has been
NOTE . .. When necessary, the airframe can be obtained. It is also advisable to provide a duct from
cosdered a suitable test stand for running in the cylinder scoop to the generator or alternator
overhauled engines contingent on use of a test vent tube, or to provide a separate scoop.
propeller and equipped with a suitable shroud or
scoop to gather and direct cooling air over the d. INDUCTION AIR INTAKE. An air filter
cylinders. Engine must be equipped with cylinder and housing should be attached to the turbo-
head pickups on all cylinders and other instru- charger air inlet flange. The filter area must be
mentation as needed. sufficient to avoid restriction of air flow. Filter
should be cleaned before each test. Calculations of
14-2. TEST EQUIPMENT. filter area should be based on approximately 389
c.f.m. of air required by the engine at full throttle
a. TEST CLUB. Unless a dynamometer is and on the filter capacity per unit of area. The
used to apply controlled loads to the crankshaft, it calculated area of a clean filter should be increased
will be necessary to install a wood test club, such by at least 50% to allow for the accumulation of
as those supplied by the Hartzell Propeller Fan Co., dirt.
Piqua, Ohio. Test clubs are customarily supplied in
standard diameters, so that the blade length must e. EXHAUST STACKS. The exhaust mani-
be reduced by the "cut and try" method until the fold system as furnished by the aircraft manu-
club will absorb the BHP at the RPM specified in facturer should be used in testing. Should this
the following tables for the model on test. The test system not be available, an exhaust system con-
club is usually calibrated for the test stand and forming to the Teledyne Continental drawing for
engine combination. the applicable engine model should be used.
b. TEST STAND. Any rigid supporting stand f. CONTROLS. The only necessary controls
of adequate strength and suitable shape and are a mixture control and throttle control capable
dimensions may be fitted with adapters to accept of operating the fuel control and metering shafts
the engine mount bracket locations and sheer through their complete ranges. Also, a standard
rubber mount bushing dimensions shown in the twin magneto switch connected to the magneto
installation drawings. The crankshaft should be at grounding terminals.
A-14-1
g. ELECTRICAL WIRING. A 24-volt storage manifold valve.
battery must be connected by a No. 0 stranded
copper cable from its positive terminal to the 14-3. ENGINE TEST AFTER OVERHAUL.
power terminal of the starter or starter solenoid.
The battery negative terminal must be connected a. After a partial or complete disassembly and
to the engine or both battery terminal and engine repair of an engine in which no major part
may be grounded. A small insulated wire should (cylinder, piston, bushings, gear, etc.) was replaced,
connect the starter solenoid coil terminal to a 5 the engine may be tested in accordance with Table
amp pushbutton switch. The other switch terminal outlined in the Difference Data Section.
must be connected to the engine, or both to a
common ground. b. Extend the second period of each test
schedule, if necessary, to raise the oil temperature
h. INSTRUMENTS. The control panel should to 1000 F.
be equipped with the following engine instru-
ments: NOTE ... If tests must be conducted in extremely
cold weather, it may be necessary to shield the
1. An electrically powered (1/2 engine RPM) crankcase from the cooling air stream, since it
tachometer is necessary on some engine models. takes some heat from the oil.
2. An oil pressure gauge and tube connection. c. Take instrument readings at the beginning,
in the middle, and at the end of the full throttle
3. An oil temperature gauge and capillary period. Take one reading during each of the other
assembly. periods as soon as conditions have stabilized.
4. A cylinder head temperature gauge, wiring d. Make one check on performance of each
and spark plug bayonet thermocouple. (Install magneto alone at 1500 RPM. Clear spark plugs by
under a lower spark plug.) operating with both magnetos on for a few seconds
between checks.
5. A water manometer with rubber hose
connection to the vacuum pump oil return hole at NOTE .. . The maximum allowable cylinder head
the rear of the crankcase. temperature and the maximum allowable oil
temperature must not be exceeded at any time
6. An ammeter connected in the alternator during the test.
circuit.
14-4. PRE-STARTING PROCEDURE.
i. BREATHER. A substantial hose of 3/4
inch I.D. should be securely clamped over the a. Service the lubricating system with non-
crankcase breather elbow and supported so as to detergent mineral oil (MIL-C-6529 Type II).
lead to a point above and to the rear of the engine. 1. Grade SAE 50 (above 400 F.)
2. Grade SAE 30 (below 400 F.)
FUEL SYSTEM. The test stand fuel system
b. Rotate the propeller by hand through
is to incorporate an auxiliary pump capable of
several cycles with the spark plugs removed.
delivering fuel to and through the engine system at
a pressure of 2 to 2-1/2 psi indication on fuel c. Motor the engine with the starter until
pressure gauge. Means of determining, by weight, a positive oil pressure is observed or pre-oil the lu-
fuel consumption for given periods of time and at brication system using an external oil system pres-
specified percentage of power should also be sure system.
included. Connect stand fuel supply line to upper
elbow projection from left side of fuel pump d. Install the spark plugs.
shroud. Connect fuel pump-to-supply tank return
line to upper elbow projecting from right side of 14-5. STARTING PROCEDURE.
fuel pump. Connect fuel pressure gauge line to the
fitting projecting from the center rear of fuel a. Open throttle to approximately 1000 to
A-14-2
1200 RPM position. run-in. Never perform run-in or run-up over a dusty
surface or loose earth or gravel.
b. Turn magneto switch to "BOTH" position.
3. Head aircraft into the wind.
c. Press boost pump button and hold in until
2.5 - 3.00 p.s.i. nozzle pressure is obtained: then 4. Propeller in low pitch - high RPM.
release boost pump button and press s tarter
button. 5. Have engine fully cowled with cowl flaps
full open.
NOTE . .. During operation of starter, the boost
pump may be used intermittently to maintain 2.5- 6. Run-in in two ten-minute increments, the
3.0 p.s.i. nozzle pressure. DO NOT use boost pump first not to exceed 1200 RPM, the second not to
after engine is running smoothly. exceed 1500 RPM, with a cooling off period in
between.
14-6. PRESERVATION. If the engine is not to
be installed in an aircraft and placed in service NOTE Inspect for leaks etc. after each run.
immediately, an additional period of 15 minutes
test time will be required to preserve the engine
internally. The engine must be stopped so the oil 7. Run-up very briefly to check full power
may be drained and replaced with a corrosion- performance.
preventive oi mixture (suitable for flight
operation). During the same period unleaded 8. Observe cylinder head temperature and oil
gasoline should be supplied to the fuel system. temperature limits at all times.
NOTE . .. For test schedule see Difference Data 9. Check oil level before flight with aircraft in
Section for specific models. level ground attitude. (Alternate method is to
weight oil.)
14-7. ENGINE RUN-IN AFTER TOP OVER-
HAUL OF ONE OR MORE CYLINDERS. The 10. Take off using full power and fly around
need for a recommended run-in procedure after the airport for one hour at (75%) seventy-five
top overhaul with the engine installed in the percent power.
aircraft using a flight propeller has become evident
and we therefore propose the following: 11. After flight, check oil level with aircraft in
same ground attitude as before-flight check.
1. In hot weather, select the coolest time of (Alternate method -weightil.)
day for both ground run-in and in-flight break-in.
12. Record observed oil consumption in engine
2. Select the most dust free area for ground log book.
A-14-3/A-14-4
TABLE OF LIMITS
Ref. Chart Serviceable New Parts

No. No. Description Limit Mi n. Max.
CYLINDER AND HEAD ASSEMBLY
1 Cylinder bore (lower 4.25 " of barrel)......Diameter: 5.256 5.25 1 5.2 53
2 1 Cylinder bore choke (at 5.75" from open end
of barrel).................Taper: - 0.001 0.00 10 0.0025
3 1 Cylinder bore out- of-round .. .......... 0.002 0.000 0.00 1
4 1 Cylinder bore .... ....... Allowable Oversize: 5.26 1 5.255 5.256
5 1 Cylinder bore roughness .. .......... RMS: 15 30
6 1 Intake valve seat insert in cylinder head ...... ameter: 0.007T 0.010T
7 1 Intake valve guide incylinder head .. .... iameter: 0.00 1T 0.0025T
8 1 0 Exhaust valve guide in cylinder head ...... iameter: 0.001T 0.0025T
1 OExhaust valve guide in cylinder head .. ... Diameter: 0.0012T 0.0027T
9 1 Exhaust valve seat insert in cylinder head .. .. Diameter: 0.007T 0.010T
1 I nta ke valve seat...............Width: 0.063 0.140
11 1 Exhaust valve seat ..... ......... Width: 0.063 0.140
Exhaust valve seat to valve guide axis.......Angle: 44030' 45000'
Intake valve seat to valve guide axis........Angle: 59030' 60000'
ROCKER ARMS AND SHAFTS

12 1 Rocker shaft in rocker arm bushing.......Diameter: 0.004L 0.0010L 0.0025L
13 1 Rocker arm bushing in rocker arm .. ..... Diameter: 0.002T 0.0 06 T
14 1 Intake valve in guide .. .......... Diameter: 0.005L 0.0012L 0.0027L
14 1 Intake valve in guide .. .......... Diameter: 0.0010L 0.0036L
15 1 ©Fxhaust valve in guide............Diameter: 0.007 L 0.003L 0.0047L
15 1 ®TExhaust valve in guide............Diameter: 0.0035 L 0.0062L
16 1 Intake valve face to stem axis..........Angle: 5945' 60015'
17 1 Exhaust valve face to stem axis .. ....... Angle: 45000' 450 30'
18 1 Intake 'valve (Max. tip regrind 0.015") .. .... Length: 4.789 4.804 4.824
19 1 Exhaust valve (Max. tip regrind 0.01 5") ..... Length: 4.79 1 4.806 4.826
20 1 Intake and exhaust valve concentricity ........ 0.004 0.000 0.002
Rocker arm foot to end of valve .. ..... Clearance: 0.060 0.200
PISTONS,RINGS AND PINS

21 1 Piston (bottom of skirt) in cylinder.......Diameter: 0.016 L 0.008L 0.014L
22 1 First piston ring in groove ........ ide Clearance: 0.006L 0.00 15L 0.0040L
First piston ring (standard gap).........Tension: 12 lbs. 12.5 lbs. 17.5 lbs.
23 1 Second piston ring in groove .. ..... Side Clearance: 0.006 L 0.0015L 0.0040L
Second piston ring (standard gap)........Tension: 8 lbs. 9.5 lbs. 14.5 lbs.
24 1 *)Third piston ring in groove........Side Clearance: 0.0035 L 0.00551
Third piston ring (standard gap) .. ...... Tension: 8 lbs. 9 lbs. 14 lbs.
25 1 Fourth piston ring in groove .. ..... Side Clearance: 0.006L 0.008L
Fourth piston ring (standard gap)........Tension: 8 lbs. 9lbs. 13 lbs.
26 1 Fifth piston ring in groove .. ...... Side Clearance: 0.006L 0.008L
Fifth piston ring (standard gap).........Tension: 8 lbs. 9 lbs. 13 lbs.
27 1 First piston ring in cylinder............Gap: 0.033 0.044
28 1 Second piston ring in cylinder...........Gap: 0.030 0.046
29 1 @Third piston ring in cylinder .. ......... Gap: 0.030 0.0.46
30 1 Fourth piston ring in cylinder...........Gap: 0.059 0.033 0.049
31 1 Fifth piston ring in cylinder............Gap: 0.059 0.033 0.049
32 1 Piston pin in piston (Std or 0.0005" OS).....Diameter: 0.00 13 L 0.0003L 0.0007L
33 1 Piston pin in connecting rod bushing .. .... Diameter: 0.0040L 0.0022L 0.0026L
34 1 Bushing in connecting rod .. ........ Diameter: 0.0025T 0.0050T
MARCH 1981 B-1
Noa. No. Description Limit Min. Max.
35 Connecting rod bearing on crankpin .. .... Diameter: 0.0009L 0.0034L
36 Connecting rod on crankpin ....... Side Clearance: 0.016 0.006 0.010
37 Bolt in connecting rod............Dameter: 0.0000 0.0018L
38 Connecting rod bearing and bushing twist or
convergence per inch of length.......... 0.001 0.0000 0.0005
CRANKSHAFT
39 Crankshaft in main bearings ... .. ..... Diameter: 0.005L 0.001 L 0.004L
40 Propeller reduction gearshaft in bearing ...... Diameter: 0.001 L 0.004L
41 2 Propeller drive shaft in bearing... .. .... Dameter: 0.001 L 0.004L
42 2 OCrankpins...............Out-of-round: 0.00 15 0.0000 0.0005
43 2 0 Main journals..............Out-of-round: 0.00 15 0.0000 0.0005
44 2 Propeller drive shaft .. ......... Out-of-round: 0.002 0.0000 0.0020
44-1 2 Transfer tube sleeve in drive gear .. .. .... Diameter: 0.0005T 0.0025T
44-2 2 Transfer tube in sleeve and adapter.. ...... Diameter: 0.0008 L 0.0020L
45 2 Propeller drive shaft in thrust bearing . ... End Clearance: 0.020 0.006 0.0152
46 2 Propeller reduction gearshaft .. ..... End Clearance: 0.0055 0.0115
47 Crankshaft in crankcase..........End Clearance: 0.0 10 0.0 16
48 2 Crankshaft run-out at center main journals
(shaft supported at front and rearjournals)
2
full indicator reading............. 0.0 15 0.000 0.0 15
49 2 Propeller shaft flange run-out (when supported at
2 front and rear journals) Full indicator reading .. .. 0.003 0.000 0.002
50 0 amper pin bushings in crankcheek extension...Dameter: 0.00 15T 0.003T
2
51 ODamper pin bushings in counterweight ........ 0.0015T 0.003T
52 2 Damper pin in counterweight -...... End Clearance: 0.040 0.00 1 0.023
53 Alternator drive gear on reduction gear ..... Diameter: 0.005T 0.0035T
54 2 Crankshaft gear on crankshaft............ 0.000 0.00T
2
2 CAMSHAFT
55 Camshaft journals in crankcase-........Diameter: 0.005L
2 0.00 1L 0.003L
56 Camshaft in crankcase..........End Clearance: 0.0 14 0.005 0.009
57 Camshaft run-out at center journals (shaft supported
2
attend journals) full indicator reading ....... 0.0 03 0.000 0.00 1
58 Camshaft gear on camshaft flange .. ..... Dameter: 0.0005T 0.0015
2
59 Governor drive gear on camshaft-.......Diameter: 0.006 L 0.0005L 0.0020L
2
CRAN KCASE
60 Thru bolts in crankcase-..........Diameter: 0.005T 0.0013L
61 3
Hydraulic lifter in crankcase-.........Diameter: 0.003 5L 0.00 1L 0.0025L
62 Governor drive shaft in crankcase .. ..... Diameter: 0.0014L 0.0034L
2
OIL PRESSURE RELIEF VALVE
63 2 Adjusting screw in plunger-..........Diameter: 0.003L 0.005L 0.0020L
2
2 ACCESSORY DRIVE IDLER GEAR
64 Bushing in idler gear .. .......... Dameter: 0.001 T 0.003T
65 Idler gear support in bushing .D........iameter: 0.005L 0.0035T
0.0015L
66 MAGNETO AND ACCESSORY DRIVE
2
Bushing in magneto & accessory drive adapter. ..- Diameter: 0.00 1T 0.004T
67 Magneto & Accessory drive gear
in adapter bushing ... ......... Diameter: 0.005L 0.0015L 0.0035L
68 Oil seal in adapter ... .......... Diameter: 0.001T 0.007T
B-2 October 1980

Ref. Chart Serviceable
No. Description Min. Max.
69 2 Sleeve in magneto and accessory drive gear....Dameter: 0.00 1T 0.004
70 2 Magneto and accessory drive gear .. ... End Clearance: 0.003 0.04 1
71 2 Magneto coupling retainer in
magneto gear slot...........Side Clearance: 0.040L 0.002 L 0.0281L
OIL PUMP
72 4 Oil pump driver gear in housing .. ...... Diameter: 0.0040L 0.0065L
73 3 Oil pump driver gear shaft in pump housing . . .. Diameter: 0.0045L 0.00 15L 0.0030L
74 4 Oil pump driven gear in housing .. .. .... Dameter: 0.0040L 0.0065L
75 3 Oil pump driven gear in housing......End Clearance: 0.00 19 0.0044
76 3 Oil pump driver gear in housing .. .... End Clearance: 0.00 19 0.0044
77 3 Oil pump driven gear on shaft ... .. .... Dameter: 0.004 L 0.0005 L 0.0025L
78 4 Scavenge pump driver gear in housing . . D....0iameter: 0.010L 0.0055L 0.U080L
79 3 Scavenge pump driver gear in housing....End Clearance: 0.005 0.0005 0.0030
80 3 Scavenge pump driver gear on drive shaft ..... Dameter: 0.004L 0.00 15L 0.0030L
81 4 Scavenge pump driven gear in housing . .. ... Diameter: 0.010 L 0.0055 L 0.0080L
82 3 Scavenge pump driven gear in housing....End Clearance: 0.005 0.0005 0.003 0
83 3 Scavenge pump driven gear bushing on shaft . . .. Diameter: 0.004L 0.0005L 0.0025L
84 3 Tach drive gear shaft in scavenge pump cover Diameter:
.. 0.004L 0.001 5L 0.0030L
STARTER DRIVE
85 3 Starter shaftgear in bearing .D........Diameter: 0.0005 L 0.0020L
86 3 Starter clutch drum on starter shaftgear.....Diameter: 0.008L 0.0045L 0.0065L
87 3 Starter shaftgear in ball bearing .. ...... Diameter 0.0001T 0.0008 T
88 3 Worm wheel gear............End Clearance: 0.0026 0.0286
89 3 Clutch spring on clutch drum.........Diameter: 0.0 12T 0.01 T 0.022T
90 3 Clutch spring on starter shaftgear
(over knurl) ......... ..... Diameter: 0.013 L 0.006 L 0.009L
91 3 8 Clutch spring in clutch spring sleeve .. .... Diameter: 0.027T 0.034T 0.038T
92 3 Starter adapter cover surface to thrust pads .. .... 1-444 1.438 1.440
93 4 Ball bearing in starter adapter.........Diameter 0.000 1T 0.0010T
94 4 Worm gearshaft in ball bearing .. ...... Diameter: 0.0001L 0.0007T
95 4 Starter worm gear on shaft..........Diameter: 0.004L 0.0005L 0.0025L
96 4 Starter pilot to starter drive adapter .. .... Diameter: 0.00 10L 0.0065L
97 4 Starter drive tongue to worm shaft
drive slot..............Side Clearance: 0.010 0.02 1
FUEL PUMP ADAPTER

98 2 Fuel pump gear in adapter .. ........ Diameter: 0.0 04 L 0.0005L 0.0025L
99 2 Fuel pump gear in crankcase .. ..... End Clearance: 0.002 0.036
100 2 Seal in fuel pump adapter .. ........ Diameter: 0.003T 0.009T
GEAR BACKLASH
101 2 Crankshaft gear and camshaft gear .. ..... Backlash: 0.0035 0.0082
102 2 Prop drive shaft and prop reduction gear.....Backlash: 0.00 13 0.0067
103 2 Crankshaft gear and idler gear.........Backlash: 0.0028 0.0089
104 2 Idler gear and magneto drive gear .. ..... Backlash: 0.008 1 0.0 146
105 2 Idler gear and accessory drive gear .. ..... Backlash: 0.0081 0.0 146
106 4 Oil pump driver and driven gear .. ...... Backlash: 0.027 0.0 14 0.02 18
107 4 Scavenge pump driver and driven gear......Backlash: 0.027 0.0 14 0.0218
108 3 Starter shaftgear and crankshaft gear .. .... Backlash: 0.0 10 0.0037 0.0078
109 4 Starter wormwheel gear and worm gear .. ... Backlash: 0.020 0.0086 0.0 14 1
110 2 Governor drive and driven gears . . . .... Backlash: 0.009 0.00 14 0.0085
111 2 Alternator face gear and driven gti.. .... Backlash: 0.0 12 0.002 0.009
112 Fuel pump gear and cam cluster gear .. .... Backlash: 0.0 16 0.0087 0.0 127
B-3
No. No. Description Limit Max.
SPRING TEST DATA
Oil temperature control valve 0.090 inches
minimum travel at ..... ..... Temperature: 120 F 170 F
Oil temperature control valve must
close between...........Oil Temperature: 168 F 1720 F
113 3 Relief valve spring (632652) compressed to
1.24 inch length...............Load: 46.5 lbs 49.6 lbs 54.6 lbs
114 4 Oil filter by-pass valve spring (631478) in
pump compressed to 1.09 inch length .. .... Load: 5.0 lbs 5.3 lbs 5.9 lbs
115 Inner valve spring (637836) compressed to
1.329 inch length ..... ......... Load: 73 lbs 78 lbs 88 lbs
115 Inner valve spring (637836) compressed to
116 Outer valve spring (637837) compressed to
116 Outer valve spring (637837) compressed to
Use 0.005 inch oversize pistons and 0.005 inch oversize rings.
Clearances for standard guides P/N 631496
Clearances for nitraloy prefinished guides P/N 641973
Fourth ring groove in five ring piston.
Third ring groove in five ring piston.
If crankshafts are worn beyond these limits they may be repaired by grinding crankpins and journals to 0.01 0 inch under new shaft
limits and renitriding the crankshafts.
Refer to para. A-9-14 for allowable wear at damper pin bushings.
Sandblasted finish. When finish is worn to 75 RMS. Replace sleeve.
B4 MARCH 1981
61
FIGURE B-1. LIMITS CHART (CHART 1)
B-5
B-6 JUNE 1980

82 83
84
T-12

B-7
1067 74
81
107
FIGURE B4. LIMITS CHART (CHART 4)
B-8
TABLE 2
TIGHTENING TORQUES
Ref. Chart Thread Torque

No. No. Special Applications Size Quantity In. Lbs. Ft. Lbs.
T1 2 Crankcase through bolt ......... 1/2-20 8 690-710 57.5-59.2

T2 2 Crankcase through bolt (nose) ....... 1/2-20 4 640-660 53.3-55.0
T3 2 Crankcase through bolt. ............... 7/1 6 20 4 490-510 40.8-42.5
T4 2 Crankshaft face gear screw (alternator). ..... 5/1 6-24 4 140-150 11.7-1 2.5
T5 2 Crankshaft gear screw. ................ 5/16-24 6 380-420 31.7.35.0
T6 2 Camshaft gear screw. ................. 5/16-24 4 240-260 20.0-2 1.7
T7 1 Connecting rod bolt nuts............... 7/1 6-28 12 550-575 45.8-47-9
T8 I Cylinder hold down nuts. .............. 7/1 6-20 36 490-510 40.8.42.5
TS 1 Cylinder hold down nuts. .............. 1/2-20 12 690.710 57.5-59.2
T10 4 Oil filter plug (with new gasket). ......... 1-3/4-16 1 500-520 41.6-43.3
Alternator mounting nut. .............. 5/1 6-18 4 150-180 12.5-1 5.0
Alternator shaft nut. ................. 5/8-32 1 450-500 37. 5-41.7
T11 1 Spark plugs. ....................... 18 mm 12 300-360 25.0-30.0
T12 3 Starter shaft nut. ................... 3/4-16 1 - 180.0-220.0
T13 1 Rocker retaining screw ..... .......... 5/16-18 24 190-210 15.8-17.5
After specifited torque is reached, do not realign hex to suit tabs on washer. Exact alignment of tab to hex not required.
TABLE 3
GENERAL USE - TIGHTENING TORQUES
BOLTS, NUTS & SCREWS DRIVING STUDS

Size In. Lbs. Ft. L bs. In. Lbs. Ft. Lbs.
8-32 22.0 - 30.0 1.8 - 2.5

10-32 36.0 - 50.0 3.0 - 4.2
1/4-20 75.0 - 85.0 6.3 - 7.1 50.0 - 70.0 4.2 - 5.8
1/4-28 90.0 - 110.0 7.5 - 9.2
5/16-18 155.0 - 175.0 12.9 - 14.6 100 - 150 8.3 - 12.5
5/16-24 180.0 -220.0 15.0.- 18.3
3/8-16 220.0 - 260.0 18.3 -21.7 200 - 275 16.7 - 22.9
3/8-24 275.0 - 325.0 22.9 - 27.1
7/16-14 300 -425 25.0 -35.4
7/16-20 400.0 - 450.0 33.3 - 37.5
1/2-20 550.0 - 600.0 45.8 -50.0
B-9
NOTE .. Torque loads are listed for use with oil on threads,
except for studs. Stud driving torques apply when
the threads are coated with Alcoa thread lube if
hole is blind, or with National Oil Seal compound
if hole is through to a cavity subject to oil.
If cotter pin holes must be aligned, set torque
wrench at low limit and tighten nut to first hole
beyond this torque. However, on connecting rod
nuts the torque limits must be maintained. Replace
nut and repeat as required. In no case shall con-
necting rod nuts be torqued below low limit or over
high limit.
TABLE 4
PIPE PLUGS
Size In. Lbs. Ft. Lbs.
1/8-27 60-80 5.0 - 6.7
1/4-18 130-150 10.8 -12.5
3/8-18 185-215 15.4 -18.0
1/2-14 255-285 21.3 - 23.8
3/4-14 310-350 25.8 -29.2
NOTE... .Torque values for pipe plugs are for use with
"Never Seeze" (Snap-On Tool Corp.) on threads.
B-10
TABLE 5
MAGNETIC PARTICLE INSPECTION
FLUORESCENT METHOD PREFERRED,

WET CONTINUOUS PROCEDU RE REQUIRED
*Method of AC or DC Possible
Part Magnetization Ampres Critical Areas Defects
Crankshaft Circular or 2000 Journals, fillets, oil Fatigue cracks, heat

Longitudinal holes, thrust flanges, cracks. Flange cracks
prop flange, from prop strike
Connecting rod Circular or 1500 All areas. Fatigue cracks.

Longitudinal
Camshaft Circular or 1500 Lobes, Journals, Heat cracks,

Longitudinal drilled hole edges. Fatigue cracks
Piston pin Circular or 1000 Shear planes, ends, Fatigue cracks

Longitudinal center.
Rocker arms On Conductor Bar 1000 Pad, socket under Fatigue cracks.
and Single Between side arms and boss.
Heads 800
Gears to 6 inch Circular or 1000 to Teeth, Splines, Fatigue cracks.

diameter on Center 1500 Keyways.
Conductor
Gears over 6 Shaft Circular 1000 to Teet h, Spli nes. Fatigue cracks.
inch diameter Teeth Between 1500
Heads two times
90
Shafts Circular or 1000 to Splines, Keyways Fatigue cracks, heat

Longitudinal 1500 Change of Section. cracks.
Thru Bolts, Circular or 500 Threads Under Head. Fatigue cracks.

Rod Bolts Longitudinal
June1980 B-11
TABLE 6
CRITICAL NEW PART DIMENSIONS
NEW DIMENSION
PART NAME FEATURE (INCHES)
Cylinder Head 642343 Intake Valve Guide Bore 0.43 50 - 0.4371
Standard Intake Valve Guide Bore 0.43 52 - 0.4362
642343 Exhaust Valve Guide Bore 0.437 5 - 0.4395
Standard Exhaust Valve Guide Bore 0.4370 - 0.4380
Valve Rocker Shaft Outside Diameter 0.7490 -0.7495
Valve Rocker Bushings Inside Diameter 0.7 505 -0.7 51 5
Intake Valve Stem Diameter 0.4 33 5 0.4340
Exhaust Valve Stem Diameter 0.4 3 35 -0.4340
Piston (Standard) *Diameter at Top 5.2020 5.2068

* Diameter Below 1st Groove 5.2140 -5.2160
*Diameter at Bottom 5.2394 -5.2404
Pin Bore Diameter 1.1246 - 1.1250
Piston Pin Assembly Length (Including Plugs) 5.2050 - 5.2200

Diameter 1.1243 -1.1245
Connecting Rod Bushing Bore Diameter 1.1267 - 1.1269

Bushing Center-to-Crankpin Center 6.6230 - 6.6270
Crankshaft Assembly Damper Pin Bushing I.D. 0.7540 - 0.7560
Crankshaft Main Journal Diameter 2.6240 - 2.6250
Crankpin Diameter 2.2490 - 2.2500
Reduction Gear Reduction Gear Bearing Diameter 2.6240 - 2.6250
Prop Shaft Gear Prop Shaft Gear Bearing Diameter 2.3 733 -2.3 743
Hole for Transfer Sleeve 0.468 - 0.469
Transfer Tube Sleeve Small Outside Diameter 0.4095 - 0.4705

Large Inside Diameter 0.4973 -0.4980
Camshaft Journal Diameter 1.2480 -1.2490
Crankcase Camshaft Bearing Diameter 1.2500 - 1.2510

Crankshaft Bearing Diameter 2.8160 - 2.8170
Reduction Gear Bearing Diameter 2.8160 - 2.8170
Prop Shaft Bearing Diameter 2.562 5 - 2.563 5
Prop Shaft Oil Transfer Sleeve O.D. 0.469 5 - 0.470 5
Prop Shaft Oil Transfer Sleeve I.D. 0.497 3 - 0.4980
Prop Shaft Oil Transfer Tube Dia. (Both Ends) 0.4965 -0.4960
Prop Shaft Oil Transfer Adapter I.D. 0.4973 -0.4980
Tappet Guides Diameter 1.0005 - 1.0015
Governor Driven Gear Bearing Diameter 0.8750 - 0.8760
B-12 June1980
TABLE 6
CRITICAL NEW PART DIMENSIONS (Continued)
NEW DIMENSION
PART NAME FEATURE (INCHES)
Starter Worm Drive Shaft Small End Diameter 0.5615 - 0.5625
Starter Shaftgear Front Journal Diameter 0.7495 - 0.7500

Knurled Drum Diameter 1.9310 -1.9 320
Clutch Drum Support Diameter 1.3060 - 1.3070
Starter Clutch Spring Outside Diameter 2.3740 -2.3 760
Inside Diameter 1.9380 - 1.9400
Starter Drive Adapter Sleeve Front End I.D. 2.3 380 - 2.3430
Alternator Driven Gear Bushing Inside Diameter 0.9985 - 0.9995
Oil Pump Driver Gear Shaft Diameter 0.5600 -0.5605
Oil Pump Driven Gear Shaft Hole Diameter 0.5030 -0.5040
Oil Pump Housing and Driven Gearshaft Diameter 0.5015 -0.5025

Shaft Assembly Driver Gearshaft Hole Diameter 0.5620 - 0.5630
Gear Chamber Depth 2.623 5 - 2.6250
Magneto Drive Gears Shaft Diameter 0.8120 - 0.81 30
Magneto and Accessory Bushing Inside Diameter 0.8145 -0.815 5

Drive Adapter
Idler Gear Assembly Bushing Inside Diameter 0.8 120- 0.8130
Idler Gear Support Pin Gear Support Diameter 0.8095 - 0 .8 105
Hydraulic Valve Tappets Outside Diameter 0.9990 - 0.999 5
June 1980 B-13

TABLE 7
INSPECTION CHART
SUBASSEMBLY SPECIAL
AND PART INSPECT NATURE OF INSPECTION CONSIDERATIONS
CYLINDER Head/Barrel Discoloration, Seepage Sec Paragraph 6-6.
ASSEMBLY Junction
Head & Barrel
Interior Walls Corrosion, pitting, scoring Defects not permissible
after removal of glaze.
Bore Diameters Wear in ring traversed Refer to Table of Limits

area and step at top. Use for standard size bore or
dial-type gauge set to for oversize bore.
zero near open end of
bore.
After honing or rough- Dimensional honing

ening of glaze measure should remove ring step
diameters, out-of- of more than 0.002 inch
roundness and taper. diameter. Taper limit
(Table of Limits) must
not be exceeded by
honing.
Bore Walls After roughening or Refer to Table of Limits.

honing, inspect scratch
pattern and, if possible,
measure surface rough-
ness in micro inches RMS
as a quality check.
Stern Holes in Scoring, diameters, flare Diameters of stem holes

Valve Guides at ends. in new guides must be
within limits for new
parts and free of tool
marks.
Valve Seats Roughness caused by If seats cannot be made

burning. serviceable by grinding
within width limit, they
must be replaced.
Cooling Fins Cracks and broken areas. Cracked and/or broken

cylinder head fins may be
repaired, providing a
total of not more than
five square inches is, or
has been removed.
Base Flange If attaching nuts were Allow not over 0.001

found loose at dis- inch out-of-flat on
assembly, test for flatness machined surface.
of mounting face.
B-14
SUBASSEMBLY SPECIAL
Head and Barrel Pilot Out-of-roundness of pilot
(Continued) below face flange.
Spark Plug Distortion or improper

Thread Insert fit in cylinder head hole.
Pushrod Hous- Looseness, leakage.

ing Stems
Valve Stems Scori ng, nicks in grooves, Polishing must not

wear on tips. reduce diameter below
minimum for new parts.
Valve Heads Use dial indicator to

determine warp. Make
sure that grinding has not
cut through stellite face
of exhaust valve or
entered rounded edge on
intake valve hood.
Valve Length Use height gauge to Stretched valves may fail.

detect stretch and check Shortened valve may
for reduction due to tip exceed ability of hydra-
grinding. ulic lifters to take up
lash.
Valve Rockers Contact Foot Scoring.
Oil Passages Obstruction.
Hub Side clearance between Refer to Table of Limits.

cylinder head supports.
Rocker Shaft Outside Diameter, scoring.

Surface
CONNECTING
ROD
ASSEMBLY
Bushing Inside Measure with telescoping New bushings must be
Diameter gauge and micrometer reamed within diameter
caliper. limits for new parts.
Sharp edges must be
broken slightly. (Refer to
Table of Limits, for wear
limit, for new bushing
limits and new bushing
alignment limits.)
B-15
SUBASSEMBLY SPECIAL
CRANKSHAFT
ASSEMBLY
Crankshaft Main Journals Diameters, scoring, burn- Must be polished before
ing. magnetic inspection.
Crankpins Diameters, scoring, burn- Must be polished before

ing. magnetic inpsection.
Oil Seal Race Scoring. Must be polished.
Screw Holes Damaged or dirty

threads.
Oil Holes Obstructions.
Bending Measure run-out at center Required only if shaft

journal, end wobble on has been subject to
face of flange. shock.
Crankshaft Teeth. Scoring, burning, pitting,

Gear wear enough to alter
profile.
Gear Dowel Tight Fit Attempt to pull out by

hand only.
Accessory Teeth, Screw Burning, scoring, wear

Drive Gear enough to alter profile.
Damaged or dirty
threads.
PROPELLER
DRIVE SHAFT
Driveshaft Main Diameters, scoring, burn- Must be polished before
Journals ing. magnetic inspection.
Thrust Washer Thickness, excessive wear.
Oil Transfer Fit in driveshaft. Check If worn, replace.

Sleeve, Tube for wear.
and Elbow
Oil Seal Race Scoring. Must be polished.
Gear Teeth Scoring, burning, wear

enough to alter tooth
profile. Also, check for
edge loading.
Propeller Face Check for out-of-square

Mount Flange with shaft.
B- 16
SUBASSEMBLY SPECIAL
CAMSHAFT
ASSEMB LY
Camshaft Journals Diameter and fit in Excessive bearing wear
crankcase bearings. Scor- may be compensated by
ing, pitting and corro- enlarging bearing and
sion. installing oversize shaft.
Refer to "Crankcase".
Lobes Pitting along toe line, loss Serious pitting not

of slope along toe line, permissibe Toe line
width across heel and toe must taper in relation of
at center of length. axis to rotate valve
lifters.
Flange Distortion of threads.

Screw Holes
Edge & Rear Nicks, peening, other Must be smooth to align

irregularities. gear.
Gear Teeth Scoring, burning, pitting,

wear enough to alter
profile.
CRANKCASE
ASSEMBLY
Crankcase Castings Valve Lifter Diameter, scoring.
Guides
Bearing Seats Roughness, wear in tang Refer to Table of Limits.

notches.
Camshaft Diameter, scoring, fit of Excessively worn bear-

Bearings rear bearing between ings may be line bored
camshaft flanges. for 0.020 oversize cam-
shaft.
Oil Passages Inspect visually, galleries,
main and camshaft
bearing supply holes,
using inspector's flash-
light to illuminate. Probe
other oil holes with brass
rod.
Tapped Holes Deformed or dirty

threads.
Studs Threads Distortion.
Height Check for backing out. Refer to Stud Height

Table.
B-1 7
SUBASSEMBLY SPECIAL
Studs (Continued) Squareness Use toolmaker's square Refer to Stud Height
to check studs suspected Table.
of being bent.
Idler Gear
Support and Bore Inside diameter, scoring. Refer to Table of Limits.
Bushings
Needle Bearing Rollers Roughness or excessive

play.
Oil Filler Neck Tightness Attempt to rock and pull Must be tight in casting.
out by hand only.
Oil Gauge Rod Distortion Look for bent blade,

obliterated "FULL" and
"LOW" marks, loose
collar, deformed cap.
Oil Gauge Tightness Attempt to move tube by

Support hand only.
Engine Machined Warpage and scratches.

Mounting Brackets Surfaces
All areas Cracks.
Plugs Threads Look for distortion.
Wrench Flats Look for damaged

corners.
Squirt Nozzles Openings Plugged openings and

foreign particles.
OIL COOLER
ASSEMBLY
Oil Cooler Headers, Fins Inspect visually for dents,
and Core deformed fins, punctures,
stripped plug hole
threads, cracks and
scratches.
Machined Warpage and scratches.

Surfaces
All areas Cracks.
Oil Temperature Seat Roughness.

Control Valve
Bore Inside diameter, scoring.
B- 18
SUBASSEMBLY SPECIAL
OIL SUMP
ASSEMBLY
Casting Tapped Holes Damaged threads, cracks
around holes.
Mounting Scratches, warpage, cracks.

Surfaces
All areas Cracks.
Plugs Threads Look for distortion.
Wrench Flats Look for damaged

corners.
Oil Suction Thread, Damaged threads, dented

Tube Tube Filter tube, cracks in tube,
distorted or plugged
filter.
OIL PUMP
ASSEMBLY
Housing All areas Cracks, scratches on
machined surfaces,
restrictions in oil holes.
Gearshaft Look for scoring, meas- Gears must turn freely.

ure diameter. (Refer to Table of
Limits.)
Plugs Distorted threads, damag-
ed wrenching surfaces.
Gears Shafts Measure diameters and

compare with bushing
diameters.
Gear Tecth Scoring, burning or wear

profile.
Splines Look for wear on side of

splines and residual
sludge.
Gear Bushings Bore Diameters Use telescoping gauge Refer to Table of Limits.
and micrometer caliper.
Oil Pressure Relief Outside Measure diameter. Look

Valve Plunger Surface for scoring, nicks, etc.
Conical Face Roughness. Must seat perfectly in

housing.
B-19
SUBASSEMBLY SPECIAL
Oil Pressure Relief Plunger Seat Spread Prussian blue oil
base pigment on face of
plunger and turn on seat,
all around. Plunger face
must be lapped to seat.
(Plunger held centered
and aligned.)
Oil Filter Threads, Screen Damaged threads, punc-

Filter Cup tured screen, out-of-round
pilot cup.
SCAVENGE PUMP
ASSEMBLY
Housing All areas Cracks, scratches on
machined surfaces.
Gears Shafts Measure diameters and Refer to Table of Limits.

diameters.
Gear Teeth Scoring, burning or wear

profile.
Gear Bushing Bore Diameter Use telescoping gauge Refer to Table of Limits.
and micrometer caliper.
Scavenge Pump All areas Cracks, scratches on

machined surfaces.
STARTER ADAPTER
ASSEMBLY
Adapter All areas Cracks, scratches on
machined surfaces,
damaged tapped holes.
Needle Bearing Rollers Roughness or excessive

play.
Studs Threads Distortion or stripping.
Height Check for backing, out. Refer to Stud Height Table
Alignment Check studs suspected of

bending with toolmaker's
square.
Gears Shafts Measure diameters and Refer to Table of Limits.

comp are with bushing
diameters.
B-20
SUBASSEMBLY SPECI AL
Adapter (Continued)
Gears Gear Teeth Scoring, burning or wear
profile.
Ball Bearing Balls, Cage Surface roughness out-

of-round, excessive depth
and looseness.
Adapter Cover All areas Cracks, scratches on

machined surfaces, da-
maged mounting holes.
Shaft Bearing Look for scoring.
Bore Measure diameter.
Oil Seal See that oil seal was

removed without damage
to casting.
Torsional Unit Visual for damage and

Damper obvious leakage.
ALTERNATOR
Hub Assembly All areas Scored or undersize Refer to Table of Limits.
bearing surfaces.
Spring Damaged or broken.
Gear Look for chipped,

cracked or broken tee th,
scoring, burning and wear
profile.
Gear Bushing Measure bore diameter. Refer to Table of Limits.
Thrust Washer Thickness, excessive wear.

INDUCTION
SYSTEM
Intake Manifold Flanges Check for warpage by
placing flanges on surface
plate. Look for cracks.
Tubes Look for dents, out-of-

round ends, cracks.
Plug Bosses Damaged threads, cracks

around bosses.
B-2 1
SUBASSEMBLY SPECIAL
Clamps Shape Look for distortion, such
as out-of-roundness and
lugs converging.
FUEL INJECTION
SYSTEM
Fuel Pump All areas Cracks, damaged mount-
Adapter ing holes, inspect tapped
holes. Measure bore
diameter.
Fuel Pump Teeth Look for chipped, crack-

Drive Gear ed or broken teeth,
scoring, burning and wear
enough to alter profile.
Shaft Measure outside diameter Refer to Table of Limits.

and compare with bore
diameter.
Gear Plug Make sure that new plug
was installed after mag-
netic particle inspection
of gear and visual
inspection for cleanliness
of center bore.
Drive Coupling Fit Check for looseness.
Fuel Pump and Outside area Inspection is limited Teledyne Continental

Vapor Separator strictly to visual for Motors does not auth-
evidence of damage or orize any diassembly and
deterioration. repair of these units
unless proper equipment
is available. Refer to
Form X-30091 for
overhaul instructions.
Shroud Assembly All areas Inspect visually for dents,
cracks and broken joints.
Air Throttle Tapped Holes Damaged threads, cracks

Assembly around holes.
Studs Bent or stripped stud

threads.
AU areas Cracks.
Shaft Check alignment. Meas- No wear limits establish-

ure diameter. ed.
Plate Check for warpage.
B-22 MARCH 1981

SUBASSEMBLY SPECIAL
Fuel Discharge All areas Look for cracks, flat
Tubes spots, out-of-round ends.
Pipe Fittings Threads Distortion or stripping.
Wrench Flats Look for damaged corn-

ers.
TURBOCHARGERS
Rotor Bearings Check for freedom of Do not disassemble,
rotation. replace unit if damaged.
All areas Visually inspect for any Replace unit if

signs of damage. serviceability is question-
able.
MAGNETO AND
ACCESSORY DRIVE
ASSEMBLY
Adapter Gear bushing Measure bore diameters. Refer to Table of Limits.
Oil Seal Observe that old oil seal

has been removed
without damage to
casting bore.
Studs Look for stripped and

deformed threads.
Gear Teeth Scoring, burning or wear

profile.
Shaft Measure diameters and Refer to Table of Limits.

diameter.
B-2 3
TABLE 8
STANDARD AND OVERSIZE STUD IDENTIFICATION
OVERSIZE ON OPTIONAL IDENTIFICATION IDENTIFICATION

TYPICAL PITCH DIA OF MARKS ON COARSE THREAD END COLOR
TYPICALCOARSE THREAD
PART NO. (inches) STAMPED MACHINED CODE
XXXXXX STANDARD NONE NCNE
XXXXXXP003 .003 RED
XXXXXXPOO6 .006 BLUE
XXXXXXP009 .009 GREEN
XXXXXX007 .007 BLUE
XXXXXXPO12 .012 GREEN
13
FIGURE B-5. CRANKCASE STUD HEIGHTS
B-24
TABLE 9
STUD SETTING HEIGHTS
(See Figure B-5)
SETTING
LOCATION THREAD SIZES HEIGHT QUANTITY
1. Cylinder Mount Pads 7/16-14 x 7/16-20 13/16 24
2. 7/16-14 x 7/16-20 13/16 12
3. Engine Mount Pads 3/8-16 x 3/8-24 3-1/16 1
4. 3/8-16 x 3/8-24 1-3/8 1
5. 3/8-16 x 3/8-24 1-9/32 3
6. 3/8-16 x 3/8-24 2-11/16 4
7. 3/8-16 x 3/8-24 3-11/16 1
8. 3/8-16 x 3/8-24 2-1/4 1
9. 3/8-16 x 3/8-24 4-1/2 1
10. 3/8-16 x 3/8-24 4-5/16 1
11. 3/8-16 x 3/8-24 1-3/4 1
12. Oil Cooler Mount Pad 5/16-18 x 5/16-24 4-1/4 2
13. 5/16-18 x5/16-24 53/64 1
1 4. 5/16-18 x 5/16-24 1-7/16 1
15. Governor Mount Pad 5/16-18 x 5/16-24 1-3/8 4
16. Magneto Mount Pads 5/16-18 x 5/16-24 11/16 4
17. 5/16-18 x 5/16-24 3/4 2
18. 5/16-18 x5/16-24 7/8 4
19. 3/8-16 x 3/8-24 1-3/16 2
20. Idler Pin Pad 1/4-20 x 1/4-28 5/8 2
21. Starter Drive Pad 5/16-18 x 5/16-24 13/16 2
22. Fuel Pump Pad 5/16-18 x 5/16-24 3/4 4
23. Oil Pump Pad 1/4-20 x 1/4-28 6-3/8 5
24. 1/4-20 x 1/4-28 7/8 1
25. 1/4-20 x 1/4-28 2-5/16 2
26. 1/4-20 x 1/4-28 6-1 5/3 2 1
27. Alternator Mount Pad 5/16-18 x 5/16-24 13/16 4
28. Crankshaft Cover 1/4-20 x 1/4-28 11/16 4
29. Camshaft Cover 1/4-20 x1/4-28 11/16 2
Magneto Adapter Assembly 1/4-20 x 1/4-28 7/8 2
Cylinder Studs -
Intake Manifold Flange 1/4-20 x 1/4-28 25/32 3
Exhaust Manifold Flange 1/4-28 x 5/16-18 7/8 4
Oil Pump Housing and
Shaft Assembly 1/4-20 x 1/4-28 3-1/8 2
Cover, Scavenge Pump and
Tachometer Drive 1/4-20 x 1/4-28 3/4 4
Starter Adapter Assembly 3/8-16 x 3/8-24 1 2
B-2 5
TABLE 10
HELICAL COIL AND SPECIAL TOOL DATA
HELI-COIL
Heli-Coil Drilled Special Thread Tang
Thread Part Corp. Hole Tap No. * Plug Installing Tools Break- Heli-Coil
Size t No. Part No. Diameter Rough Fin. Gag Std. Prewind off Tool Extractor
1/4-20 243234 11854 .261-.266 186-4 1874 188-4 7244N 5284N 1195-4 1227-6
5/16-18 24323-5 1185-5 .328-.3 33 186-5 187-5 188-5 724-5N 528-5N 1195-5 1227-6
3/8-16 24323-6 1185-6 .390-.395 186-6 187-6 188-6 724-6N 528-6N 1195-6 1227-6
7/16-14 24323-7 1185-7 .453-.458 186-7 187-7 188-7 724-7N 528-7N 1195-7 1227-16
18 mm 520112 C2-52 .718-.723 2-22 2-21 2-1 - 543 - 1227-16
-For aluminum alloy castings. For number of taps designed for steel refer to the manufacturer's Bulletin No. 650-R.
Teledyne Continental Part Numbers: To basic part number add "B" for phosphor bronze, or "C" for stainless steel. Add -1, -1.5
or -2 for length equal to nominal diameter times 1, 1-1/2 or 2, respectively. (All Teledyne Continental furnished inserts
are
notched.)
Heli-Coil Corporation Part Numbers: To basic part number, as listed, add "B" for phospher bronze, or "C" for stainless steel and
"N" fur a notched insert, if desired. Add "X" and length desired, expressed as a fraction of an inch.
Example: 1185-5CN x 15/32 represents 5/16 - 18 N.C. insert of stainless steel whose length is 15/32 inch. or 1-1/2 times it
nominal diameter.
TABLE 11
CRANKSHAFT AND CRANKCASES
Connterihght
Crankcase Crankshaft Cheek Cheek Pin COUNTERWEIGHT
ENGINE Studding & Damper Loca- Bushing Conn. Conn.
MODEL Assembly Assml tion Bushing Rod Rod
I.D. 630261- Dia. Assy.A t re ID. Assy. Bearing
GTSIO- 520-C 642132
GTSIO-520-D
.756 .4906 .756
642133 635104 2.5.8 34
.4902 631810 6 3 .754 632043 630826
GTS IO-520-H
GTSIO 520 L
642135
GTSIO-520-M
GTSIO-520-N 643724
B-26 OCTOBER 1980

TABLE 12
TABLE OF LUBRICANTS
MATERIAL OR
ITEM APPLICATION TRADE NAME COMPANY
1 All moving parts and bearings Corrosion-preventive Various
except following: compound
2 Crankshaft oil seal lip, all Molyshield grease American Lubricants Company
synthetic rubber oil seals, Dayton, Ohio 45400
valve stem in guides and
crankshaft thrust bearings.
3. All tapered pipe threads, all Thread lubricant and Snap-On Tools Corporation
fuel injector nozzles, sealing compound 8049 - 28th Avenue
connecting rods and nuts. Kenosha, Wisconsin 53140
4. Valve stem ends, valve rocker Grade 30 Aviation Various

arm feet, connecting rods lubricating oil
and crankshaft bearings, all
gears, valve rocker shafts,
piston pin in piston, piston
rings and piston.
5. Fuel injection linkage. Dry lubricant Dri-Slide Sales

1 Industrial Park
Fremont, Michigan 49412
6. All studs, all press-type plugs. National Oil Sealer Standard Pressed Steel Co.
Highland Avenue
Jenkinstown, Pennsylvania
7. Magneto Adapter Assembly Loctite retaining Loctite Corporation

compound 1 15 North Mountain Road
All pipe thread fittings Loctite Hydraulic Newington, Connecticut 06111
on fuel pump, manifold Sealant
valve, metering unit and
pressure regulator.
8. Idler pin gaskets, oil drain Tightseal Radiator Specialty Company

back tubes, oil filler neck. Charlotte, N. Carolina 28200
9. All contacting surfaces No. 50 Silk Thread, Various

between bodies and covers Grade "A"
where gaskets are not
specified. No. 3 Aviation Permatex Company, Inc.
Permatex 1720 Avenue Y
Brooklyn, New York 11200
Low viscosity
10. Flushing of oil cooler. Various
lubricating oil
11. Engine storage. Preservative oil Viscosity Oil Company

Chicago, Illinois 60600
B-27/B-28
CHAPTER C
SECTION I
DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-520-C
Overhaul and test procedures for the model While certain parts may have a different part
covered in this section are the same as those for the number and different physical characteristics (for
basic engine except for the specific differences example, the reduction gears) their function is the
noted in this section. The essential differences are a same as those in the basic engine, and all
lower horsepower rating and a different redirection inspection, repair or replacement procedures will
ratio. Specific differences are the induction system be the identical to those in the basic engine
and fuel injection system. section. For this reason those parts will not be
covered separately herein.
See Service Bulletin M77-20 Rev 1 Prestolite 24 Volt Delco 24 Volt - 50 Amp Bendix
C-1-1
GENERAL INFORMATION -GTSIO-520-C.
The engine is geared, turbocharged, six-cylinder, pump, low pressure, multi-nozzle, continuous flow
fuel injected, horizontally opposed and developes fuel injection system, pressure type intake
340 horsepower at 2400 propeller RPM. Installed manifold piping, integral oil pump and externally
on each engine are two magnetos, twelve spark mounted oil cooler, starter, and various adapters,
pl ugs, ignition harness and wiring, primer clamps and brackets for mounting these items on
distribution lines and fittings, engine-driven fuel the engine.
DETAIL ENGINE SPECIFICATIONS.
Model................................. GTSIO-5 20-C
Rated Horsepower at 3200 RPM (2400 Prop RPM) ............... .... ... 340
Limiting Manifold Pressure. ... (Sea Level,Inches Hg. at 3200 RPM)......... ....... 34.5
(Critical Altitude, Inches Hg.) ........... ....... 34.5
Maximum Recommended Cruise Horsepower at 2800 RPM (2100 Prop RPM)..... .... ... 255
Limiting Manifold Pressure. ... (Sea Level, Inches Hg. at 2800 RPM)......... ....... 29.0
(Critical Altitude, Inches Hg.) ........... ....... 29.0
Propeller Drive Ratio........................... ... 0.750:1
Propeller Shaft Rotation (Looking forward) Clockwise'
Propeller Attachment (Flange) ......... ..... ...... ... .. ... .. APR 502Type I
Bore, Inches ................ . . . . .. .. .. . .. .. . . . . . . . . . . . . . . . 5 .2 50
Stroke, Inches ............... 4.000
Displacement, Cubic Inches .......... 520
Compression Ratio.............. . . .. . . .. .. .. . .. . . . . . . . . . . . . . . . 7 .5 :1
Oil SAE Number Above 40 F. ........ ... .. .. ...

... ... .. ... .. SA E N o. 50
Below 40 F.......... ......... 10W3 0 Multi-Viscosity or SAE No. 30
Oil Sump Capacity . . . . . . . . . . . . . . .. . . .. . .. .. . . . . . . . . . . . . . . . . 13 Qts.
Fuel, Aviation Grade, Octane (Minimum). 100/130
Fuel System ................ .......... Continental Fuel Injection
Fuel Injector................ .....

.... .... .... Continental Fuel Injection
Magneto Drive, Ratio to Crankshaft ......... 1.5:1
C- 1-2
Magnetos (1) Bendix S61-N-201 ......................... Clockwise*
(1) Bendix S6LN-205 ......................... Clockwise*
Tachometer Drive, Ratio to Crankshaft..........................5:1

Rotation...........................Clockwise*
Starter Drive, Ratio to Crankshaft...........................3 2:1

Rotation..........................Counterclockwise*
Generator Drive, Ratio to Crankshaft .......................... 3:1

Rotation ........................... Clockwise*
Vacuum Pump Drive, Ratio to Crankshaft........................1.5:1

Rotation ...................... Counterclockwise*
Vacuum Pump Drive, (Deice)............................ 1.5:1

Rotation ....................... Counterclockwise*
Vacuum Pump Drive, (Autopilot) .......................... 1.5:1

Propeller Governor Drive, Ratio to Crankshaft ..................... 0.809:1

Rotation........................Clockwise*
Spark Plug - See Service Bulletin M77-1 0...........................
Spark Occurs (Degrees BTC) Both Magnetos ....................... 220
Spark Plug Gap...............................0.016 -0.018
Firing Order.................................1-4-5-2-3 -6
Fuel Pressure (Lbs. Per Sq. Inch)

Maximum...................................18.0
minimum....................................2.5
Oil Pressure (Lbs. Per Sq. Inch)

Normal ............................. (See Operating Limits)
Maximum....................................100
Idling (Minimum) ................................ 10
Oil Temperature (F)

Normal....................................1700
Maximum...................................240'
Cylinder Head Temperature (0 F)

Maximum...................................4600
Minimum (Takeoff)...............................200-
Standard Engrine Dry Weight (Lbs.) .......................... 509
0Direction of rotation facing engine drive pad.
C-1 -3
OPERATING TEST LIMITS
(a) Run-In Schedule .................... 2 Hrs. 15Min.
(b) Maximum Rated RPM and Tolerance ............ 3 175-3225 RPM
(c) Fuel Flow Limits.................... 215-225 Lbs./Hr.
(d) Fuel Pump Pressure Limits ................ 3 0.0-3 3.0 PSI
(e) Metered Fuel Pressure Liniits ............... 16.5-17.5 PSI
(f) Oil Consumption at Maximum Rated Power ......... 3.00 Lbs./Hrs. Maximum
(a) Oil Grade to be used................... SAE No. 50
(h) Propeller Transfer Leakage with 225-240' F- Oil

at 200-220 PSI (Move crankshaft slowly during reading). 0.05-0.50 Lbs./Min.
(j) Fuel Grade to be used.................. 100LL(Blue) or 100(Green)
(k Idling RPM and Tolerance ................ 600 ± 24 RPM
(I) Manifold Pressure at Maximum Rated Power ......... 34.3" to 34.7" Hg.
Manifold Pressure at Idle................. 15.9" to 18.0" Hg.
(in) Magneto Spread at 2400 RPM............... 50 RPM Maximum
(n) Crankcase Pressure*................... 4.0" H 2 0 Maximum
(p) Oil Temperature .................... 240 F. Maximum

Oil Temperature - Desired Range.............. 150-200 F.
7 0 to 100 F.
(r) Engine Intake Air Temperature (S/C Inlet)..........
(s) Oil Pressure at Maximumi Rated Power
(Engine Oil Temperature 1750 - 185 F.)........... 5 0-60 PSI (On 24-6 Side)
Oil Pressure at Idle
(Engine Oil Temperature 140 - 150 F.)........... 30 PSI Minimum
(t Timing of Engine and Tolerance .............. Left: 22 BTC ± 1

Right: 220 BTC ± 10
(u) T/C Air Inlet Air Pressure................. 1.0" H2 0 Maximum
(v) T/C Air Outlet Pressure ................. 36.0" Hg. Maximum
(w) T/C Exhaust Outlet Pressure ............... 3.0" Hg. Maximum Ref.
(x) Cylinder Headed Temperature............... 460 F. Maximum

(At Bayonet Thermocouple)
C-1-4
(y) Normal Rated Power....................340 BHP at 3200 RPM
. A sudden increase in crankcase pressure, during which the liquid in the manometer fluctuates rapidly, is usually an indication of
rings beginning to stick. However, before removing cylinders, investigate the breather and manometer.
NOTE. ... Turbocharger inlet air may be regulated to provide engine operation within Test Limits.
MAJOR OVERHAUL TEST RUN
TIC Outlet PR. "Hg

Time - Minutes RPM (Reference)
5 1200
10 1500
10 2100
10 2600
10 2800
10 3000
5 3200±25 100 %Power 35.0 -36.0
5 * 3000 82.3 % Power - (280 BHP) 34.7 - 3 5.7
5 * 2600 5 3.5 % Power -(1 82 BHP) 34.4 - 3 5.4
10 600 ± 25 Idle Cooling Period
NOTE . .. Engine oil pressure must be supplied to NOTE . .. Stop engine, drain oil, weigh in oil for
propeller transfer tube during all testing. oil consumption determination and replace in
engine.
START OIL CONSUMPTION DETERMINATION
T/C Outlet PR. "Hg.

Time - Minutes RPM (Referen ce)
10
30 **3200 ± 25 100 % Power
5 t 2400 Check magnetos
NOTE .. . Stop engine, drain oil, weigh and record value in excess of 3.00 lbs-/hr. is determined, rerun
engine oil consumption. Oil consumption at the one hour. If oil consumption is still excessive,
rate of 3.00 lbs./hr. maximum is acceptable. If return engine to overhaul.
Magneto spread to be taken after completion of oil consumption run. Engine must be throttled to specified RPM and temperature
allowed to settle out before taking magneto spread.
* See fuel charts for actual RPM.
**Readings must be recorded after completion of each 15 minutes interval during oil consumption run.
C-1-5
FUEL INJECTION SYSTEM (See Figure C-1-1) and replacement of any of these parts could allow
small metal shavings to become lodged in the
a. Disconnect six fuel discharge tubes (1) equipment causing a malfunction.
from manifold valve (5) and nozzles (3). Compress
spring legs of each clamp (2) and remove clamp. If it should be necessary to replace any connection
Disconnect hose assembly (6) from manifold valve or fitting, use only a fuel soluble thread lubricant.
and junction box. Remove nozzles (3) and washers
(4). Store in a clean container. a. Place shroud (23) and control assembly
(21) under throttle (26) and attach with three
NOTE...- Further disassembly of the nozzles or screws (19) and tab washers (20). Tighten screws
any applicable fuel injection system component and bend ear of tab washers to flat side of hex
should not be further disassembled unless flow test head on screw. Attach shroud (18) to shroud (23)
equipment is available. with screws (17).
b. Remove cotter pin (7) washer (8) and wave b. Place wave washer (15) on rod end (16)
washer (9). Remove nut (10), rod end (1 1) and and insert into throttle lever. Install washer (14)
spring (1 2). Remove cotter pin (13), washer (14), and co tter pin ( 13).
wave washer (1 5) and link rod (14).
c. Slide spring (12) onto link rod (16). Install
c. Remove four screws (1 7) and me tering unit rod end (11) and secure with elastic stop nut (10)
shroud (18). Use a screwdriver and pry down the slide wave washer (9) over rod end (11) and insert
locking ears of tab washers (20) and remove along rod end into control lever. Install washer (8) and
with screws (19). Control unit (21) and shroud cotter pin (7). Adjustment of linkage will be
(23) are now free to be removed. established at final assembly.
d. The throttle and lever assembly (26) will be d. The nozzles, clamps, brackets and discharge
removed with the induction system. tubes will be installed in accordance with in-
structions in the basic engine section.
e. Remove six screws (29), nut (30) and fuel
pump shroud (3 1). Remove four sets of attaching e. The fuel pump will be installed in accord-
parts (33, 34, 35) and pull off fuel pump (36). ance wtih instructions in the basic engine section
Remove coupling (45), gasket (42) and gear unless the pump to be installed is of the old style.
assembly (43, 44). Parts indexed (37 thru 41) are In that instance proceed in the following manner.
no longer used with the current production pump. Lubricate fuel pump drive gear assembly (43, 44)
If they are to be re-used, the oil seal (40) must be and install in crankcase. Coat both sides of gaskets
replac ed. (42) with tite-seal compound and install on mount-
ing studs. Coat both sides of gaskets (39, 37) with
CLEANING, INSPECTION AND REPAIR tite-seal compound and install adapter (41) gasket
(39) insulator (38) and gasket (37). Install pump
a. Parts may be cleaned in Stoddard solvent (36) and secure with four sets of attaching parts
or equivalent and rinsed in mineral spirits. Dry (3 5, 34, 33).
with filtered air.
NOTE. . Mounting studs for the old style pump
b. Inspection and Repair is limited to visual must be P/N 401814 installed to 1.31 inch
unless proper flow equipment is available. If extension. The new pump studs are to be P/N
equipment is avalabe use procedures outlined in 402151 installed to .75 inch extension.
Fuel Injection Overhaul Manual Form X-30091.
INDUCTION SYSTEM (See Figure C-1-2)
REASSEMBLY
a. Loosen two hose clamps (1) sleeves (2) and
CA UTION ... The fuel injection equipment is remove air throttle assembly (3). Remove flexible
calibrated with plugs and fittings intact. Removal hose (4) from riser tube (5).
C-1-6
b. Remove crankcase breather hose and of flexible hose (4). Install clamps (1) over sleeves
eighteen sets of attaching parts (6, 7, 8). Induction and slide onto end of riser (5). Secure flexible hose
system can now be lifted off and disassembled on onto riser. Slide air throttle assembly (3) into
the bench. Remove and discard six gaskets (9). flexible hose (4) and tighten clamp assembly (1, 2).
c. Loosen hose clamps (10, 14 and 18) and h. Install seal (30) on sleeve (27). Connect air
separate induction tubes, balance tube and riser. manifl tubes (25, 26) to sleeves. Connect
Remove hoses from components. junction box (24) to air manifold tubes (25, 26).
Install junction box to fuel pump tube (2 3).
d. Disconnect tube (23) from air junction
fitting(24). Disconnect the 1-3-5 side air manifold CRANKCASE See Figure C-1-3.
tube (25) and the 2-4-6 side air manifold tube (26)
from the junction fitting (24) and sleeves (27). Except for the crankcase breather hoses and lifting
eyes and the location of the fuel manifold valve,
e. Remove sleeves (27) and washers (28, 29). the instructions for the crankcase as described in
Seal (30) may be removed if necessary. the basic engine section will apply.
CLEANING, INSPECTION AND REPAIR a. Remove clamp (1), hoses (2, 3) and tee (4).
Remove two screws (5), nuts (6), washers (7),
Cleaning, Inspection and Repair will be in accord- spacers (8) and lifting eye(9). Remove two screws
ance with the basic engine manual. (10), nuts (11), washers (12) and remove lifting
eye (13).
REASSEMBLY
b. Installation is in reverse order of dis-
a. Turn engine stand so engine is in upright assembly.
position.
b. Slide sleeve assembly over nozzle and MAGNETO AND ACCESSORY DRIVES.
install rubber washer (28) and plain washer (29).
Connect fuel discharge tubes. a. On the 1-3-5 side, remove four sets of
attaching parts,(1, 2, 3) cover (4) and gasket (5).
c. Place a new gasket (9) on the intake flange
of each cylinder. Loosely assemble intake tubes b. Remove three sets of attaching parts (6, 7,
(16, 17, 21) with hose (1 1) and clamps (14). Slide 8) one set of attaching parts (9, 10, 11) adapter
the assembled tubes over the intake port studs and (12) and gasket (13). Using arbor press remove
secure with three sets of attaching parts (6, 7, 8). bushing (14) and seal (1 5) from adapter.
d. Repeat procedure for intake tubes on 1-3-5 c. Remove magneto and accessory drive gear
side. and sleeve assembly (16, 19) coupling bushings
(17) and retainer (18).
e. Slide hoses (19) and clamps (18) onto ends
of balance tube (22) far enough to permit d. The 24-6 side will be removed using the
connecting balance tube to intake tubes (20, 21). same procedure.
Equally space hoses and tighten clamps.
CLEANING, INSPECTION AND REPAIR.
f. Loosely assemble riser tube (5) and tubes
(12, 13) with hoses (1 1) and clamps (10). Slide the Cleaning, Inspection and Repair will be the same as
remaining two hoses (1 1) and clamps (1 0) over the the basic engine section.
ends of tubes (15, 16). Slide tube assemblies (5,
12, 13) in place, space hoses and tighten clamps. REASSEMBLY.
g. Slide hose clamp sleeve (2) over each end Assemble in the reverse order of disassembly.
C- 1-7
TURBOCHARGER OIL INLET ADAPTER. Intake and exhaust lifters can be readily identified
by the width of the groove around their outside
It has been demonstrated that it is possible to diameter. See diagram below.
crack the turbocharger oil inlet adapter (Teledyne
Continental Motors' P/N 628675) and cause an oil
leak by improperly torqueing the retaining bolts or
.281
by overtorqueing the steel inlet oil line fitting. To
preclude the possibility of this occurring, the
adapter material has been changed from aluminum
to steel and the new part is P/N 640793.
628488
This product improvement was incorporated on all Intermittent Feed Lifters, (Intake)
new production and remanufactured engines
assembled on and after August 10, 1973. Engines
having the following serial numbers and all
subsequent have the steel adapter incorporated:
New Engine Remanufactured

Engine Model Serial Number Engine Serial Number 641709
GTSIO-5 20-C 602002 155 371 Continuous Feed Lifters (Exhaust)
Engines having serial numbers prior to those listed

above must have the turbocharger oil inlet adapter
P/N 628675 replaced by steel adapter P/N 640793.
The change in the exhaust rocker arm is in the
IMPROVED VALVE STEM AND GUIDE LUBRI- angle of the squirt hole which results in pstv
CATION. lubrication of the valve stem. See below.
To provide better lubrication to exhaust valve

stems and exhaust valve guides, improved exhaust
rocker arms and exhaust lifters are now in
production on all GTSIO-5 20 engines. The purpose
of this change is to increase valve guide service life
and it is recommended that these new parts be Old Style P/N 639576
installed at the next top or major overhaul.
Old P/N New P/N

639576 Rocker Arm Assembly 640941
See Bulletin M72-14
628488 Lifter Assembly 641709

(Intermittent Feed) (Continuous Feed) New Style P/N 640941
Care must be taken to make certain these new These new parts went into production on the
parts are installed in the exhaust location. The following engine serial numbers and all subsequent.
intake lifter assemblies and rocker arms have not Remanufactured
been changed and, therefore, remain in their same Engines Engines
location. GTSIO-520-C 602004 155 376
C-1-8 June 1980

45
FIGURE C-1-1. FUEL INJECTION SYSTEM

1. Tube, Fuel Discharge 16. Rod, Link 32. Grommet
2. Clamp, Fuel Discharge Tube 17. Screw 33. Nut, Hex
3. Nozzle Assembly 18. Shroud, Top 34. Washer, Lock
4. Washer, Copper 19. Screw 35. Washer, Plain
5. Valve, Fuel Manifold 20. Washer, Tab 36. Pump, Fuel and Vapor
6. Tube 21. Control Separator
7. Pin, Cotter 22. Bumper, Shroud * 37. Gasket
8. Washer, Plain 23. Shroud, Bottom * 38. Insulator, Fuel Pump
9. Washer, Wave 24. Nut, Tinnerman * 39. Gasket
10. Nut, Elastic Stop 25. Grommet * 40. Seal, Oil
11. Rod End, Special 26. Throttle Body * 41. Adapter, Fuel Pump
12. Spring 27. Nut, Castle 42. Gasket
13. Pin, Cotter 28. Pin, Cotter 43. Gear, Fuel Pump
14. Washer, Plain 29. Screw 44. Plug
15. Washer, Wave 30. Nut, Tinnerman 45. Coupling
31. Shroud, Fuel Pump 46. Brackets
C-1-9
FIGURE C-1-2. INDUCTION SYSTEM
1. Clamp, Hose 17. Tube Assembly, Intake Manifold,

2. Sleeve, Hose Clamp No. 3 and 4 Cylinders
3. Throttle Assembly, Air 18. Clamp, Hose
4. Hose, Flexible 19. Hose, Balance Tube
5. Tube Assembly, Riser 20. Tube Assembly, Intake Manifold
6. Nut, Hex No. 5 Cylinder
7. Washer, Lock 21. Tube Assembly, Intake Manifold,
8. Washer, Plain No. 6 Cylinder
9. Gasket, Intake Manifold Flange 22. Tube, Balance
10. Clamp Assembly, Hose 23. Tube Air, Junction-Box-to-Fuel Pump
11. Hose, Intake Manifold 24. Box, Junction
12. Tube Assembly, 1-3-5 Side 25. Tube, Air Manifold, 1-3-5 Side
13. Tube Assembly, 2-4-6 Side 26. Tube, Air Manifold, 2-4-6 Side
14. Clamp, Hose 27. Sleeve Assembly, Injection Nozzle
15. Tube Assembly, Intake Manifold, 28. Washer, Rubber
No. 1 Cylinder 29. Washer, Plain
16. Tube Assembly, Intake Manifold, 30. Seal
No. 2 Cylinder
C-1- 10
FIGURE C-1-3. CRANKCASE ASSEMBLY
1. Clamp, Breather Hose 6. Nut 10. Bolt
2. Hose 7. Washer 11. Nut
3. Hose 8. Spacer 12. Washer
4. Tee Breather 9. Eye, Engine Lifting, Front 13. Eye, Engine Lifting, Rear
5. Screw
C-1-11
19
16
11
3 21
FIGURE C-14. MAGNETO AND ACCESSORY DRIVES
1. Nut, Hex 11. Washer, Plain

2. Washer, Lock 12 Adapter, Accessory
3. Washer, Plain 13. Gasket
4. Cover 14. Bushing
5. Gasket 15. Seal, Oil
6. Nut, Hex 16. Gear
7. Washer, Lock 17. Bushing, Coupling
8. Washer, Plain 18. Retainer
9. Nut, Hex 19. Sleeve
10. Washer, Lock
C-1-12
FIGURE C-1-5. FUEL MANIFOLD VALVE FITTING LOCATIONS
A B I c D E
0
GTSIO 520-C PLUG 90 Elbow (1800)NIPPLE, UNION 45 EIbow -
C-1-13
2700
180, D
r
FIGURE C-1-6. CONTROL VALVE FITTING LOCATIONS
A B C D E
Mixture Fuel Inlet
Return and Fuel
To Pump Pressure Conn. Outlet
0
9 El bow (1 80)
GTSIO-520-C PLUG NIPPLE -
RED UCER -
PLUG
TEE
NIPPLE
(180)
-
NIPPLE -
REDUCER -
CONNECTOR - CONNECTOR- CONNECTOR -
C-1-14
F
A
C
0
B
FIGURE C-1-7. FUEL PUMP FITTING LOCATIONS
A B C D E F
900 Elbow 900 Elbow 900 Elbow

GTSIO-520-C 90 Elbow 0
(75) (90) (285) (345) PLUG (9 E lbow (0)
Connector Connector Connector
C-1 -15
FIGURE C-1-8.
CRANKCASE STUD SETTING HEIGHTS
Setting
Location Thread Sizes Heights Model "C"
1. Magnego & Accessory
Drive Adapter 5/16-18 x 5/16-24 3/4 6
2. Magncto & Accessory

Drive Adapter 3/8-16 x 3/8-24 13/16 2
3. Engine Mount Legs 3/8-16 x 3/8-24 1-11/32 3
C- 1-16
CHAPTER C
SECTION II
DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-520-D
Overhaul and test procedures for the model major differences between the "D" model and the
covered in this section are the same as the basic engine model. The fuel injection system and
procedures for the basic engine except for the the induction system are covered completely in
specific differences noted herein. There are no this section.
0 "
633090
1 637847 632590 63 3091 632188 633274--4 634735A1
633090
2 637847 632590 633091 632188 63 3274-4 635089A1
633090
3 637847 633091 636414 632188 63 3274-4 634735A1
4 637847 633090 636414 632188 633274-4 635089A1

3091
633090
5 637847 633091 632188 63 3274-4 634735A1
6 637847 633091 632188 63 3274-4 635089A1
63 3090
9 637847 633091 632188 63 3274-4 634735A1
633090
10 637847 633091 632188 63 3274-4 635089A1
633090 1
21 637847 633091 632188 633274-4 639624A2
633090 1
22 637847 633091 632188 63 3274-4 639623A2
®) See Service Bulletin M77-20 Rev 1.

(c) Spec 21 & 22 have single stage pump. When ordering fuel pump for Specs 1 thru 10, ascertain whether or
not Fuel System has been converted.
(2) Prestolice 24 Volt a Delco 24 Volt - 50 Amp ® Bendix
C-2-1
GENERAL INFORMATION -GTSIO-520-D.
fuel injected, horizontally opposed and developes fuel injection system, pressure type intake
on each engine are two magnetos, twelve spark mounted oil cooler, intake air intercooler, starter
plugs, ignition harness and wiring, primer and various adapters, clamps and brackets for
distribution lines and fittings, engine-driven fuel mounting these items on the engine.
Propeller Drive Ratio............................... 0.667:1
Propeller Shaft Rotation (Looking Forward) .. ........ ... Clockwise*
Propeller Attachment (Flange) ........ ... .. ...... .. ... .. .. APR 502 Type I
Bore, Inches ............... . . .. . . . .. .. . . . . . . . . . . . . . . . . 5 .2 5 0
Stroke, Inches ........... .I .... ....... ... . . .. ... . .. . . . . 4 .000
Displacement, Cubic Inches ...... . .. .. . .. .. .. . . . . . . . . . . . . . . . . . . . 520
Compression Ratio.......... . . . . .. .. . .. .. .. . . . . . . . . . . . . . . . . . 7 .5 :1
Turbosupercharged (Maximum RPM) .. . . . . . . .. .. .. .. . .. .. .. .. . . . . .. . . .. .. . 7 5 ,0 00
Oil SAE Number Above 400 F. .... . . . . . . ... ...

... ... .. ... ... ... .. SA E N o. 50
Below 400 F...... . . . . . . ............ 10W30 Multi-Viscosity or SAF. No. 30
Oil Sump Capacity.......... . . . . . . ...... .. .. .... .. . .. . .... . .. . . . l3 Qts.
Fuel, Aviation Grade, Octane (Minimum) Low Le ad Fuels approved for use). .. 100LL(Blue),100(Green)
Fuel System ............ ...... ..........

..... ..... Continental Fuel Injection
Fuel Injector............ ...... .....

..... ..... .... Continental Fuel Injection
Magneto Drive, Ratio to Crankshaft ... . .. . .. .. .. .. . .. .. . . . . . . . . . . . . . . . . 1 .5 :1
Magnetos (1) Bendix S6LN-1 201 (Left Magneto on LH and RH Engines) ......... Clockwise*
(1) Bendix S6LN-1205 (Right Magneto on LH and RH Engines)........Clockwise*
Tachometer Drive, Ratio to Crankshaft......................5 .1

Starter Drive, Ratio to Crankshaft...........................32. 1

Alternator Drive, Ratio to Crankshaft ................. I........3:1

Rotation ........................ Clockwise*
C-2-2 June 1980

DETAIL ENGINE SPECIFICATIONS (Continued)
Vacuum Pump Drive, Ratio to Crankshaft.......................1.14:1

Vacuum Pump Drive, (Deice)............................1.14:1

Rotation ...................... Counterclockwise'
Vacuum Pump Drive, (Autopilot)..........................1.14:1

Propeller Governor Drive, Ratio to Crankshaft ...................... 809:1

Spark Plug Type, AC ............................... AC 273
Breaker Point Setting (Both Magnetos)....................20' BTC
Spark Plug Gap............................... 0.017 - 0.018
Firing Order.............................14-5-2-3-6
Fuel Pressure (Lbs. Per Sq. Inch) Unmetered @450 Propeller RPM ............. 6.0 PSI
Auxiliary Pump Resistor @ 450 Propeller RMP ..... 5.5 ± .25 PSI
Maximum Metered Fuel Pressure 3 9.5 " Hg MP & 2 2 75 Propeller R PM ...... 16.0)- 17.0 PSI
Metered Fuel Pressure Shown Here is Referenced to Compressor Discharge Pressure
Minimum Auxiliary Pump Pressure Switch @ 450 Propeller RPM..........4.0 ± .25 PSI

Normal ............................. (See Operating Limit)
Maximum ................................... 100
Idling (Minimum) ................................ 10
Oil Temperature (- F)
Normal....................................1700
Maximum...................................2400

Maximum...................................460'
Minimum (Takeoff)...............................200'
Standard Engine Dry Weight (Lbs.) ......................... 550.39

*Direction of rotation facing engine drive pad.
C-2-3
OPERATING TEST LIMITS.
(a) Run-In Schedule .................... 2 Hrs. 25 Min.
(b) Maximum Rated RPM and Tolerance ............ 3375 - 3425 RPM
(c Fuel Flow Limits.................... See Page C-2-14
(d) Fuel Pump Pressure Limits ................ See Page C-2- 15
(c Metered Fuel Pressure Limits ............... See Page C-2-16
(f) Oil Consumption ® Maximum Rated Power.......... 1.0 Lb./1/2 Hr. Maximum
(g) Oil Grade to be used................... SAE No. 50
(h) Propeller Transfer Leakage with 225 - 240 F.

Oil at 200-220 psi (Move Crankshaft slowly during reading) 0.05 - 0.50 Lbs./Min.
(k) Idling RPM and Tolerance ................ 700 ± 25 RPM
(I) Manifold Pressure @ Maximum Rated Power ......... 39.3 -39.7

@Idle................. 15.9 - 18.0
(n) Crankcase Pressure * .................. 4.0"' H 2 0 Maximum

Oil Temperature -Desired Range ............. 1500-2000 F.
(r) Oil Pressure at Maximum Rated Power

(Engine Oil Temperature 1750 - 185' F.).......... 50 - 60 psi (On 24-6 Side)
(Engine Oil Temperature 140' - 1500 F.).......... 30 psi Minimum
(S) Timing of Engine and Tolerance .............. Left: 200 BTC ± 1

Right: 20 BTC ± 10
(t T/C Air Inlet Air Filter Pressure Drop............ 6.0" H 2 0 Maximum
(u) T/C Air Outlet Pressure ................. 43.0" Hg. Maximum
(v) T/C Exhaust Outlet Pressure ............... 1.0" Hg. Maximum Ref.
(W Cylinder Head Temperature................ 460 F. Maximum

(x) Normal Rated Power .................. 375 BHP at 3400 RPM
C-24 June 1980

OPERATING TEST LIMITS (Continued)
(y) Power Correction for Intake Air Temperature:......... . 1% per 6 F.

Correct H.P. for TIC Inlet Air Temperature as follows:
(1) Add 1% for each 6 F. hotter than 60 F.
(2) Subtract 1% for each 6 F. colder than 60 F.
A sudden increase in crankcase pressure, during which the liquid in the manometer fluctuates rapidly, is usually an indication of
NOTE ... Turbocharger inlet air may be regulated to provide engine operation within Test Limits.
SPECIAL TEST ITEMS REQUIRED OR AE7010201 J 0310, (filter to oil cooler) No. AE
EQUIVALENT. 7010201 J 03 10, Oil Filter and adapter AC
External oil lines (oil pump to filler) Aeroquip No. 6435 853 Type OF 103A.

GTSIO-520-D
T/C Outlet PR. "Hg
Period Time - Minutes RPM (Reference)
1 5 1200
2 10 1500
3 10 2100
4 10 2600
5 10 2800
6 10 3000
7 10 3200
8 5 3400± 25 100% Power 42.0 -43.0
9 5 *3000 68.5% Power (257 BHP) 34.8 - 35.8
10 5 *2600 44.8% Power (168 BHP) 33.5 -34.5
11 10 600 ± 25 Idle Cooling Period
NOTE ... Engine oil pressure must be supplied to NOTE ... Stop engine, drain oil, weigh in oil for
engine.

GTSIO-520 D
T/C Outlet PR. "
12 10 Warm-Up
13 30 ** 3400 ± 25 100% Power
14 5 t 2400 Check Magnetos
NOTE. ... Stop engine, drain oil, weigh and record excess of 1.00 lbs./l/2 hr. is determined, rerun one
engine oil consumption. Oil consumption at a rate hour. If oil consumption is still excessive, return
of 1.00/1/2 hr. maximum isacceptable. Ifvalue in engine to overhaul.
Magneto drop to be taken after completion of oil consumption run. Engine must be throttled to specified RPM and temperature
allowed to settle out before taking magneto drop.
Readings must be recorded after completion of each 15 minute interval during oil consumption run.
C-2-5
FUEL INJECTION SYSTEM (See Figure C-2-1) latest pump, it will also require some airframe
modification. (See Cessna Service Letter
DISASSEMBLY ME71-13). New crankcase mounting studs, fuel
pump drive gear (50, 51) and coupling (52) will
a. Disconnect six fuel discharge tubes (1) also be required.
spring legs of each clamp (2) and remove clamp. CLEANING, INSPECTION AND REPAIR
Manifold valve to mixture control hose and
mixture valve to fuel pump hoses are customer Precedures listed in the basic engine section will
supplied and may have been removed. If not, they apply.
may be removed at this time. Remove nozzles (3)
and washers (4); store in a clean container. REASSEMBLY
NOTE. ... Further disassembly of nozzles should CA UTION ... Use only a fuel soluble thread
not be attempted unless flow-test equipment is lubricant on any fuel injection system connection
available. or fitting.
NOTE. . . Air Throttle Assembly, Metering and a. Install gasket (32) and controller (31) onto
Mixture Control Assembly and Controller air throttle body (36) and secure with attaching
Assembly are calibrated as an integral unit, and parts (29, 30).
b. Attach adapter (24) and retainer (25) to
b. Remove cotter pins (6), washers (7), wave shroud (23). Install controller (28) and shroud (26)
washers (8), and remove link rod assemblies (9 thru on air throttle body and secure with tab washers
13) and (14 thru 18). (22) and screws (21). Secure tab washer to screw.
Install shroud (23) on shroud (26) and secure with
c. Remove sheet metal screw (19), speed screws (19) and speed nuts (20).
washer (20), bolt (21) and tab washer (22),
separate shroud (23, 24, 25, 26) and control c. Install link rod assemblies (9 thru 13) and
assembly (28) from air throttle body (36). (14 thru 18) using washers (7) wave washers (8)
and cotter pins (6).
d. Remove sheet metal screws (37) speed nuts
(38) and remove shroud (39) from fuel pump (44). d. Lubricate fuel pump drive gear and install
in crankcase. Coat both sides of gasket (49) and
e. Remove attaching parts (41, 42, 43) and install on crankcase studs. Lubricate coupling (52)
pull fuel pump (44) and gasket (49) from crank- and install in fuel pump drive gear. Install fuel
case studs. Remove fuel pump drive gear and plug pump (44) and secure with attaching parts (41, 42,
assembly (50, 51) and coupling (52). 43).
f. If parts marked (*) are a part of fuel pump e. If either the original pump (64) or the later
installation the pump is no longer available. If the single stage pump is used, it will be necessary to
pump is serviceable and is to be reused, the install adapter (48) gaskets (45) and insulator (46).
associated parts are still available as replacement
parts. In the event that the pump must be replaced, f. Install grommets (40) in shroud (39) and
the fuel pump drive gear will also need to be install on fuel pump. Secure with screws (37) and
replaced and the coupling will have to be added. It speed nuts (38).
will also be nccessary to replace the crankcase
mounting studs. The extension for the new stud g. Install copper washer (4) on base threads of
will be .75 compared to the 1.31 for the old pump. nozzle (3) and install in cylinder. Slide sleeve over
nozzle. Install rubber washer and plain washer over
g. Pump and shroud parts (53 thru 64) were nozzle and seat on sleeve. Connect fuel discharge
original equipment on specifications 1 thru 10. If it tubes (1). Install a clamp (2) over each discharge
is neccssary to replace a pump of this type with the tube and insert spring legs of clamp in bracket (65).
C-2-6
INDUCTION SYSTEM (See Figure C-2-2) INDUTIO
SYSEM
SeeigueC-2)TURBOCHARGER
OIL INLET ADAPTER.
DISASSEMBLY It has been demonstrated that it is possible to

a. Parts (1 thru 7) were removed prior to Continental Motors' P/N 628675) and cause an oil
removing engine from aircraft. leak by improperly torqueing the retaining bolts or
by overtorqueing the steel inlet oil line fitting. To
b. Remove attaching parts (8, 9 and 10, 11) preclude the possibility of this occuring, the
and lift intercooler (14). Remove gasket (15). adapter material has been changed from aluminum
c. Bracket (16) is retained by nut and
lockwasher This produce improvement was incorporated on all
d. Loosen clamps (18) and slide hose assembled on and after August 10, 1973. Engines
connectors (19) onto intake tubes (23). having the following serial numbers and all
Remove intake manifold assembly (17). subsequent have the steel adapter incorporated:
e. Remove nuts (20), lockwashers (21) and New Engine Remanufactured

plain washers (22) and lift off intake tubes (23) Engine Model Serial Number Engine Serial Number
and flanges (24). Remove gaskets (25). GTSIO-520-D 601006 219162
f. Remove air manifold tubes (26, 27, 28), Engines having serial numbers prior to those listed
fuel pump to air manifold tube (29) and air above must have the turbocharger oil inlet adapter
manifold fitting assembly (30). Disconnect fuel P/N 628675 replaced by steel adapter P/N 640793.
nozzle sleeves (31).
CLEANING, INSPECTION AND REPAIR. IMPROVED VALVE STEM AND GUIDE

LUBRICATION.
Procedures in basic engine section will apply.
REASSEMBLY. stems and exhaust valve guides, improved exhaust
rocker arms and exhaust lifters are now in
a. Install flanges (24) on intake tubes (23) production on all GTSIO-520 engines. The purpose
and loosely assemble intake tubes to spider mani- of this change is to increase valve guide service life
fold (17). Place a gasket (25) on the intake port and it is recommended that these new parts be
flange of each cylinder. Locate spider manifold and installed at the next top or major overhaul.
intake tubes assembly and secure with attaching
parts (20, 21, 22). Adjust hoses and clamps to Old P/N New P/N
proper positions and tighten clamps. 639576 Rocker Arm Assembly 640941
See Bulletin M72-14
b. Install bracket (16) on two upper inside
magneto adapter studs. Lubricate seal (15) and 628488 Lifter Assembly 641 709
install intercooler (14). Secure to intake manifold (Intermittent Feed) (Continuous Feed)
assembly with screw (8) and washer (9). Secure to
bracket (16) with insulator (13) sleeve (12) plain Care must be taken to make certain these new
washer (11) and bolt (10). parts are installed in the exhaust location. The
intake lifter assemblies and rocker arms have not
c. Place seal (32) on nozzle sleeve and attach been changed and, therefore, remain in their same
sleeves to air manifold tubes (26). Attach tubes location.
(27, 28) to air manifold tubes and junction box
(30). Install tube assembly (29) to junction box Intake and exhaust lifters can be readily identified
(30) and fuel pump. by the width of the groove around their outside
June 1980 C-2-7

dizmeter. See diagram below. diameter.
lubrication
See
diagram
below.
of the valve stem. See below.
I 1 ~~.281
628488
Intermittent Feed Lifters (Intake) Old Style P/N 639576
.438
New Style P/N 640941

641709
Continuous Feed Lifters (Exhaust) These new parts went into production on the
following engine serial numbers and all subsequent.
Ncw R emanu fact ured

The change in the exhaust rocker arm is in the Engines Engines_
angle of the squirt hole which results in positive GTSIO-520-D 601008 194538
C-2-8 June 1980

1. Tube, Fuel Discharge 23. Shroud, Top 45. Gasket
2. Clamp, Fuel Discharge Tube 24. Adapter, Elbow 46. Insulator
3. Nozzle Assembly 25. Retainer 47. Seal, Oil
4. Washer, Copper 26. Shroud, Bottom 48. Adapter, Fuel Pump
5. Valve, Fuel Manifold 27. Bumper, Rubber 49. Gasket
6. Pin Cotter 28. Control Assembly 50. Gear, Fuel Pump
7. Washer 29. Screw 51. Plug
8. Washer, Wave 30. Washer 52. Coupling
9. Nut, Elastic Stop 31. Controller 53. Screw
10. Rod End, Special 32. Gasket, Controller 54. Nut
11. Nut 33. Bushing 55. Shroud, Upper
12. Spring 34. Lever 56. Shroud, Lower
13. Rod and Link Assembly 35. Pin, Tubular 57. Shroud, Side
14. Nut, Elastic Stop 36. Air Throttle 58. Clamp, Hose
15. Washer 3 7. Screw 59. Grommet
16. Rod End, Special 38. Nut 60. Grommet
17. Spring 39. Shroud, Upper 61. Nut, Plain Hex
18. Rod and Link Assembly 40. Grommet 62. Washer, Lock
19. Screw 41. Nut, Plain, Hex 63. Washer, Plain
20. Nut, Typej 42. Washer, Lock 64. Fuel Pump
21. Screw 43. Washer, Plain 65. Brackets
22. Washer,.Tab 44. Fuel Pump
C-2-9
3
3:.
1. Coupling, Channel Band 18. Clamp

2. Sleeve, Channel Band 19. Hose
3. Turbocharger 20. Nut, Plain, Hex
4. Clamp 21. Washer, Lock
5. Sleeve 22. Washer, Plain
6. Air Throttle 23. Tube, intake
7. Duct, Air Induction 24. Flange, Intake
8. Screw 25. Gasket, Intake
9. Washer, Copper 26. Tube, Air Fuel Nozzle
10. Screw 27. Tube, Air Manifold No. I Side
11. Washer 28. Tube, Air Manifold No. 2 Side
12. Sleeve 29. Tube Asscmbly, Air
13. Insulator 30. Fitting, Air Manifold
14. Inter-cooler 31. Sleeve Assembly, Injection Nozzle
15. Seal 32. Seal
16. Bracket 3 3. Washer, Rubber
17. Manifold, Intake 34. Washer, Plain
C-2-10
27
1800
Do
1800
FIGURE C-2-3. FUEL MANIFOLD VALVE FITTING LOCATIONS
I A lI B I I DI I
GTSIO-520 03 900 Elbow (3400) 1900 Elbow (200) iNIPPLE, UNION 1450 Elbow 1900 Elbow (110c)
C-2-11
00
2700.90 901)
161.1-
FIGURE C-24. CONTROL VALVE FITTING LOCATIONS
A S C 0 E
Mixture Fuel Inlet
Return and Fuel
900 Elbow (1800) NIPPLE-

GTSIO-520-D PLUG ADAPTER - PLUG EE. CON9NECTOR ADAPTER-
0
450 Elbow (3Q ) 450 Elbo (4 Elbow (00)
450
C-2-12
0a
,27 n 0
1800
D
E
1800
I I ~~~~Al B Ic D E
GTSIO-520-D TEE (300) 450 Elbow (00) CONNECTOR PLUG 900 Elbow (00)
June1980 C-2-13
i llIIl~I
111111111 IIlii I
11pu11lpilipiq11111 I11111 ii ll I
ii 111111111 ii111 I 11 IJ
I
FUEL FLOW LIMITS FOR GTSIO-520-D ENGINES
CHART INSTRUCTIONS:
1. Obtain actual maximum rated RPM.
- 2. Determine required RPM forl100%, 68.5%, and 44.8% power by reading directly above-
the artiiml mAyirnim r~atprl RPM nrnint
3. Determine fuel flow limits for100%. 68.5%, and 44.8% power by reading directly above
the actual maximum rated RPM point.
-EXAMPLE:
100% Power RPM 3400 ± 10, Flow Limits 250 - 260 lbs./hr.
6-8.5% Power RPM 3000 ±.10. Flow Limits 137 -144 lbs./hr.
44.8% Power RPM 2600 ± 10, Flow Limits 90 - 96 lbs./hr.
(a) This chart is based on 701F. injector fuel temperature. For every 100F. increase in
injector inlet fuel temperature, subtract 1 lb. of fuel from the curve value. For every
10cF. decrease in iniector inlet fuel temnerature. add 1 lb. of ftial to the tijrve vslue
I I I
. ILimit
L .. High
E
U)=
I-
L
LOW L~i
-C -90
I 2575 2600 2625
:naine IPM for 44.8% Power
z -145-
z
~LL -1 40*
-135-
2975 3000 3025
Engine RPM for 68.5% Power
-260-
0 t - 255-
-250-
335 3400 3425
Engine RPM for 100% Max. Rated Power.

El
I II I It
~~~~~~~~I
_tm=bE =to=t =n =t= hi

Ili iIII
hn ~I
- -------
idIII nIIII
1LLLtiI lihI I ~ I ,II mI TH
diiitL
-
C-2-14 June 1980
100% POWER FUEL PUMP PRESSURE LIMITS FOR GTSIO-520-D
NOTE: This data to be used when checking pressure at fuel pump outlets with
gage vented to atmospheric pressure.
CHART INSTRUCTIONS:
2. Determine fuel pressure limits for 100% maximum power by reading
directly above actual maximum rated RPM point.
- EXAMPLE: 100% Power Fuel Pump Pr. Limits @ 3400± 10 RPM, 30.5 - 35.0 PSI.
NOTE: Idle (600 + 25 RPM) Pump Pr. 5.75- 6.25 PSI.
35 __U
-1- -33t-
a~ .
~E 32- __
0 7
- - _ _ _ _ _ _ -3 1 - _ _ _ _ _ __ _
L.o' LUMIT
-- 30- ____ _
3375 3400 3425
LJ~~m
~u ~ ± WI 'I '" ~
June 1980 C-2-15

C21
111111111 Ii 111111111 11lIl1lI1111 1111111111 lii 111111111 11111111 liii 11111 lii 11111111111111 11111
11111iii Ill I liii Iii 111111
-1 I I I II I II I I I II I I II
I I I I
METERED FUEL PRESSURE LIMITS FOR GTSIO-520-D ENGINES
CHART INSTRUCTIONS:-
1 Obtain actual maximum rated RPM.__
-
2. Determin reuied RPM for 100%. 68.5% and 44.8% power by reading directly above
3.Determine metered fuel pressure limits for 100%, 68.5%, and 44.8% maximum power
by reading directly above actual maximum rated RPM point.
EXAMPLE: 100% power 3400 t_ 10, Metered Fuel Pr. Limits 16.5 - 17.5 PSI,
NOTF- Mpti-ri-r Fuejl Prpessutre Limit-, at 1600 + 25 RPM)Idle. 3.5 -40 P.S.I
4 U_ 2575 2600 2625
____ ~~Engine RPM for 44.8% Power_____ __
6 CL ~~~~HighILimitI I
Q) 2(5n300 I 305
Engine RPM for 68.5% Power
Q)IL 18.0 _ _ _ _ _ _ _ __
7.
LL 33753400
16.0 3425
____ _____
____ ~Engine RPM for 100% Max.~
C-2-16 C-2-16
June 1980
CHAPTER C
SECTION III
DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-520-H
Overhaul and test procedures for the model Section. The fuel injection system and the
covered in this section are the same as the induction system for this model are covered
procedures for the basic GTSIO-520 except for the completely in this section.
specific differences noted by this Difference Data
See Service Bulletin M77 20 Rev 1 (3 Prestolite 24 Volt cZ, Bendix
C- 3-1
GENERAL INFORMATION - GTSIO-520-H.
fuel injected, horizontally opposed and develops fuel injection system, pressure type intake
plugs, ignition harness and wiring, primer and various adapters, clamps and brackets for
distribution lines and fittings, engine-driven fuel mounting these items on the engine.
Propeller Drive Ratio............. ..... ..... ..... ..... ..... .... 0.667:1
Propeller Shaft Rotation (Looking Forward). ........ .... ... .... .... ... C lockw ise*
Propeller Attachment (Flange) ......... APR 502 Type I
Bore, Inches ................ . . . . .. . .. . . .. .. . . . . . . . . . . . . . . . 5.2 50
Stroke, Inches ............... . . . . .. . . ... .... . . . . . . . . .. . . . . 4.0 0 0
Displacement, Cubic Inches .......... . .. .. . .. .. .. . . . . . . . . . . . . . . . ... 5 20
Compression Ratio.............. .. . .. . .. .. .. . . . . . . . . . . . . . . . . . 7 .5 :1
Turbosupercharged (Maximum RPM) ...... . . .. ... . .. . .. .. .. .. . . .. .. . .. . 7 5,00 0
OilSANumber Above 40' F. ........ ....... .... .... ... .... ... SA E N o. 50
Below 40 F.......... .......... 10W30 Multi-Viscosity or SAE No. 30
Oil Sump Capacity.............. 13 Qrs.
Fuel, Aviation Grade, Octane (Minimum) (Low Lead Fuels approved for use). . 100LL(Blue) or 100(Green)
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . .. Continental Fuel Injection
Fuel Injector .......... ................ Continental Fuel Injection
Magneto Drive, Ratio to Crankshaft..........................1.5:1
Magnetos (1) Bendix S6LN 1201 (Left Magneto on LH and RH Engines) ......... Clockwise*
(1) Bendix S6LN-1 205 (Right Magneto on LH and RH Engines).........Clockwise*
Tachometer Drive, Ratio to Crankshaft ......................... 5 1

Rotation...........................Clockwise'
Starter Drive, Ratio to Crankshaft...........................32:1

C-3-2
Alternator Drive, Ratio to Crankshaft..........................3:1

Vacuum Pump Drive, Ratio to Crankshaft.......................1.14:1

Vacuum Pump Drive, (Deice)............................1.14:1

uum Pump D Rotation ...................... Counterclockwise*
Vacuum Pump Drive, (Autopilot)..........................1.14:1

Propeller Governor Drive, Ratio to Crankshaft.....................0.809:1

Spark Plug Type, AC ............................... AC 273
Spark Occurs (Degress BTC) Both Magnetos......................200 BTC
Spark Plug Gap............................... 0017 -0.018
Firing Order ................................. 14-5-2-3-6
Fuel Pressure (Lbs. Per Sq. Inch) Unmetered @450 Propeller RPM ............. 6.0 PSI
Auxiliary Pump Resistor ® 450 Propeller RMP .. ... 5.5 -. 25 PSI
Maximum Metered Fuel Pressure @ 39.5" Hg MP & 2275 Propeller RPM ...... 16.0 -17.0 PSI
Metered Fuel Pressure Shown Here is Referenced to Compressor Discharge Pressure
Minimum Auxiliary Pump Pressure Switch @450 Propeller RPM..........4.0 ± .25 PSI

Normal.............................(See Operating Limits)
Maximum ................................... 100
Idling (Minimum).................................10
Oil Temperature (F)

Normal....................................1700
Maximum...................................240'
Cylinder Head Temperature (F)

Maximum...................................4600
Minimum (Takeoff)...............................2000
Standard Engine Dry Weight (Lbs.)......................... 550.39
Direction oF rotation facing engine drive pad.
June 1980 C-3-3

OPERATING TEST LIMITS.-
(b) Maximum Rated RPM and Tolerance ............ 3375 - 3425 RPM
(c) Fuel Flow Limits.................... See Page C-3-15
(d) Fuel Pump Pressure Limits ................ See Page C-3-16
(e) Metered Fuel Pressure Limits ............... See Page C-3-17
(f Oil Consumption @Maximum Rated Power.......... 1.0 Lb./1/2 Hr. Maximum
(g) Oil Grade to be used . . . . . . . . . . . . . . . . . . SAE No. 50

() Fuel Grade to be used.................. 100LL(Blue) or 100(Green)
(k) Idling RPM and Tolerance................. 700 ± 25 RPM
(1) Manifold Pressure @Maximum Rated Power .,......... 39.3 - 39.7

@Idle................. 15.9 - 18.0
(n) Crankcase Pressure * .................. 4.0" H20 Maximum

Oil Temperature - Desired Range ............. 150-200 F
(r Oil Pressure at Maximum Rated Power

(Engine Oil Temperature 175 - 185 F.).......... 50 - 60 psi (On 24-6 Side)
(Engine Oil Temperature 140 - 150 F.).......... 30 psi Minimum
(s) Timing of Engine and Tolerance .............. Left: 200 BTC ± 10

w) Cylinder Head Temperature................ 460 F. Maximum

(x Normal Rated Power .................. 3 75 BHP at 3400 RPM
C-3-4 June 1980

(y) Power Correction for Intake Air Temperature: ... .. ..... 1% per 6 F.
Correct H.P. for T/C Inlet Air Temperature as follows:
* A sudden increase in crankcase pressure, during which the liquid in the manometer fluctuates rapidly, is usually an indication of
NOTE.-. Turbocharger inlet air may be regulated to provide engine operation within Test Limits.
-
SPECIAL TEST ITEMS REQUIRED OR AE7010201 J 0310, (filter to oil cooler) No. AE
EQUIVALENT. 7010201 J 0310, Oil Filter and adapter AC
External oil lines (oil pump to filler) Aeroquip No. 6435853 Type OF103A.

GTSIO-520-H
T/C Outlet Pr. "Hg
5 1200
10 1500
10 2100
10 2600
10 2800
10 3000
10 3200
5 3400 ± 25 100% Power 42.0 - 43.0
5 * 3000 68.5% Power - (257 BHP) 34.8 -35.8
5 * 2600 44.8% Power - (168 BHP) 3 3.5 - 34.5
NOTE ... Engine oil pressure must be supplied to NOTE. .. Stop engine, drain oil, weigh in oil for
engine.

GTSIO-5 20-H
/C Outlet PR. "Hg.
12 10 Warm-Up
13 30 ** 3400 ± 25 100% Power
14 5 t 2400 Check Magnetos
NOTE. ... Stop engine, drain oil, weigh and record excess of 1.00 lbs./1/2 hr. is determined, rerun one
of 1.00/1/2 hr. maximum is acceptable. If value in engine to overhaul.
**Readings must be recorded after completion of each 15 minute interval during oil consumption run.
C-3-5
FUEL INJECTION SYSTEM (See Figure C-3-1) replaced and the coupling will have to be added. It
will also be necessary to change the crankcase
DISASSEMBLY mounting studs. The extension for the new stud
will be .75 inch compared to 1.31 inch for the old
a. Disconnect six fuel discharge tubes (1) stud.
spring legs of each clamp (2) and remove clamp. CLEANING, INSPECTION AND REPAIR.
The manifold valve to mixture control hose and
mixture valve to fuel pump hoses are customer Procedures as listed in the basic engine section will
supplied items. They should have been removed; if apply.
not, do so at this time. Remove nozzles (3) and
washers (4); store in a clean container. REASSEMBLY. (See Figures C-3-3, C-3-4, C-3-5)
NOTE. ... Further disassembly of nozzles should CA UTION... Use only a fuel soluble thread
not be attempted unless flow-test equipment is lubricant on any fuel injection system connection
available. or fitting.
NOTE .. . Air Throttle Assembly, Metering and a. Assemble fuel pressure regulator (20) and
Mixture Control Assembly and Controller bracket (16) to air throttle body (54) using
Assembly are calibrated as an integral unit, and attaching parts (14, 15). Connect tube assembly
should not be disassembled unless necessary. (23) and parts (6 thru 13) in order shown to
regulator assembly.
b. Remove and disassemble parts (6 thru 13).
Disconnect tube assembly (23). Remove three b. Install gasket (50) and controller assembly
screws (14) and washers (15); lift off fuel pressure (49) onto throttle body (54) using attaching parts
regulator assembly (20) and bracket (16). (47, 48).
c. Remove cotter pins (24), washers (25), c. Attach adapter (42) and retainer (43) to
wave washers (26) and remove rod and link shroud. Install shroud (44) and control assembly
assemblies (27 thru 31) and (32 thru 36). (46) on throttle body. Secure with tab washers
(40) and screws (39). Bend up ears of tab washers.
d. Remove attaching parts (47, 48) and Install shroud assembly (41) and secure with
separate controller assembly (49) and gasket (50) screws (37) and speed nuts (38).
from air throttle body.
d. Install link rod assemblies (27 thru 3 1) and
e. Remove sheet metal screw (37), speed (32 thru 36) in order shown with wave washers
washers (38), bolt (39) and tab washer (40); (26) plain washers (25) and cotter pins (24). Final
separate shrouds (41 thru 44) and control assembly adjustment of rod linkage will be established at
(46) from air throttle body (54). final assembly.
e. Lubricate fuel pump dirve gear and install
f. Remove sheet metal screws (60, 61), speed in crankcase. Coat both sides of gasket (73) and
nuts (64) and shroud (62) from fuel pump (68). install on crankcase studs. Lubricate coupling (76)
and install in fuel pump drive gear. Install fuel
g. Remove attaching parts (65, 66, 67) and pump (68) and secure with attaching parts (65, 66,
pull fuel pump (68) and gasket (73) from crank- 67). If the old style pump is to be used it will be
case studs. necessary to press a new seal (71) in adapter (72)
and mount on crankcase studs. Coat both sides of
h. If parts marked (*) are a part of fuel pump gaskets (69) and install with insulator (70) on
installation the pump is no longer available. If the studs.
pump is serviceable and is to be re-installed on the
engine, those parts marked (*) are available as f. Insert grommets (63) in shroud and install
replacement parts. In the event the pump must be on fuel pump. Secure with screws (61) and speed
replaced , the fuel pump drive gear will have to be nuts (64).
C-3-6
g. Install copper washer (4) on base thread of install intercooler (14). Securc to intake manifold
nozzle (3) and install nozzle in cylinder. Slide assembly with screw (8) and washer (9). Secure to
sleeve (3 1, Fig. C-3-2) over nozzle. Install rubber bracket with insulator (13), sleeve (12), plain
washer (33 Fig. C-3-2) and plain washer (34, Fig. washer (11) and bolt (10).
C-3-2) over nozzle and seat on sleeve. Connect fuel
discharge tubes (1) to nozzles and fuel manifold c. Place seal (32) on nozzle sleeve and attach
valve (5). Install a clamp (2) on each fuel discharge sleeves to air manifold tubes (26). Attach tubes
tube and insert spring legs of clamp in bracket (27, 28) to air manifold tubes (26) and junction
(78). box (30). Install tube assembly (29), junction box
to fuel pump.
INDUCTION SYSTEM (See Figure C-3-2)
d. Install rod and link assemblies (27 thru 3 1)
DISASSEMBLY and (32 thru 36), in order shown, with attaching
parts (24, 2 5, 26). Final adjustment of rod linkage
a. Parts (1 thru 7) were removed prior to will be established at final assembly.
removing engine from aircraft.
IMPROVED VALVE STEM AND GUIDE
b. Remove attaching parts (8, 9 and 10,11) LUBRICATION.
and lift intercooler (14). Remove gasket (1 5).
c. Bracket (16) is retained by nut and lock- stems and exhaust valve guides, imp roved exhaust
washer (6, 7, Figure C-3-3). rocker arms and exhaust lifters are now in
production on all GTSIO-520 engines. The purpose
d. Loosen clamps (18) and slide hose of this change is to increase valve guide service life
connectors (19) onto intake tubes (23). Remove and it is recommended that these new parts be
intake manifold assembly (17). installed at the next top or major overhaul.
e. Remove nuts (20), lockwashers (21) and Old P/N New P/N
plain washers (22) and lift off intake tubes (23)
and flanges (24). Remove gaskets (25). 639576 Rocker Arm Assembly 640941
Sec Bulletin M72-14
f. Remove air manifold tubes (26, 27, 28),
628488 Lifter Assembly 641709
fuel pump to air manifold tube (29) and air mani-
(Intermittent Feed) (Continuous Fccd)
fold fitting assembly (30). Disconnect fuel nozzle
sleeves (3 1).
Care must be taken to make certain these new
CLEANING, INSPECTION AND REPAIR parts are installed in the exhaust location. The
intake lifter assemblies and rocker arms have not
Procedures as written in basic engine section will been changed and, therefore, remain in their same
location.
apply.
REASSEMBLY Intake and exhaust lifters can be readily identified

by the width of the groove around their outside
a. Install flanges (24) on intake tubes (23) diameter. See diagram below.
and loosely assemble intake tubes to spider mani-
fold (17). Place a new gasket (25) on the intake
part flange of each cylinder. Locate manifold and
tubes assembly and secure with attaching parts (20, .281
21, 22). Adjust hoses and clamps to proper
positions and tighten clamps.
b. Install bracket (16) on two upper inside 628488

magneto adapter studs. Lubricate seal (15) and Intermittent Feed Lifters (Intake)
June1980 C-3-7
These new parts went into production on the
following engine serial numbers and all subsequent.
New Remanufactured
Engines Engines
GTSIO-520-H 600245 218059
641709 TURBOCHARGER OIL INLET ADAPTER

Continuous Feed Lifters (Exhaust)
It has been demonstrated that it is possible to
Continental Motors' P/N 628675) and cause an oil
leak by improperly torqueing the retaining bolts or
The change in the exhaust rocker arm is in the by overtorqueing the steel inlet oil line fitting. To
angle of the squirt hole which results in positive preclude the possibility of this occurring, the
lubrication of the valve stem. See below. adapter material has been changed from aluminum
This product improvement was incorporated on all

assembled on and after August 10, 1973. Engines
having the following serial numbers and all
subsequent have the steel adapter incorporated:
Old Style P/N 639576
New Remanufactured
Engine Engine
Engine Model Serial No. Serial No.
GTS 10- 520-H 600119, 218047
600137
Engines having serial numbers prior to those listed

above must have the turbocharger oil inlet adapter
New Style P/N 640941 P/N 628675 replaced by steel adapter P/N 640793.
C-3-8 June 1980

25
27
19 j
23
FIGURE C-3-1. FUEL INJECTION SYTEM
C-3-9
1. Trube, Fuel Discharge 39. Screw
2. Clamp, Fuel Discharge Tube 40. Washer, Tab
3. Nozzle Assembly 41. Shroud Assembly, Top
4. Washer, Copper 42. Adapter, Elbow
5. Valve, Fuel Manifold 43. Retainer
6. Tube Assembly, Air 44. Shroud Assembly, Bottom
7. Reducer, Tee 45. Bumper, Rubber
8. Gasket 46. Control Assembly
9. Tee 47. Screw
10. Nut 48. Washer, Lock
11. Tee 49. Controller Assembly
12. Union, Tee 50. Gasket
13. Tube Assembly, Air Pressure 51. Bushing
14. Screw 5 2. Lever
15. Washer, Plain 5 3. Pin, Tubular
16. Bracket 54. Air Throttle Assembly
17. Screw 55. Pin, Cotter
18. Washer, Plain 56. Nut
19. Nut, Self-Lock 57. Gasket
20. Regulator Assembly, Fuel Pressure 58. Nipple
21. Nipple Assembly, Restrictor 59. Plug
22. Nipple 60. Screw
23. Tube Assembly 61. Screw
24. Pin, Cotter 62. Shroud
25. Washer, Plain 63. Grommet
26. Washer, Wave 64. Nut, Type J
27. Nut 65. Nut, Hex
28. Rod End, Special 66. Washer, Lock
29. Nut 67. Washer, Plain
30. Spring 68. Fuel Pump
31. Rod and Link Assembly *69. Gasket
32. Nut * 70. insulator
33. Washer, Plain *71. Seal, Oil
34. Rod End, Special 172. Adapter, Fuel Pump
3 5. Spring 73. Gasket
36. Rod and Link Assembly 74. Gear, Fuel Pump
37. .Screw 75. Plug
38. Nut, Type J 76. Coupling
77. Brackets
C-3- 10
14
5
'4
1. Coupling, Channel Band 18. Clamp

2. Sleeve, Channel Band 19. Hose
3. Turbocharger 20. Nut, Plain, Hex
4. Clamp 21. Washer, Lock
5. Sleeve 22. Washer, Plain
6. Air Throttle 23. Tube, Intake
7. Duct, Air Induction 24. Flange,Intake
8. Screw 25. Gasket, Intake
9. Washer, Copper 26. Tube, Air Fuel Nozzle
10. Screw 27. Tube, Air Manifold No. 1 Side
11. Washer 28. Tube, Air Manifold No. 2 Side
12. Sleeve 29. Tube Assembly, Air
13. Insulator 30. Fitting, Air Manifold
14. Inter-cooler 31. Sleeve Assembly, Injection Nozzle
15. Seal 32. Seal
16. Bracket 33. Washer, Rubber
17. Manifold, Intake 34. Washer, Plain
C-3 -11
00
2700.
2700
1800O
FIGURE C-3-3. CONTROL VALVE FITTING LOCATIONS
A B C D E
Mixture Fuel Inlet
Return and Fuel
0
900 Elbow (18O ' NIPPLE -
GTSIO-520-H- PLUG TEE (30 ) PLUG TEE, ADAPTER -
eeConnector (400 450 Elbow (001
C-3-12
no
nO A
1800
2700
E
i 800
FIGURE C-3-4. MANIFOLD VALVE FITTING LOCATIONS
I I ~~~ 81
~~Al cD E
GTSIO-520-H 900 Elbow 434Q0) 900 Elbow (200) NIPPLE, UNION 450 Elbow 900 Elbow i 1100)
C-3- 13
Do
A
D
B
00
B
/ 10
I0~~~~~~~~~~~~~~70
2700.
90go
EE E
C- 3-14
. .... - .. - ..... ... .. . ... ... .. - - II.. ..... .. . .... .. ... .... ... .. .. .. . I ... .. . ..I .. ... . . ...... .. . ... .. .... . I... . .. .. ... . .. . ... ..
I iIIIHIIHiIII IHIIIiiPHIII Ylly ll 111111!1111! IiIy u p upul1111111111p ullu 111111
I
FUEL FLOW LIMITS FOR GTSIO-520-H ENGINES
CHART INSTRUCTIONS:
2. Determine required RPM for 100%. 68.5%, and 44.8% power by reading directly above-
3. Determine fuel flow limits for I100%. 68.5%, and 44.8% power by reading directly above__
- ~~~the
actual maximum rated RPM point.
__EXAMPLE:
100% Power RPM 3400 ± 10, Flow Limits 250 - 260 lbs./hr.
- ~~68.5% Power RPM 3000 + 10, Flow Limits 137 - 144 lbs./hr.
- ~~~44.8% Power RPM 2600 ±+10, Flow Limits 90 - 96 lbs./hr.
(a) This chart is based on 701F. injector fuel temperature. For every 101F. increase in
injector inlet fuel temperature, subtract 1 lb. of fuel from the curve value. For every
101F, decrease in injector inlet fuel temperature, add 1 lb. of fuel to the curve value.
I 1 .^I- I I I
I
I
HighILimit
2
U-
n- -95
z
D -0
LL
Io~
0_R Qa --- I
0 I
0 I
-J 257EI 726 00 2625 I
Engine RPM for 44.8% Power -I -
;z
-145- -High LimitI
U-6
U.
.0 1 A^f
In
LoW Limit
E
2975 30100 I 3025'l
Engine RPM for 68-5% Power
I
I I
I _t=
High Limit I
-260-
0-"
LL- -255- I
oU
-250- LOVV Limit I

- ----- I
3375 3400 -V=
I
Engine RPM for 100% Max. Rated Power.
I I I
I I I
I ftm El~I E±1 =±E17TtF Tt7 I I I I~~~~~~~~~~~~111r
wi
June 1980 C-3-15
C31
100% POWER FUEL PUMP PRESSURE LIMITS FOR GTSIO-520-H
NOTE: This data to be used when checking pressure at fuel pump outlets with
gage vented to atmospheric pressure.
CHART INSTRUCTIONS:
2. Determine fuel pressure limits for 100% maximum power by reading
directly above actual maximum rated RPM point.
EXAMPLE: 100% Power Fuel Pump Pr. Limits © 34001 10 RPM, 30.5 - 35.0 PSI.
NOTE: Idle (6001 25 RPM) Pump Pr. 5.75- 6.25 PSI.
- ~
I ~ ~ ~ ~ 3
I { .~~~~ _
10)
-31 - _ _ _ _ _ _ _ _ _
3375 3400 3425
Tfl-~ ~ t_____ __dm__ ___________
C-3-16 C-3-16
.June 1980
K -
IIHIIII IIIII! I1111 II III IIIIII III 11III III III Ifj
T1 -I I
I1111 II11111 III II11111
I I I
III II IM LL111-1-LITHTF17H1111110 III II IIII 11III11111 III H
I I
METERED FUEL PRESSURE LIMITS FOR GTSIO-520-H ENGINES
-- I I I
CHART INSTRUCTIONS:
1.Obtain actual maximum rated RPM.
2. Determine required RPM forl100%, 68.5% and 44.8% power by reading directly above
3.Determine metered fuel pressure limits for 100%. 68.5%, and 44.8% maximum power
by reading directly above actual maximum rated RPM point.
EXAMPLE: 100% power 3400 ±. 10, Metered Fuel Pr. Limits 16.5 - 17.5 PSI.
hIifiT;:-KMjatorc~-ri Pii Proq c i iro I imitc n t tArY) + 9F; RPPA rIpPl-
IH -4a0 P S;I
(L.-6.0-
Z>d57 60 22
Z_-
Z_- 10.07_0_
-0 :- -8.0-1-
'i 2575
LL 3000 3025
W ~~~Engine RPM for 648.% Power _
- -18.0 __
a, ~~~~~~HghLimit
17.0Low Limit -
OD 29'375 3400 3425

_____ ____ ~~Engine RPM for 6800% Max:r
F:
- !111
I I I I I~~~~~~~~~~~~~~~~~~~~~~~~~II
June 1980 C-3-

1980
June 17/C-3-18
CHAPTER C
SECTION IV
DIFFERENCE DATA SECTON FOR THE MODEL GTSIO-520-K
Overhaul and test procedures for the model specific differences noted by this Difference Data
covered in this section are the same as the Section.
procedures for the basic GTSIO-520 except for the
See Service Bulletin M77-20 Rev 1
CA-4-
GENERAL INFORMATION - GTSIO-520-K.
The engine is geared, turbocharged, six-cylinder, fuel injection system, pressure type intake mani-
fuel injected, horizontally opposed and develops fold piping, integral oil pump and externally
435 horsepower at 2275 propeller RPM. Installed mounted oil cooler, intake air intercooler, starter
on each engine are two magnetos, twelve spark and various adapters, clamps and brackets for
plugs, ignition harness and wiring, primer dis- mounting these items on the engine.The engine
tribution lines and fittings, engine-driven fuel also includes engine bracketed turbocharger and
pump, low pressure, multi-nozzle, continuous flow a complete exhaust system.
DETAIL ENGINE SPECIFICATIONS
Rated Maximum Take-off Horsepower..........................435
Rated Maximum Continuous Horsepower ........................ 435
Rated Speed - Crank RPM..............................3400
Rated Speed - Prop RPM .............................. 2265
Rated Manifold Pressure in Hg ............................ 44.5
Propeller Drive Ratio .............................. 0.667:1
Propeller Rotation (Looking Forward) ....................... Clockwise
Bore, Inches...................................5.25 "
Stroke, Inches .................................. 4.00"
Displacement, Cubic Inches .......................... 520 Cu. In.
Compression Ratio ................................ 7.5:1
Oil SAE Number Above 400 F....................... ..... SAE No. 50

Below 400 F................ 10W30 Multi-Viscosity or SAE. No. 30
Oil Sump Capacity ............................... 12 Quarts
Fuel, Aviation Grade,Octane (Minimum )Low Lead Fuels are approved for use) ...... 100LL(Blue)
or 100 (Green)
Fuel System .... . . . . . . . . . . .. . . . . . . .

.Continental . . ... Fuel Injection
Fuel Injector .......................... Continental Fuel Injection
Magneto Drive, Ratio to Crankshaft ......................... 1.5:1
Magneto (1) Drive Direction...........................Clockwise*
Tachometer Drive, Ratio To Crankshaft. .......................... 5:1

Rotation...........................Clockwise'
C-4-2
Starter Drive, Ratio To Crankshaft ........................... 32:1

Alternator Drive. Ratio To Crankshaft...........................3:1

Vacuum Pump Drive (Deice)............................1.14:1

Rotation.......................Counterclockwise*
Propeller Governor Drive, Ratio To Crankshaft .................... 0.809:1

Rotation ....................... Clockwise*
Firing Order................................. 14-5-2-36
Oil Pressure (PSI)

Normal..................................30 -60PSI
Maximum..................................100 PSI
Idling (Minimum) ............................... 10 PSI
Oil Temperature (0 F)
Normal .................................... 1700
Maximum ................................... 2400

Maximum ..... I..............................4600
Minimum (Takeoff) ............................... 200'
Standard Engine Dry Weight...........................599 Lbs.
Direction of rotation facing engine drive pad.
June 1980 C-4-3

OPERATING TEST LIMITS
Run-in schedule .............................. 2 hrs. 3 5 min.
Maximum rated RPM and Tolerance.....................3375 -3425 RPM
Oil Consumption at maximum rated power ................... 1.0 lbs./1/2 hr.

Oil grade to be used..............................SAE No. 50
Fuel grade to be used.......................100LL(Blue) or 100(Green)
Idling RPM and Tolerance .............. ........... 900 ± 25 RPM
Manifold pressure at maximum rated power-................44.0" - 45.0" Hg. Abs.
Manifold pressure at idle ....................... 15.9" -18.0" Hg Abs.
Magneto spread at 2400 RPM ......................... 50 RPM max.
Crankcase pressure* ............................ 4.0" H 2 0 max.
Oil temperature...............................2400 F. max.
Oil temperature - desired range ....................... 1500 - 2000 max.
Oil pressure at maximum rated power

(engine oil temperature 1750 - 185 F.) ................ 50 - 60 psi (24-6 side)
Oil pressure at maximum rated power

(engine oil temperature 1400 - 1500 F.) ................... 30 psi minimum
Timing of engine and tolerance......................Left: 200 BTC ± 10

Turbocharger air inlet air filter pressure drop...................6.0" H 2 0 max.
Turbocharger air outlet pressure ........................ 46.2 Hg max.
Turbocharger exhaust outlet pressure....................1.0" lIg max. (Ref.)
Cylinder head temperature................4600 F max. (at bayonet thermocouple)
Normal rated power ......................... 435 BHP at 3400 RPM
Power correction for intake air temperature ......... ......... 1% per 6' F.
**Correct horsepower for turbocharger inlet air temperature is as follows:
C-44
GTSIO-520-K
Full Rich Metered Fuel Pr.

Time -Minutes RPM Fuel Flow (No./Hr.) (vented) -psi
5 1200
5 1500
10 2100
10 - 95 5.65/ 6.15
10 2800
10 - 165 8.3 5/ 8.85
10 -2 35 12-65/13.15
5 305 17.95/18.45
ADMP T/C Outlet Pr.

Time - Minutes RPM Power "Hg. (Ref.) "Hg. (Ref.)
5 *3400 ±25 100% (43 5 BHP) 44.0/45.0 45.2/46.2
5 *3300 91.4% (398 BHP) 39.8/40.8 41.4/42.4
5 * 3150 79.5% (346 BHP) 35.3/36.3 37.5/38.5
5 * 3000 68.7% (299 BHP) 31.5/32.5 34.3/3 5.3
2700 Lean out mixture until all cylinder head temperatures have peaked.
All must peak within 5 lbs/hr. fuel flow (.25 psi metered fuel pressure).
5 *2600 44.7% (195 BHP) 25.2/26.5 3./ .
10 900 ± 25 Idle Cooling
PROPELLER STAND. NOTE . .. Stop en ine, drain oil, weigh in oil for
NOTE. ... Engine oil pressure must be supplied to oil consumption determination and replace in
propeller transfer tube during all testing. engine.
ADMP T/C Outlet Pr.

Time-Minutes RPM Power "Hg. (Ref.) "Hg. (Ref.)
10 Warm-Up
30 3400 ± 25 100% Power - See (a)
5 2400 Check Magnetos - See (b)
10 900 ± 25 Idle Cooling
Stop engine, drain oil, weigh and record engine oil consumption - See (c)
145 3090 75% (326 BHP) 13 3.5/34.5 36/3 7
Inspect engine and apply corrosion prevention treatment in accordance with TCM
drawing No. 5 31148. (Apply after "Final Test" on teardown engines.)
(a) Readings m us t be recorded afte r completion of each1 5 minute interval during oil consumption run.
(b) Magneto spread to be taken after completion of oil consumption run. Engine must be throttled to specified RPM and temperature
allowed to settle out before aking magneto spread.
(c) Oil consumption at a rate of 1.0 lb./1!2 hr. maximum is acceptable. If value in exces of 1.0 lb./ 1/2 hr. is determined, rerun one
hour. I f c onsumption is still excessive, return for inspection.
See fuel charts for actual RPM.
C-4-5
EXHAUST ASSEMBLY (See Figure C4-1) NOTE .. . Further disassembly of nozzles should
not be attempted unless flow test equipment is
REMOVAL AND DISASSEMBLY. available.
a. Loosen couplings (14) and slide onto NOTE .. Air throttle assembly and controller
exhaust tubes (1. 3). assembly are calibrated as an integral unit. They
b. Remove exhaust-to-cylinder head attaching
parts (47,FigureC-44). Remove and separate left c. Remove cotter pins (8), washers (9), , wave
exhaust parts (3, 5. 7, 8, 9). Repeat for right side washers (10) and link rod assembly (11 thru 15).
exhaust parts (1, 2, 4, 6, 8, 9).
d. Remove attaching parts (18, 19) and
c. Remove exhaust-to-turbocharger attaching separate controller (17) and gasket (16) from
parts (1 1, 12, 13) and adapter (1 0). throttle body (27).
ASSEMBLY AND INSTALLATION. e. Remove attaching parts (25, 26) and

separate pressure relief valve assembly (24) and
a. Assemble in reverse order of disassembly. gasket (23) from throttle body (27).
HOT PRIME EQUIPMENT (See Figure C4-2) f. Remove attaching parts (29, 30), and pull
fuel pump (28) and gasket (31) from crankcase
REMOVAL AND DISASSEMBLY. studs. Remove drive coupling (32), gear (33) and
plug (34) from crankcase cavity.
a. Remove hose assembly (1 1) from solenoid
valve fitting (10) and from tee located beneath air
throttle assembly. ASSEMBLY AND INSTALLATION.
b. Remove heater-to-primer tube assembly a. Assemble in reverse order of disassembly.

(3).
INDUCTION SYSTEM (See Figure C-44)
e. It is not necessary to remove the rest of the
hot prime equipment as it does not interfere with REMOVAL AND DISASSEMBLY.
any other disassembly operation. However, if
replacement is necessary, remove and separate a. Steps b, c and d may be disregarded if
parts as shown in Figure C4-2. hoses (1 thru 4), turbocharger parts (5 thru 8) and
air throttle parts (27. 28, 29) have been removed
ASSEMBLY AND INSTALLATION. prior to engine removal from airframe.
a. Assemble in reverse order of disassembly. b. Disconnect and remove hose (1) located
between actuator oil outlet and controller, hose (2)
FUEL INJECTION SYSTEM (See Figure C-4-3) located between crankcase and controller oil drain
elbow, hose (3) located between crankcase and
REMOVAL AND DISASSEMBLY. turbo oil inlet and hose (4) located between turbo
oil outlet and scavenge pump. Also disonc
a. Remove hose assembly (1), fuel pump- clamps (40) and remove hose (39) located between
to-control, and hose assembly (2), control- air throttle and air manifold junction box.
to-manifold valve.
C. Loosen clamps (5) and remove hoses (6)
b. Disconnect six fuel discharge tubes (3) and induction tube (7). Remove turbo from its
from manifold valve (7) and nozzles (5). Compress mounting bracket.
spring legs of each clamp (4) and remove clamps.
Remove nozzles (5) and washers (6); store in a d. Loosen clamps (10) and remove hose (11)
clean container. along with air throttle (9).
C-4-6
e. Remove attaching parts (12, 13) and (14, b. Remove spacers (3, 4), "O" ring (12), two
1 5) to lift off intercooler (22). Remove gasket gaskets ( 1) and spacer ( 2 ).
(2 3).
c. Remove oil temperature control valve (20).
f. Bracket (16) may be disassembled from
intercooler by removing screw and washer (20, 21). d. Remove bolt (7) and washer (6) and
Bracket (1 7) is retained by nut and lockwasher (6, separate turbo mounting bracket from crankcase.
7, Figure C-4-6)
ASSEMBLY AND INSTALLATION.
g. Loosen clamps (24, 31) and slide hose
connectors (32) onto intake tubes (35). Remove a. Assemble in reverse order of disassembly.
intake manifold assembly (28).
.OIL PUMP ASSEMBLY (See Figure C-4-7)
h. Remove intake tube flange attaching parts
(36, 37, 38) and lift off intake tubes (35) and REMOVAL AND DISASSEMBLY.
flanges (34). Also remove gaskets (33).
a. Loosen oil screen plug (44), by-pass plug
i. Disconnect fuel nozzle sleeves (42). (21) and oil pressure relief valve housing (15) to
Remove air manifold tubes (47 thru 50), air facilitate later removal.
manifold tube (41) and air manifold junction
assembly (46). b. Remove nine sets of attaching parts (2, 3,
4), but not those indexed (33, 34, 35). Pull
ASSEMBLY AND INSTALLATION. complete oil pump assembly from crankcase cover
studs. Remove and discard gasket (1).
a. Assemble in reverse order of disassembly.
c. Remove oil screen plug(44)and gasket(43).
OIL SUMP (See Figure C-4-5)
d. Remove tach drive housing (40) and related
REMOVAL AND DISASSEMBLY. parts (31, 36, 37, 38, 39, 41) from tach drive cover
(32).
a. Drain plug (14) and gasket (13) should
have been removed when engine was mounted on e. Remove two sets of attaching parts (33, 34,
test stand. 35) from two studs (6). Withdraw the tach drive
cover (32).
b. Remove attaching parts (10, 11, 12) and
lift sump (9), gasket (6), spacer (7) and gasket (8) f. Slide scavenge driven gear assembly (28,
from engine. Discard gaskets. 29) off shaft (27) and out of scavenge pump body
(25). Remove tach drive gear (30) and pin (23)
C. Remove bolts (4, 5), washers (3) and lift from shaftgear (22). Pull scavenge driver gear (26)
off suction tube assembly (2). Remove and discard off shaftgear (22) and remove key (24). Remove
gasket (1). scavenge pump body(25) from oil pump housing(5).
ASSEMBLY AND INSTALLATION. g. Remove oil pump driver shaftgear (22) and
oil pump driven gear assembly (8, 9) from oil
a. Assemble in reverse order of disassembly. pump housing (5).
OIL COOLER (See Figure C-4-6) h. Remove oil pressure relief valve (10 thru
17) and by-pass valve (18 thru 21). Remove plug
REMOVAL AND DISASSEMBLY. (7). to facilitate cleaning. Studs (6) should be
removed only if replacement is necessary.
a. Remove four sets of attaching parts (9, 10,
ASSEMBLY AND INSTALLATION.
11), one set of attaching parts (13, 15) and lift off
oil cooler (8). a. Assemble in reverse order of disassembly.
C-4-7
9
a
7
9 8
8
.14
3 3 ~~~~10
13
14
FIGURE C-4-1. EXHAUST ASSEMBLY
1. Tube Assembly 8. Packing

2. Elbow and Riscr Assembly 9. Clamp Assembly
3. Elbow Assembly 10. Adapter
4. Exhaust Riser Assembly 11. Bolt
5. Exhaust Riser Assembly 12. Washer
6. Exhaust Riser Assembly 13. Nut
7. Exhaust Riser Assembly 14. Coupling
C-4-8
2
% ~~~~~~ I~~
IV
/~8 9
12 7
FIGURE C4-2. HOT PRIME EQUIPMENT
1. Electric Heater Assembly

2. Heating Element Housing
3. Tube Assembly
4. Primer Nipple Assembly
5. Tee
6. Solenoid Valve
7. Mounting Bracket
8. Washer, Lock
9. Screw
10. Nipple
11. Hose Assembly
12. Clamp Assembly
C-4-9
7
,/I
28
29 -4
-0
30-
FIGURE C4-3. FUEL INJECTION SYSTEM
1. Hose Assembly 13. Nut 2 5. Washer

2. Hose Assembly 14. Spring 26. Screw
3. Tube Assembly, Fuel Discharge 15. Rod and Link Assembly 27. Air Throttle Body
4. Clamp, Fuel Discharge Tube 16. Gasket, Controller 28. Fuel Pump Assembly
5. Nozzle Assembly 17. Controller 29. Washer
6. Washer, Copper 18. Washer 30. Nut
7. Valve, Fuel Manifold 19. Screw 31. Gasket
8. Pin, Cotter 20. Bushing 3 2. Drive Coupling
9. Washcr 21. Lever 33. Gear
10. Washer, Wave 22. Pin, Tubular 34. Plug
II. Nut, Elastic Stop 23. 0-Ring
12. Rod End, Special 24. Valve Assembly, Pressure Relief
C-4-10
FIGURE C44. INDUCTION SYSTEM
CA-1l
1. Hose Assembly 37. Washer, Lock
2. Hose Assembly 38. Nut, Plain, Hex
3. Hose Assembly 39. Hose
4. Hose Assembly 40. Clamp
5. Clamp Assembly 41. Tube Assembly, Air
6. Hose 42. Sleeve Assembly, Injection Nozzle
7. Tube, Air Induction 43. Seal, Compression
8. Turbocharger 44. Washer, Plain
9. Air Throttle 45. Washer, Rubber
10. Clamp 46. Junction Assembly, Air Manifold
11. Hose 47. Tube Assembly, Air Manifold,
12. Screw No. 1 Side
13. Washer, Copper 48. Tube Assembly, Air Manifold,
14. Bolt No. 2 Side
15. Washer 49. Tube Assembly, Air Manifold,
16. Bracket 1-3-5 Side
17. Bracket 50. Tube Assembly, Air Manifold,
18. Grommet 2-4-6 Side
19. Sleeve 51. Gasket
20. Washer, Plain 52. Adapter
21. Screw 5 3. Washer, Plain
22. Intercooler 54. Screw
23. O-Ring 55. Extension
24. Clamp 56. Tee
25. Bolt 57. Reducer
26. Washer 58. Gasket
27. Nut 59. Adapter
28. Intake Manifold 60. Washer, Plain
29. Insert 61. Screw
30. Plug 62. Extension
31. Clamp 63. Elbow
32. Hose, Intake Manifold 64. Gasket
33. Gasket 65. Nut
34. Flange, Intake Manifold 66. Elbow
35. Tube, Intake Manifold 67. Fitting
36. Washer, Plain
C-4-12
I
-10
-11
14
FIGURE C-4-5. OIL SUMP
1. Gasket
2. Tube Assembly
3. Washer
4. Bolt
5. Bolt
6. Gasket
7. Spacer
8. Gasket
9. Sump Assembly
10. Washer
11. Washer, Lock
12. Screw
13. Gasket
14. Plug
C-4-13
17 0
1s
FIGURE C4-6. OIL COOLER
1. Gasket 11. Nut

2. Spacer 12. O-Ring
3. Washer 13. Bolt
4. Washer 14. Bolt
5. Bracket, Turbocharger 15. Nut
Mounting 16. Elbow
6. Washer, Lock 17. Nut
7. Screw 18. O Ring
8. Oil Cooler 19. Gasket
9. Washer 20. Valve Assembly,
10. Washer, Lock Temperature Control
C4-14
FIGURE C4-7. OIL PUMP ASSEMBLY
1. Gasket 15. Housing, Oil Pressure 30. Gear, Tach Drive

2. Washer Relief Valve 31. Gear, Tach Drive
3. Washer, Lock 16. Washer, Copper 32. Cover, Tach Drive
4. Nut 17. Nut, Adj.usting Screw 3 3. Washer
5. Housing and Shaft Assembly 18. Valve, Oil By-Pass 34. Washer, Lock
6. Stud 19. Spring, Oil By-Pass 3 5. Nut
7. Plug 20. Gasket, Copper 36. Shaft, Tach Drive
8. Gear, Driven 21. Plug and Pin Assembly, 37. Pin, Dowel
9. Bushing Oil By-Pass 38. Washer, Tach Drive
10. Plunger, Oil Pressure 22. Shaftgear 39. Gasket, Tach Drive Housing
Relief Valve 23. Pin, Dowel .40. Housing, Tach Drive
11. Spring, Oil Pressure 24. Key, Woodruff 41. Seal, Oil
Relief Valve 25. Body, Scavenge Pump 42. Nipple
12. Washer, Spring Guide 26. Gear, Driver 43. Gasket
13. Screw, Adjusting 27. Shaft, Driven Gear 44. Oil Screen Assembly
14. Gasket, Copper 28. Gear, Driven 45. Plug
29. Bushing
C-.4-15
.5
2
FIGURE C4-8.
Setting model
Location Thread Sizes Heights GTSIO-520-K
1. Oil Cooler Mount Pads 5/16-18 x 5/16-24 ¶ 5/8 1
2. Oil Cooler Mount Pads 5/16 18 x 5/16-24 1-1/64 1
3. Oil Cooler Mount Pads 5/16-18 x 5/16-24 4-15/16 1
4. Oil Cooler Mount Pads 5/16-18 x 5/16 24 4-7/16 1
Early crarnkcaiss. cidntifled by PIN 640034 steel stamped above the crankcase serial nuamber on the 2-4-6 side. use a shorter stud
in the cylinder deck on the side opposite the through bolts. rFOr LoteC~t part numnber. see Parts Catalog, Form X-30046A.
C-4-16
00 00
00
c; C ~~~~~~~~~~~~~~~
2 70 '
I A
III
I B I CI D
I
E
I
I
0
CONNECTOR 900 Elbow (1200) 450 Elbow)113 P) 900 Eibow(900) 450 Elbow (1800)
C-4-17
fib
1800
1800
FIGURE C4-10. FUEL MANIFOLD FITTING LOCATIONS
A B C D E
900 Elbow (900) 900 Elbow (3300) NIPPLE, UNION 450 Elbow 900 Elbow (2050)
C-4- 18
00 ~~~~~~~~~~~~~~~~~~~~
Do
FIGURE C-4-11. AIR THROTTLE & CONTROLLER FITTING LOCATIONS
C4-1 9/C4-20
CHAPTER C
SECTION V
DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-520-L
Overhaul and test procedures for the model specific differences noted by this Difference Data
procedures for the basic GTSIO-520 except for the
See Service Bulletin M77-20 Rev 1 ( Bendix
C-5-1
GENERAL INFORMATION - GTSIO-520-L.
fuel injected, horizontally opposed and develops fuel injection system, pressure type intake mani-
375 horsepower at 2275 propeller RPM. Installed fold piping, integral oil pump and externally
plugs, ignition harness and wiring, primer dis- and various adapters, clamps and brackets for
tribution lines and fittings, engine-driven fuel mounting these items on the engine.
Rated Maximum Take-off Horsepower.......................... 37 5
Rated Speed - Crank RPM..........I.....................33 50
Rated Speed - Prop RPM...............................22 33
Rated Manifold Pressure in Hg.* ........................... 39.0
Propeller Drive Ratio ............................... 0.667; 1
Propeller Rotation (Looking Forward)........................Clockwise
Bore, Inches ................................... 5.25"
Stroke, Inches...................................4.00"
Displacement, Cubic Inches ........................... 520 Cu. In.
Compression Ratio ................................. 7.5:1
Oil SAE Number Above 4Q0 F ......................... SAE No. 50

Below 40 F .10............. W30 Multi-Viscosity or SAE No. 30
Oil Sump Capacity...............................13 Quarts
Fuel, Aviation Grade,Octane (Minimum XLow Lead Fuels are approved for use)......100LL(Blue)
or 100 (Green)
Fuel System ........................... Continental Fuel injection
Fuel Injector.......................... Continental Fuel Injection
Magneto Drive, Ratio to Crankshaft .......................... 1.5:1
Magneto (1) Drive Direction ........................... Clockwise*
Tachometer Drive, Ratio To Crankshaft ......................... 5:1

C-5-2
Starter Drive, Ratio To Crankshaft...........................32:1

Alternator Drive, Ratio To Crankshaft..........................3:1


Vacuum Pump Drive (Autopilot) .......................... 1.14:1

Propeller Governor Drive, Ratio To Crankshaft......................809: 1

Firing Order..................................14-5-2-3-6
Oil Pressure (PSI)

Normal..................................30 - 60 PSI
Maximum..................................100 PSI
Oil Temperature (F)

Normal .................................... 1700
Maximum ................................... 2400
Cylinder Head Temperature (F)

Maximum ................................... 4600
Minimum (Takeoff) ............................... 2000
Standard Engine Dry Weight .......................... 550.5 Lbs.
**Manifold Pressure boss located on propeller end of spider.
June 1980 C-5-3

(b Maximum Rated RPM and Tolerance ............ 3350 -3400 RPM
(c Fuel Flow Limits.................... See Page C-5-14
(f) Oil Consumption @Maximum Rated Power.......... 1.0 Lb./1/2 Hr. Maximum

(k) Idling RPM and Tolerance................. 700 ± 25 RPM
(1) Manifold Pressure @Maximum Rated Power ......... 39.0

18.0
@ Idle.................
(m Magneto Spread at 2400 RPM............... 50 RPM Maximum
(n) Crankcase Pressure * .................. 4.0" H 2 0 Maximum

Oil Temperature - Desired Range ............. 150 Min. -200 F.Max.

(Engine Oil Temperature 175 185 F. ) ........ 40-60 psi (on 2-4-6 side)
(s) Timing of Engine and Tolerance .............. Left: 240 BTC ± 1

Right: 240 BTC ± 1
w) Cylinder Head Temperature................ 460 F.Maximum

(x) Normal Rated Power .................. 375 BHP at 3350 RPM
C-5-4 June1980
(y) Power Correction for Intake Air Temperature: ... .. ..... 1% per 6F.
(2) Subtract 1% for each 6 F.colder than 60 F.
*A sudden increase in crankcase pressure, during which the liquid in the manometer fluctuates rapidly, is usually an indication of
NOTE .. . Turbocharger inlet air may be regulated to provide engine operation within Test Limits.
SPECIAL TEST ITEMS REQUIRED OR lines (oil pump to filler) Aeroquip No. AE7010201
EQUIVALENT. J 0310, (filter to oil cooler) No. AE 7010201 J
Exhaust and wastegate system to conform to TCM. 0310, Oil Filter and adapter AC 6435853 Type
Drawing No. 641774, (GTSIO-520-L). External oil OF103A.

GTSIO-520-L
r/c Outlet PR. "Hg.
5 1200
10 1500
10 2100
10 2600
10 2800
10 3000
10 3200
5 * 3350 100% Power 41.5 - 42.5
5 * 3040 75% Power (282 BHP) 3 5.0 - 36.0
5 2600
NOTE . . . Engine oil pressure must be supplied to NOTE ... Stop engine, drain oil, weigh in oil for
propeller transfer tube during all testing. olconsumption determination and replace in
engine.
START OIL CONSUMPTION DETERMI NATION
GTSIO-520-L
T/C Outlet PR. "Hg.
Period Time -Minutes RPM (Reference)
12 10 Warm-Up
13 30 3 350 100% Power
14 5 t 2400 Check magnetos
15 10 700 t 25 Idle Cooling Period
NOTE ... Stop engine, drain oil, weigh and record excess of 1.00 lbs./1/2 hr. is determined, rerun one
**Readings must be recorded after completion of each 15 minute interval during oil consumption run.
C-5-5
INDUCTION SYSTEM (See Figure C-5-1) washer (36) and secure fuel discharge tube. Install
new seals (28, 30, 32) on tubes (27, 29, 31) and
a. Remove clamps (1) and sleeves (2) and secure to junction box (3 3) and air manifold tubes
separate throttles and control unit (3) and duct (4) (26). Attach tube (31) to fuel pump.
from intercooler (1 1).
FUEL INJECTION SYSTEM (See Figure C-5-2)
b. Remove bolt (5) and washer (6). Remove
screw (7), washer (8) sleeve (9) and insulator (10) a. Disconnect six fuel discharge tubes (1)
and lift off intercooler (11). Remove seal (12). from manifold valve (5) and nozzles (3). Compress
Bracket (1 3) is retained by accessory drive adapter spring legs of clamps (2) and remove. Remove
attaching parts. nozzles (3) and washers (4). Store in clean con-
tainer.
c. Remove attaching parts (19, 20, 21) and
lift off intake tubes (23, 24) and intake manifold NOTE ... Further disassembly of nozzle should
assembly (14) as a unit. Loosen clamps (17) and not be made unless flow test equipment is avail-
hoses (18) and separate components. Remove able.
flanges (22) from pipes. Remove and discard
gaskets (25). b. Remove cotter pins (6) washers (7) and
wave washers (8) and separate link rod assemblies
d. Remove air manifold tubes (26, 27, 29) (9 thru 13) and (14 thru 18).
tube (31) and junction box (33). Remove com-
pression seals (28, 30, 32). c. Bend up ears of tab washers (20) and
remove screws (19) and tab washers. Separate
e. Detach fuel discharge tube from nozzle and control assembly (21) from throttle body.
remove sleeve and seal assembly (34, 35) plain
washer (36) and rubber washer (37). d. Remove attaching parts (22, 23) and
separate controller assembly (24) and gasket (25)
CLEANING, REPAIR AND REPLACEMENT from air throttle body.
Procedures described in the basic engine section e. Remove fuel pump attaching parts (30,3 1,
will apply. 32) and pull fuel pump (33) from crankcase.
Remove coupling (34), fuel pump drive gear
REASSEMBLY assembly (3 5,3 6) and gasket (3 7).
a. Install flanges (22) on intake tubes (23, 24) CLEANING, INSPECTION AND REPAIR
and loosely assemble intake tubes to spider mani-
fold (14) cylinder no. 5 intake tube is slightly Procedures listed in the basic engine section will
different than the other five tubes. Place a new apply.
gasket (25) in cylinder intake flanges and locate
manifold and tubes assembly. Secure with attach-
ing parts (19, 20, 21). Adjust hoses and tighten REASSEMBLY
clamps (1 7).
CA UTION... Use only a fuel soluble thread
b. Install bracket (13) on two upper inside lubricant on any fuel injection system fitting or
magneto adapter studs. Lubricate seal (12) and connection.
install intercooler (11). Secure to intake manifold
with screw (5) and washer (6). Secure to bracket a. Install new gasket (25) and controller (24)
with insulator (10), sleeve (9) washer (8) and screw on throttle body (29) and secure with attaching
(7). parts (22, 23).
C. Install new seal (35) on sleeves (34) and b. Secure control assembly (21) to throttle
place on nozzle. Attach sleeves to air manifold body with new tab washers (20) and screws (21).
tubes (26). Install rubber washer (37) and plain Bend up ears of tab washers.
C-5 -6
c. Install link rod assemblies (9 thru 13) and mount on crankcase studs. Secure with two sets of
(14 thru 18) in order shown and secure with wave attaching parts (3 0,3 1,3 2).
washers (8), plain washers (7) and cotter pins (6).
Final adjustment of linkage will be established at e. Install copper washer (4) on base threads of
final assembly. nozzle (3) and install nozzle in cylinder. Slide
sleeve over nozzle and install rubber washer and
d. Lubricate fuel pump drive gear (3 5) and plain washer (37, 36 Figure C-5-1) and seat on
install in fuel pump cavity. Coat both sides of sleeve. Connect fuel discharge tubes (1) to nozzles
gasket (37) and install on crankcase studs. Lubri- and fuel manifold value (5). Install a clamp (2) on
cate coupling (34) and install in fuel pump drive each tube and insert spring legs of clamp in bracket
gear. Mesh fuel pump (33) with coupling and (38).
C-5-7
/) ~ 24
12.
I -2
1
16
..---
'4
2
29
34 30
39.
44-

1. Clamp 16. Plug 31- Tube Assy
2. Sleeve 17. Clamp 3 2. Seal
3. Throttle Assy 18. I-ose 33. Junction Assy
4. Duct 19. Nut 34. Sleeve Assy
5. Bolt 20. Lockwasher 3 5. Seal
6. Washer 21. Washer 36. Washer
7. Screw 22. Flange 37. Washer Rubber
8. Washer 23. Tube 38. Screw
9. Sleeve 24. Tube, Cyl.#*5 39. Nut
10. Spacer 25. Gasket 40. Clamp
11. Intercooler 26. Air Manifold Tube 41. Turbocharger
12. Seal 27. Air Manifold Tube 42. Gasket
13. Bracket 28. Seal 43. Adapter
14. Manifold 29. Air Manifold Tube 44. Gasket
15. Insert 30. Seal
C-5-8
25
29
Q
18,
I-.
-. 411-W
1.
4 21 -C - 7
20 1 `6
32 ;-- 19
1. Fuel Discharge Tube 14. Nut, Elastic Stop 27. Lever

2. Clamp 15. Washer 28. Pin
3. Nozzle 16. Rod End 29. Air Throttle Body
4. Washer 17. Spring 30. Nut
5. Fuel Manifold Valve 18. Rod and Link Assy 3 1. Lock Washer
6. Cotter Pin 19. Screw 3 2. Washer
7. Washer 20. Tab Washer 33. Fuel Pump
8. Wave Washer 21. Control Assy 34. Coupling
9. Nut, Elastic Stop 22. Screw 35. Drive Gear
10. Rod End 23. Lock Washer 36. Plug
11. Nut, Spriing Adjustment 24. Controller Assv 37. Gasket
12. Spring 25. Gasket 38. Bracket
13. Rod and Link Assy 26. Bushing
MARCH 1981 C-5-9

C
nO A
1800
00
270" on
E
1800
I I ~ ~~~AlI B I c I I EI
GTSIO-520.L 900 Elbow (34Q0) 1900 Elbow (20)1 NIPPLE. UNION 450 Elbow 90 low ( 1100)I
C-5-10
0a
2700.
U
1800
A B C D E
Mixture Fuel Inlet
Return and Fuel
GTSIO-520-L PLUG TEE (1 800) 450 Elbow 900 Elbow 450Elw

i2700) (2250)(40
C-5-11
A
goo
FITTING ORIENTATION
FIGURE C-5-5. FUEL PUMP FITTING LOCATIONS - GTSIO-520-L
SPEC 1 SPEC 2
A. 90 Elbow (2980) A. 90 Elbow (2980)
B. 900 Elbow (2840 B. 900 Elbow (284)
C. Adapter C. Adapter
Tee (00) Tee (0)
D. 450 Elbow (1050) D. 900 Elbow (900)
E. 90 Elbow (900) E. 900 Elbow (900)
F. 900 Elbow (0) F. 900 Elbow (00)
C- 5-12
2'
FIGURE C-5-6.
Setting
Location Thread Sizes Heights Model "L"
1. Fuel Pump Mount Pads 5/16-18 x 5/16-24 .25 2
2. Oil Pump Mount Pads 5/16-18 x 5/16-24 6-1/4 1
June 1980 C-5-13

- I ~ I I `I
FUEL FLOW LIMITS FOR GTSIO-520-L MODEL ENGINE

CHART INSTRUCTIONS
2. Determine required RPM for 100% arid 75% power by reading directly above
3. Determine fuel flow limits for 100% and 75% power by reading directly above
EXAMPLE: GTSIO 520-M
1 00% Power RPM 3350 t1 10, Flow Limits 255 - 265 Lbs./hr.
75% Power RPM 3040 110, Flow Limits 176 - 186 lbs./hr.
(a) This chart is based on 70 0 F injector fuel temperature. For every 101F increase
in injector inlet fuel temperature, subtract 1 lb. of fuel from the curve value. For
every 101F decrease in injector inlet fuel temperature, add 1 lb. of fuel to the
curve value.
195- _ __ _ _
LU. -J
LL 175 -__ __
3040 3065 3090 I
ENGINE RPM FOR 75% POWER1 1 1
-265 -__ __ _
u . ~-260-__ _ _ _
WU -J LOW'
U- -255-
o 3350 3375 3400
- ENGINE RPM FOR 100% MAX. RATED POWER
C-5-14 C-5-
14 1980
June
100% POWER FUEL PUMP PRESSURE LIMITS FOR GTSIO-520-L ENGINES
NOTE: This data to beused when checking pressure at fuel pump outlets with gage
vented to atmospheric pressure.
CHART INSTRUCTIONS:
I. Obtain actual maximum rated RPM.
2. Determine fuel pressure limits for 100% maximum power by reading directly
above actual maximum rated RPM point.
EXAMPLE:
100% Power Fuel Pump Pressure Limits at 3350±+10 RPM, 29.5 - 35.0 PSI.
NOTE: Idle (700± 25 RPM) Pump Pressure. 6.00 - 6.50 PSI
W HIGH jqS
cc
35 _ _5_
C,)
C,)
-~33- _
U-
Z1. -- ~cr- -32-
ENGINE RPM FOR 100% MAX. RATED POWER
June 1980 C51

C-5-15
METERED FUEL PRESSURE
vs.
FEL FLOW
NOTE: This data is approximate, with fuel pressure gage at

the same elevation as the manifold gage and without
influence of differential head in gage line.
NOTE: Tolerance on metered fuel pressure. ± 0.30 PSI.
Check at 17, 12,

8 PSI and Idle.
18 ___
a_ 16_ _ _ _ _ __ _ _ __ _
NOTE: Specific weight of gasoline 5.87 lb./U.S. gal.

LU
LU
Uj
4-J
z 20 ~~~~60 100 140 180 220 260

____ ~~FUEL FLOW - LBS./HR. __
C-5-16 C-5-
16June
1980
CHAPTER C
SECTION VI
DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-520-M
Overhaul and test procedures for the model seific differences noted by this Difference Data
procedures for the basic CTSIO 520 except for the
See Service Bulletin M77-20 Rev 1 Bendix
C-6-1
GENERAL IN FORMATION - GTSIO-520-M
fuel injected, horizontally opposed and develops fuel injection system, pressure type intake mani-
375 horsepower at 2275 propeller RPM. Installed fold piping, integral oil pump and externally
on each engine are two magnetos, twelve spark mounted oil cooler, intake air intercooler, Starter
plugs, ignition harness and wiring, primer dis- and various adapters, clamps and brackets for
trbution lines and fittings. engine-divnfe mounting these items on the engine
Model .................................. GTSIO-520-M
Rated Maximum Take-off Horsepower............................ 375
Rated Speed - Crank RPM..............................3 350
Rated Speed -Prop RPM .............................. 223 3
Rated Manifold Pressure in Hg. *...........................40.0
Propeller Drive Ratio .............................. 0.667:1
Propeller Rotation (Looking Forward)........................Clockwise
Bore, Inches...................................5.25 "
Stroke, Inches..................................4.00"
Displacement, Cubic Inches...........................520 Cu. In.
Compression Ratio.................................7.5:1
Oil SAE Number Above 40' F......................... SAE No. 50

Below 4Q0 F................ 0W30 Multi-Viscosity or SAE No. 30
Oil Sump Capacity...............................13 Quarts
Fuel, Aviation Grade,Octane (Minimum XLow Lead Fuels are approved for use) ..... 100LL(Blue)
or 100 (Green)
Fuel System ........................... Continental Fuel Injection
Fuel Injector .......................... Continental Fuel Injection
Magneto Drive, Ratio To Crankshaft ......................... 1.5:1
Magneto (1) Drive Direction...........................Clockwise*
C-6-2
Tachometer Drive, Ratio To Crankshaft ......................... 5:1

Starter Drive, Ratio To Crankshaft...........................32:1

Alternator Drive, Ratio To Crankshaft..........................3:1


Rotation ....................... Counterclockwise*
Vacuum Pump Drive (Autopilot) .......................... 1.14:1

Propeller Governor Drive, Ratio To Crankshaft ..................... 809:1

Firing Order..................................14-5-2-3-6
oil Pressure (PSI)

Normal ............................. (See Operating Limits)
Maximum..................................100 PSI
Oil Temperature ( 0 F)
Normal .................................... 1700
Maximum.......2400
Cylinder Head Temperature (0 F) 0

Maximum ................................... 460
Minimum (Takeoff) ............................... 2000
Standard Engine Dry Weight .......................... 550.5 Lbs.
" Manifold presure boss located on propeller end of spider.

* Direction of rotation facing drive pad.
June 1980 C-6-3


Final Run-In Minor Parts Replacement ........... 2 Hrs. 25 Min.
Final Run-In Major Parts Replacement............ 2 Hrs. 25 Min.
(b) Maximum Rated RPM and Tolerance ............ 3350 -3400 RPM
(c Fuel Flow Limits .................... See Page C-6-14
(0) Oil Consumption @ Maximum Rated Power.......... 1.0 Lb./ 112 Hr. Maximum

(k) Idling RPM and Tolerance ................ 700 ± 25 RPM
() Manifold Pressure @ Maximum Rated Power ......... 40.0

Manifold Pressure @ Idle................. 18.0
(n) Crankcase Pressure * .................. 4.0" H 2 0 Maximum

Oil Temperature - Desired Range ............. 1500 Min. - 2000 F. Max.

(Engine Oil Temperature 1750 - 1850 F.) ......... 40 - 60 psi (on 24-46 side)
(s) Timing of Engine and Tolerance........... Left: 240 BTC ± 10

Right: 24 BTC ± 10
(w Cylinder Head Temperature................ 460 F. Maximum

(x Normal Rated Power .................. 375 BHP at 3350 RPM
C-6-4 June 1980

(y) Power Correction for Intake Air Temperature: ... .. 1....

% per 60 F.
NOTE. ... Turbocharger inlet air may be regulated to provide engine operation within Test Limits.
SPECIAL TEST ITEMS REQUIRED OR lines (oil pump to filler) Aeroquip No. AE7010201
EQUIVALENT. J 0310, (filter to oil cooler) No. AE 7010201 J
Exhaust and wastegate system to conform to TCM 0310, Oil Filter and adapter AC 6435853 Type
Drawing No. 641774, (GTSIO-520-M). External oil OF103A.
TOP OR MINOR AND MAJOR OVERHAUL TEST RUN

GTSIO-5 20-M
T/C Outlet PR. "Hg
1 5 1200
2 10 1500
3 10 2100
4 10 2600
5 10 2800
6 10 3000
7 10 3200
8 5 *3350 100% Power 40.0 - 41.0
9 5 3040 75% Power (282 BHP) 32.0 - 33.0
10 5 2600
NOTE. oil pressure must be supplied to
.Engine NOTE ... Stop engine, drain oil, weigh in oil for
engine.

GTSIO-520-M
T/C Outlet PR. "Hg

12 10 Warm -Up
13
30 3 350 100% Power
14 5 t 2400 Check magnetos
15 10 700 + 25 Idle Cooling Period
NOTE .. . Stop engine, drain oil, weigh and record excess of 1.00 lbs./1/2 hr. is determined, rerun one
** Readings muse be recorded after completion of each 15 minute interval during oil consumption run.
C-6-5
INDUCTION SYSTEM (See Figure C-6-1) tubes (26). Install rubber washer (37) and plain
washer (36) and secure fuel discharge tube. Install
a. Remove clamps (1) and sleeves (2) and new seals (28, 30, 32) on tubes (27, 29, 31) and
separate throttles and control unit (3) and duct (4) secure to junction box (3 3) and air manifold tubes
from intercooler (1 1). (26). Attach tube (31) to fuel pump.
b. Remove nuts (7, 10), washers (6, 9) and lift FUEL INJECTION SYSTEM (See Figure C-6-2)
off intercooler (1 1). Remove seal (12). Bracket (8)
is retained by oil cooler to crankcase attaching a. Disconnect six fuel discharge tubes (1)
bolt. from manifold valve (5) and nozzles (3). Compress
spring legs of clamps (2) and remove. Remove
c. Remove attaching parts (19, 20, 21) and nozzles (3) and washers (4). Store in clean con-
lift off intake tubes (23, 24) and intake manifold tainer.
assembly (14) as a unit. Loosen clamps (17) and
hoses (18) and separate components. Remove NOTE. ... Further disassembly of nozzle should
flanges (22) from pipes. Remove and discard not bemade unless flow test equipment is avail-
gaskets (25). able.
d. Remove air manifold tubes (26, 27, 29) b. Remove cotter pins (6) washers (7) and
tube (31) and junction box (33). Remove wave washers (8) and separate link rod assemblies
compression seals (28, 30, 32). (9 thru 13) and (14 thru 18).
e. Detach fuel discharge tube from nozzle and c. Bend up ears of tab washers (20) and
remove sleeve and seal assembly (34, 35) plain remove screws (19) and tab washers. Separate
washer (36) and rubber washer (37). control assembly (21) from throttle body.
CLEANING, REPAIR AND REPLACEMENT d. Remove attaching parts (22, 23) and
separate controller assembly (24) and gasket (25)
Procedures described in the basic engine section from air throttle body.
will apply.
e. Remove fuel pump attaching parts (30,3 1,
REASSEMBLY 32) and pull fuel pump (33) from crankcase.
Remove coupling (34), fuel pump drive gear
a. Install flanges (22) on intake tubes (23, 24) assemb ly (3 5,3 6) and gasket (3 7).
and loosely assemble intake tubes to spider
manifold (14) cylind er no. 5 intake tube is slightly CLEANING, INSPECTION AND REPAIR
different than the other five tubes. Place a new
gasket (25) in cylinder intake flanges and locate Procedures listed in the basic engine section will
manifold and tubes assembly. Secure with apply.
attaching parts (19, 20, 21). Adjust hoses and
tighten clamps (17). REASSEMBLY
b. Install bracket (8) on 1-3-5 side of crank- CA UTION... Use only a fuel soluble thread
case. Secure with oil cooler attaching bolt. Install lubricant on any fuel injection system fitting or
stud (5) in intake manifold (14) to an extended connection.
height of 4.54 inches above the manifold seal
flange. Lubricate seal (12) and install adapter (11) a. Install new gasket (25) and controller (24)
secure to intake manifold with nuts (7) and on throttle body (29) and secure with attaching
washers (6). Secure to bracket (8) with nut and parts (22, 23).
washer (10, 9).
b. Secure control assembly (21) to throttle
c. Install new seal (35) on sleeves (34) and body with new tab washers (20) and screws (21).
place on nozzle. Attach sleeves to air manifold Bend up ears of tab washers.
C-6-6
C. Install link rod assemblies (9 thru 13) and mount on crankcase studs. Secure with two sets of
(1 4 thru 18) in order shown and secure with wave attaching parts (30,31,32).
washers (8), plain washers (7) and cotter-pins (6).
Final adjustment of linkage will be established at e. Install copper washer (4) on base threads of
final assembly. nozzle (3) and install nozzle in cylinder. Slide
sleeve over nozzle and install rubber washer and
d. Lubricate fuel pump drive gear (3 5) and plain washer (37, 36 Figure C-5-1) and seat on
install in fuel pump cavity. Coat both sides of sleeve. Connect fuel discharge tubes (1) to nozzles
gasket (37) and install on crankcase studs. and fuel manifold value (5). Install a clamp (2) on
Lubricate coupling (34) and install in fuel pump each tube and insert spring legs of clamp in bracket
drive gear. Mesh fuel pump (3 3) with coupling and (38).
C-6-7
1. Clamp 16. Plug 31. Tube Assy
2. Sleeve 17. Clamp 3 2. Seal
3. Throttle Assyi 18. Hose 3 3. Junction Assy
4. Duct 19. Nut 34. Sleeve Assy
5. Bolt 20. Lockwasher 3 5. Seal
6. Washer 21. Washer 3 6. Washer
7. Screw 22. Flange 37. Washer Rubber
8. Washer 23. Tube 38. Screw
9- Sleeve 24. Tube, Cyl.#5 3 9. Nut
10. Spacer 25. Gasket 40. Clamp
11. Adapter 26. Air Manifold Tube 41. Turbocharger
12. Seal 27. Air Manifold Tube 42. Gasket
13. Bracket 28. Seal 43. Adapter
14. Manifold 29. Air Manifold Tube 44. Gasket
15. Insert 30. Seal
C-6-8
25
29
.- I W- 8-- ", 6
18-&
I 38
- 17
/14
- v.-~6
4.'
34
1. Fuel Discharge Tube 14. Nut, Elastic Stop 27. Lever

2. Clamp 15. Washer 28. Pin
3. Nozzle 16. Rod End 29. Air Throttle Body
4. Washer 17. Spring 30. Nut
5. Fuel Manifold Valve 18. Rod and Link Assy 31. Lock Washer
6. Cotter Pin 19. Screw 32. Fuel Pump
7. Washer 20. Tab Washer 34. Coupling
8. Wave Washer 21. Control Assy 3 5. Drive Gear
9. Nut, Elastic Stop 22. Screw 36. Plug
10. Rod End 23. 1Lock Washer 37. Gasket
I1. Nut, Spring Adjustment 24. Controller Assy 38. Bracket
12. Spring 25. Gasket
13. Rod and Link Assy 26. Bushing
C-6-9
nO A
18001
2700
E
1800
A I I C I D I E
GTSIO-520-M 0
900. ElIbow (3400) 9 ' El bow 120')1NIPPLE. UNION 450 7Elbow 90' Elbow (1 100)
C-6-10
B
IC
LI
1800,
A B C D E
Mixture Fuel Inlet
Return and Fuel
To Pump Premure Conn. Outlet
GTSIO-520.M PLUG TEE (1800) 900Elbow 900 Elbow (80) 450 Elbow
f 1900) (31 0)
C-6-11
F
rTTIN G
go,,
T1800
FITTING ORIENTATION
A- 900 Elbow (2980)

B. 900 Elbow (2840)
C. Adapter
Tee (00)
D. 900 Elbow (900)
E. 900 Elbow (900)
F. 900 Elbow (00)
C-6-12
2
FIGURE C-6-6.
Setting
Location Thread Sizes Heights Model "M"
1. Fuel Pump Pad 5/16-18 x 5/16-24 3/4 2
2. Oil Cooler Mount Pad 5/16 18 x 5/16-24 6-1/4 1
June1980 C-6-13
FUEL FLOW LIMITS FOR GTSIO-520-M MODEL ENGINE
7 CHART INSTRUCTIONS
2. Determine required RPM for 100% and 75% power by reading directly above
3. Determine fuel flow limits for 100% and 75% power by reading directly above
* EXAMPLE: GTSIO-520-M
1 00% Power RPM 3350 ±+10, Flow Limits 255 - 265 Lbs./hr.
75% Power RPM 3040 +1 0, Flow Limits 176 - 186 lbs./hr.
(a) This chart is based on 701F injector fuel temperature. For every 10OF increase
in injector inlet fuel temperature, subtract 1 lb. of fuel from the curve value. For
every 10OCF decrease in injector inlet fuel temperature, add 1 lb. of fuel to the
curve value.
U)
I-95
0'1
Lu-J
in 3040 3065 3090

N ~~ENGINE RPM FOR 75% POWER
Un
26-
U)
-o
- ENGINE RPM FOR 100% MAX. RATED POWER___ __
C-6-14 June 1980

100% POWER FUEL PUMP PRESSURE LIMITS FOR GTSIO 520 -M ENGINES
NOTE:- This data tobe used when checking pressure at fuel pump outlets with gage
ventedtoatmospheric pressure.
CHART INSTRUCTIONS:
2. Determine fuel pressure limits for 100% maximum power by reading directly
above actual maximum rated RPM point.
EXAM PLE:
I100% Power Fuel Pump Pressure Limits at 3350 ± 10RPM, 29.5 -35.0 PSI.
NOTE: Idle (700±+25 RPM) Pump Pressure, 6.00 - 6.50 PSI
June1980 C-6-15
METERED FUEL PRESSURE
Vs
FUEL FLOW
NOTE: This data is approximate, with fuel pressr gage a

the same elevation as the manifold gage and without___ -
influence of differential head in gage line.

NOTE. Tolerance on metered fuel pressure, -I0.30 PSI.
Check at 17. 12,

18 _ 8 PSI and Idle'.
a . 16_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _
LU ~~~NOTE: Specific weight of gasoline 5.87 lb./U.S. gal.
U)
12
LU
__ _ u- _ _
1 1~~~~
____
_ _ __
__ ____ ___ _ _ ___ FUEL FLOW -LBS./HR.
C-6-16 16 1980
C-6-
June
CHAPTER C
SECTION VII
DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-520-N
Overhaul and test procedures for the model covered basic GTSIO-520 except for the specific differences
in this section are the same as the procedures for the noted by this Difference Data Section.
® SEE SERVICE BULLETIN M77-20 REV 1 BENDIX
OCTOBER 1980 C-7-1

GENERAL INFORMATION - GTSIO-520-N
The GTSIO 520 N is a six cylinder, horizontally The engine driven pump is a dual stage, positive
opposed, geared, turbosupercha rged, fuel injected displacement, rotating vane type which incorporates
engine which develops 375 horsepower at 2233 an interstage pressure regulator referenced to
propeller RPM. compressor discharge absolute pressure.
The engine comes equipped with two magnetos and Fuel metering is accomplished by engine speed (pump
ignition harness, twelve spark plugs, a 24V - 100A output) and throttle position. The fuel control unit is
Teledyne Crittenden alternator, and a 24V starter. mounted on the throttle body. The metering valve
portion is linked to the air throttle and controls the
A seventh nozzle fuel primer system is used to aid fuel/air ratio. The fuel control unit incorporates a low
starting. The primer nozzle is located in the intake pressure relief valve to control idle fuel flow and a
manifold and uses the aircraft auxiliary fuel pumpas a variable orifice controlled by an aneroid, referenced
fuel pressure source. The primer is activated by an to compressor discharge absolute pressure, to
electric solenoid. increase fuel flow in proportion to the turbocharging
effort.
Charge air cooling is accomplished by an air to air heat
exchanger located between the throttle body and The fuel control unit also contains a mixture control
intake spider manifold. valve to allow manual leaning.
The fuel injection system is a low pressure, multi- The fuel manifold valve incorporates an engine oil
nozzle, continuous flow type. heated feature.
Rated Maximum Take-off Horsepower .............................. 375
Rated Maximum Continuous Horsepower.............................375
Rated Speed - Crank RPM....................................3350
Rated Speed - Prop RPM.....................................2233
Rated Manifold Pressure in Hg.* ................................. 39-0
Propeller Drive Ratio ..................................... 0.667:1
Propeller Rotation (Looking Forward) ............................ Clockwise
Bore. Inches .......................................... 5.25"
Stroke,Inches ......................................... 4.00"
Displacement, Cubic Inches ................................ 520 Cu. In.
Manifold Pressure boss located on propeller end of spider.
C-7-2 OCTOBER 1980

Compression Ratio ....................................... 7.5:1
Oil SAE Number - 15W-50, 20W-50 For AllTempsIf Sea Level Ambient Temp. Is:
Above 40, F............................... SAE No. 50
Below 40 F................... 10W30 Multi-Viscosity or SAE No. 30
Oil Sump Capacity ..................................... 13 Quarts
Fuel, Aviation Grade, Octane (Minimum) (Low Lead Fuels are approved for use) ....... 100LL(Blue)
or 100 (Green)
Fuel System ................................ Continental Fuel Injection
Fuel Injector ................................ Continental Fuel Injection
Magneto Drive, Ratio to Crankshaft ............................... 1.5:1
Magneto (1) Drive Direction................................Clockwise'
Tachometer Drive, Ratio To Crankshaft...............................5:1

Rotation ................................ Clockwise'
Starter Drive, Ratio To Crankshaft.................................32:1

Rotation...............................Counterclockwise*
Alternator Drive, Ratio To Crankshaft ............................... 3:1

Rotation.................................Clockwise*
Accessory Drives (2 Ea.).....................................1.14:1

Rotation..............................Counterclockwise*
Propeller Governor Drive, Ratio To Crankshaft .......................... 809:1

Rotation.............................Clockwise'
Firing Order........................................1-4-5-2-3-6
Oil Pressure (PSI)

Normal ........................................ 30 - 60 PSI
Maximum .100...................................... PSI
Idling (Minimum) .................... PSI
0.................l
Oil Temperature (F)

Normal ........................................... 1700
Maximum .......................................... 2400
OCTOBER 1980 C-7-3

Cylinder Head Temperature (F)... ............ 40
Maximum.460..........................
Minimum (Takeoff) ........... 00..........................
Standard Engine Dry Weight ............................... 556.75 Lbs.
(a) Run-In Schedule........................ 2 Hrs. 25 Min.
(b) Maximum Rated RPM ..................... 3350
(c) Fuel Flow Limits........................ See Graph C-7-1
(d) Fuel Pump Pressure Limits................... See Graph C-7-2
(e) Metered Fuel Pressure Limits .................. See Graph C-7-3
(f) Oil Consumption, LBSIBHP/HR MAX .............. .006 x % Power

100
(g) Oil Grade to be used ...................... SAE No. 50

Oil at 200-220 psi (Move Crankshaft slowly during reading) 0.05 - 0.50 Lbs./ Min.
(j) Fuel Grade to be used ..................... 00LL(Blue) or 100(Green)
(k Idling RPM and Tolerance ................... 700 ± 25 RPM
l Manifold Pressure@ Maximum Rated Power........... 39.0

@Idle.................... 18.0
(m) Magneto Check at 2100 RPM .............. ... 50 RPM Maximum Spread
1.50 RPM Maximum Drop
(n) Crankcase Pressure *.. . .... . .. . .... .. .. .. 4.0" HzO Maximum
A sudden increase in crankcase pressure, during which the liquid in the manometer fluctuates rapidly, is usually an indication of rings
beginning to stick. However, before removing cylinders, investigate the breather and manometer.
C-7-4 OCTOBER 1980

(p) Oil Temperature........................ 240 F. Maximum

Oil Temperature - Desired Range ............... 150 Min. - 2000 F. Max.
Cr Oil Pressure at Maximum Rated Power

(Engine Oil Temperature 1750 - 1850 F.)............40-60 psi (on 2-4-6 side)
(Engine Oil Temperature 1400 - 1500 F.)............30 psi Minimum
(s) Timing of Engine and Tolerance.................Left: 24' BTC ± 10

Right: 24 BTC ± 1
(t TIC Air Inlet Air Filter Pressure Drop.............. 6.0" H2 Maximum
(u) TIC Air Outlet Pressure.....................43.0" Hg. Maximum
(v) TIC Exhaust Outlet Pressure .................. 2.0" Hg. Above Ambient - Max.
(w) Cylinder Head Temperature...................4600 F. Maximum

(x) Normal Rated Power ...................... 375 BHP at 3350 RPM
(y) Power Correction for Intake Air Temperature .... ........ 1% per 60 F.
NOTE . .. Turbocharger inlet air may be regulated to provide engine operation within Test Limits.
SPECIAL TEST ITEMS REQUIRED OR EQUI, lines (oil pump to filler) Aeroquip No. AE7010201 J03 10,
VALENT. (filter to oil cooler) No. AE70 10201 J03 10, Oil Filter and
Use engine exhaust system and wastegate. External oil adapter AC 6435853 Type OF103A.
OCTOBER 1980 C-7-5

GTSIO-520-N
PERIOD TIME - MINUTES RPM (Reference)
1 5 1200
2 10 1500
3 10 2100
4 10 2600
5 10 2800
6 10 3000
7 10 *3200
8 5 *3350 100% POWER 41.5 -42.5
9 5 3040 75% POWER (282 BHP) 35.0 - 36.0
10 5 2600
11 10 700±25 IDLE COOLING PERIOD
NOTE ... ENGINE OIL PRESSURE MUST BE SUP- NOTE. ... STOP ENGINE, DRAIN OIL, WEIGH IN OIL
PLIED TO PROPELLER TRANSFER TUBE DURING FOR OIL CONSUMPTION DETERMINATION AND
ALL TESTING. REPLACE IN ENGINE.

GTSIO-520-N
PE RIOD T/C OUTLET PR. "HG-

TIME - MINUTES RPM (Reference)
12 10 WARM-UP
13 30 3350 100% POWER
14 5 t2400 CHECK MAGNETOS
15 10 700 ± 25 IDLE COOLING PERIOD
NOTE . .. STOP ENGINE, DRAIN OIL, WEIGH AND LBS./l/2 HR. IS DETERMINED, RERUN 1 HOUR. IF
RECORD ENGINE OIL CONSUMPTION. OIL CON- OIL CONSUMPTION IS STILL EXCESSIVE, RETURN
SUMPTION AT A RATE OF 1.00/1/2 HR. MAXIMUM ENGINE TO OVERHAUL.
IS ACCEPTABLE. IF VALUE IN EXCESS OF 1.00
t MAGNETO DROP TO BE TAKEN AFTER COMPLETION OF OIL CONSUMPTION RUN. ENGINE MUST BE
THROTTLED TO SPECIFIED RPM AND TEMPERATURE ALLOWED TO SETTLE OUT BEFORE TAKING
MAGNETO DROP.
* SEE FUEL CHARTS FOR ACTUAL RPM.
**READINGS MUST BE RECORDED AFTER COMPLETION OF EACH 15 MINUTE INTERVAL DURING OIL
CONSUMPTION RUN.
C-7-6 OCTOBER 1980

INDUCTION SYSTEM (See Figure C-7-1) 32) on tubes (27, 29, 31) and secure to junction box
(33) and air manifold tubes (26). Attach tube (31) to
a. Remove clamps (1) and sleeves (2) and separate fuel pump.
throttles and control unit (3) and duct (4) from
intercooler (11). FUEL INJECTION SYSTEM (See Figure C-7-2)
b. Remove bolt (5) and washer (6). Remove screw a. Disconnect six fuel discharge tubes (1) from
(7), washer (8) sleeve (9) and insulator (10) and lift off manifold valve (5) and nozzles (3). Compress spring
intercooler (11). Remove seal (12). Bracket (13) is legs of clamps (2) and remove. Remove nozzles (3) and
retained by accessory drive adapter attaching parts. washer (4). Store in clean container.
c. Remove attaching parts (19, 20, 21) and lift off NOTE . .. Further disassembly of nozzle should not
intake tubes (23, 24) and intake manifold assembly be made unless flow test equipment is available.
(14) as a unit. Loosen clamps (17) and hoses (18) and
separate components. Remove flanges (22) from b. Remove cotter pins (6) and washers (7) and
pipes. Remove and discard gaskets (25). wave washers (8) and separate link rod assemblies (9
thru 13) and (14 thru 18).
d. Remove air manifold tubes (26, 27, 29) tube
(31) and junction box (33). Remove compression seals c. Bend up ears of tab washers (20) and remove
(28, 30, 32). screws (19) and tab washers. Separate control
assembly (21) from throttle body.
e. Detach fuel discharge tube from nozzle and
remove sleeve and seal assembly (34, 35) plain washer d. Remove attaching parts (22, 23) and separate
(36) and rubber washer (37). controller assembly (24) and gasket (25) from air
throttle body.
CLEANING, REPAIR AND REPLACEMENT
e. Remove fuel pump attaching parts (30,31, 32)
Procedures described in the basic engine section will and pull fuel pump (33) from crankcase. Remove
apply. fuel pump drive gear assembly (34, 35) and gasket
(36).
REASSEMBLY
a. Install flanges (22) on intake tubes (23, 24) and CLEANING, INSPECTION AND REPAIR
loosely assemble intake tubes to spider manifold (14)
cylinder no. 5 intake tube is slightly different than the Procedures listed in the basic engine section will
other five tubes. Place a new gasket (25) in cylinder apply.
intake flanges and locate manifold and tubes
assembly. Secure with attaching parts (19, 20, 21).
REASSEMBLY
Adjust hoses and tighten clamps (17).
CAUTION . .. Use only a fuel soluble thread lubricant on any
b. Install bracket (13) on two upper inside
fuel injection system fitting or connection.
magneto adapter studs. Lubricate seal (12) and install
intercooler (11). Secure to intake manifold with screw
(5) and washer (6). Secure to bracket with insulator a. Install new gasket (25) and controller (24) on
(10), sleeve (9) washer (8) and screw (7). throttle body (29) and secure with attaching parts (22,
23).
c. Install new seal (35) on sleeves (34) and place on
nozzle. Attach sleeves to air manifold tubes (26). b. Secure control assembly (21) to throttle body
Install rubber washer (37) and plain washer (36) and with new tab washers (20) and screws (21). Bend up
secure fuel discharge tube. Install new seals (28, 30, ears of tab washers.
OCTOBER 1980 C-7-7

c. Install link rod assemblies (9 thru 13) and (14 crankcase studs. Secure with two sets of attaching
thru 18) in order shown and secure with wave parts (30, 31, 32).
washers (8), plain washers (7) and cotter pins (6). Final
adjustment of linkage will be established at final e. Install copper washer (4) on base threads of
assembly. nozzle (3) and install nozzle in cylinder. Slide sleeve
over nozzle and install rubber washer and plain
washer (37, 36, Figure C-7-1) and seat on sleeve.
d. Lubricate fuel pump drive gear (35) and install Connect fuel discharge tubes (1) to nozzles and fuel
in fuel pump cavity. Coat both sides of gasket (37) and manifold valve (5). Install a clamp (2) on each tube and
install on crankcase studs. Mount fuel pump (33) on insert spring legs of clamp in bracket (38).
1. CLAMP 16. PLUG 31. TUBE ASSY

2. SLEEVE 17. CLAMP 32. SEAL
3 THROTTLE ASSY 18. HOSE 33. JUNCTION ASSY
4. DUCT 19. NUT 34. SLEEVE ASSY
5. BOLT 20. LOCKWASHER 35. SEAL
6. WASHER 21. WASHER 36. WASHER
7. SCREW 22. FLANGE 37. WASHER RUBBER
8. WASHER 23. TUBE 38. SC REW
9. SLEEVE 24. TUBE. CLY.=5 39. NUT
10. SPACER 25. GASKET 40. CLAMP
11. INTERCOOLER 26. AIR MANIFOLD TUBE 41. TURBOCHARGER
12. SEAL 27. AIR MANIFOLD TUBE 42. GASKET
13. BRACKET 28. SEAL 43. ADAPTER
14. MANIFOLD 29. AIR MANIFOLD TUBE 44. GASKET
15. INSERT 30. SEAL
C-7-8 OCTOBER 1980

1
39--- a
32
OCTOBER 1980 C-7-9

7
9
1
16
,15
u
"- 20
11
2
1. FUEL DISCHARGE TUBE 14. NUT, ELASTIC STOP 27. LEVER

2. CLAMP 15. WASHER 28. PIN
3. NOZZLE 16. ROD END 29. AIR THROTTLE BODY
4. WASHER 17. SPRING 30. NUT
5. FUEL MANIFOLD VALVE 18. ROD AND LINK ASSY 31. LOCK WASHER
6. COTTER PIN 19. SCREW 32. WASHER
7. WASHER 20. TAB WASHER 33. FUEL PUMP
8.WAVE WASHER 21. CONTROL ASSY 34. DELETED
9. NUT, ELASTIC STOP 22. SCREW 35. DRIVE GEAR
10. ROD END 23. LOCK WASHER 36. PLUG
11. N UT, SP RI NG ADJUSTM ENT 24. CONTROLLER ASSY 37. GASKET
12. SPRING 25. GASKET 38. BRACKET
13. ROD AND LINK ASSY 26. BUSHING
C-7-10 OCTOBER 1980

"B" FITTING -
2700 METERED 00 "A" FITTING - 900
EL
ET
1800
P
"E" FITTING
"F" FITTING- OIL
"G" FITTING-OIL
00
2700 - 90w
2700--(( -900
180 lo"C"
BR
VIEW J-J 18(0 VIEW H-H
ROTATED 1550 CCW ROTATED 250 CW
"A" FITTING "B" FITTING "C" BRACKET "D" FUEL "P"DRAIN

PART & & (HORIZ.) MANIFOLD PORT
NO. ORIENT ORIENT ASSY ORIENT
MS20822-1200~ 631720~o 642095 640718-1 1800
"E" FITTING "F" FITTING "G" FITTING

PART & & &
NO. ORIENT ORIENT ORIENT
MS208 22- AN702I~X ____
OCTOBER 1980 C-7-11

I --- ~----1
"B" FITTING
TURBO DISCHARGE
PRESSURE REF
"C" FITTING "0" FITTING

FUEL OUTLET RETURN TO TANK
90 00 1800 00
90 0
g0o
ELBOW FITTING
VIEW A-A TEE FITTING ORIENTATION
ORIENTATION
FIGURE C-7-4. FUEL CONTROL FITTING LOCATIONS
C-7-12 OCTOBER 1980

TING-
.D. PRESSURE
"A',
PUMP-F UEL
FITTING FITTING
PART "A" & "B" &
NO. ORIENT ORIENT
643715-1 I 6846 0 I1[3o ,

OCTOBER 1980 C-7-13
2
FIGURE C-7-6. CRANKCASE STUD SETTING HEIGHTS
LOCATION THREAD SIZES HETINGHT MODEL "N"
1. FUIEL PUMP MOUNT PADS 5/16-18 X 5/16-24 .25 2

2. OILPUMPMOUNTPADS 5/1 & 18X 5/16-24 6-1/4 1
C-7-14 OCTOBER 1980

....
lII II
I I
I II I II I I I I I
I 1I I 1 I 1 1I I I I l iTI T ....
FUEL FLOW LIMITS FOR GTSIO-520-N MODEL ENGINE
CHART INSTRUCTIONS
1. OBTAIN ACTUAL MAXIMUM RATED RPM.
2. DETERMINE REQUIRED RPM FOR 100% AND 75% POWER BY READING
DIRECTLY ABOVE THE ACTUAL MAXIMUM RATED PRM POINT.
3. DETERMINE FUEL FLOW LIMITS FOR 100% AND 75% POWER BY
READING DIRECTLY ABOVE THE ACTUAL MAXIMUM RATED RPM POINT.
EXAMPLE:
100% POWER RPM 3350 + 10, FLOW LIMITS 255 - 265 LBS./HR.
4 75% POWER RPM 3040 + 10, FLOW LIMITS 157 - 167 LBS./HR.
Z
zzl-
(a) THIS CHART IS BASED ON 70F INJECTOR FUEL TEMPERATURE. FOR
EVERY 10 0F INCREASE IN INJECTOR INLET FUEL TEMPERATURE,
SUBTRACT 1 LB. OF FUEL FROM THE CURVE VALUE. FOR EVERY 10 0F
i
DECREASE IN INJECTOR INLET FUEL TEMPERATURE, ADD 1 LB. OF
&7 FUEL TO THE CURVE VALUE.
- mo;,- I I
I-
-175 -
-J7
I-IGI- LIMITS
-165 -
1L n LOW LIMITS
-155 -
3040 13065 3c30
4 1~ 1
ENGINE RPM FOR 75% POWER
I- c
L- -IL
4I
I01
LO
:1
-265 - _ _
1t-
5-
33501 13375~ j 3400
-7
I I GRAPH C-7-1 I I
at Eim TTHTM 7HTF I MTm 77H
---I... ..... . .. I...... ....
OCTOBER 1980 C-7-15
100% POWER FUEL PUMP PRESSURE LIMITS FOR GTSIO-520-N MODEL ENGINE
NOTE: THIS DATA TO BEUSED WHEN CHECKING PRESSURE AT FUEL PUMP

OUTLETS WITH GAGE VENTED TO ATMOSPHERIC PRESSURE.
CHART INSTRUCTIONS
1. OBTAIN ACTUAL MAXIMUM RATED RPM.
2. DETERMINE FUEL PRESSURE LIMITS FOR 100% MAXIMUM POWER BY
READING DIRECTLY ABOVE ACTUAL MAXIMUM RATED RPM POINT.
EXAMPLE: 100% POWER FUEL PUMP PRESSURE LIMITS AT 3350 +10 RPM,
33.0 - 37.0 PSI.
NOTE: IDLE (700 ±25 RPM) PUMP PRESSURE, 6.00 - 7.00 PSI.
D-37- __
0.. 36-
_-I 35 - _ _ _ _
u-
cr- 34-
0
33-_ _
I I ~~~~~GRAPH C-7-2
C-7 16 OCTOBER 1980

... 1A 11--.11- .1-1. 11.1 Jh H1i
ill IIII I III ; I-i i i ......
l l II -.. . . I .1 -11 -111 ..1 ..... I I . I -1-
I I I I - . 1 II .1 M ll If1 1 illi I L
IIIIIIIE I...
IHin'l
I1:1j1 L[Hilil WU
GTSIO-520-N I
MPTrFRFf FtJFL PRFEq[tRFE T
I ~~~vs.
I ~~FUEL FLOW
NOTE: THIS DATA IS APPROXIMATE, WITH FE z
PRESSURE GAGE AT THE SAME ELEVATION

AS THE MANIFOLD GAGE AND WITHOUT
INFLUENCE OF DIFFERENTIAL HEAD IN
GAGE LINE.
CHECK AT 17, 12,-
NOTE: TOLERANCE ON METERED FUEL 8 PSI AND IDLE.
-18- PRESSURE, ± 0.30 PSI.
v
/
7-
z_-
Lu16-
m_
NOTE: SPECIFIC WEIGHT OF GASOLINE = 5.87 LB./U.S. GAL.
7z
w 7z
ET a-
-J12- ZZ
9--
z-_
- LL
7
n -'- -Z
E
z_-
11-- R
wu
4-
4
Th- 6mor.-.-
20 6J 1i iO 14U 180 2 260
FU EL FLOW - LBS./H R. I !I
I I I
GRAPHC-7-3
E±= TTT
OCTOBER 1980 C-77

C-7-17
FUEL INJECTION ADJUSTMENT PROCEDURES lbs./hr. if maximum RPM cannot be achieved
statically, set fuel flow to 255 to 260 lbs./hr. at
NOTE . Propeller and manifold pressure maximum static RPM. Monitor fuel flow during roll
adjustments must be accomplished before fuel flow out when maximum RPM of 2233 is attained. If fuel
adjustments. All RPM's given are propeller RPM. flow is not within the 255-265 lbs./hr. limits, re-
adjust as required. The full power fuel flow setting is
a. Install an appropriate pressure gauge in the fuel made by using the variable orifice adjusting screw
line between the fuel pump outlet and the fuel control located on the throttle body fuel control unit aneroid
inlet to monitor pump outlet pressures. This gauge housing. Turn the screw CW to decrease fuel flow
should be vented to atmosphere. and CCW to increase.
b. Start and warm up engine to approximately NOTE . . . The jamb nut must be loosened before
250F cylinder head temperature. turning the screw and re-tightened carefully after
each adjustment.
C. Using throttle lever, set engine idle speed to
approximately 450 RPM. Verify that the mixture g. After completion of Item F re-check Items C, D,
control is set at full rich. and E. Re-adjust as required.
d. Set pump outlet pressure at idle RPM to 6-7 h. If difficulty is encountered in setting proper
PSIG using the relief valve adjustment screw on the fuel flows or if an abnormal decrease in fuel flow with
throttle body fuel control unit. Turn the screw CWto increasing altitude is experienced perform the
increase pressure, CCW to decrease pressure. following additional checks:
e. Maintaining the idle RPM and idle pump outlet Install an appropriate pressure gauge to the fuel
pressue specified above (reset as required), adjust the pump interstage port to check interstage pres-
idle mixture linkage on the fuel control unit to obtain sure. Perform steps B and C. Set interstage pres-
the fuel-air ratio which will result in a25-50 RPM rise sure to 5± .25 PSIG by adjusting the regulator
when the engine is leaned towards idle cut-off. Turn screw located on the end of the fuel pump. Turn
the adjustment nut CW to lean the mixture and CCW screw CW to increase CCW to decrease pres-
to enrichen. sure. Be sure to tighten jamb nut and re-safety.
Repeat steps A through G.
NOTE . .. The cylinder head temperature must be at
200-250F each time the RPM rise is checked, i. When the fuel system is accurately adjusted, set
otherwise the results may be inconsistent. engine idle speed to approximately 450 RPM with the
throttle stop adjusting screw, CW to increase, CCW
f. With mixture control full rich, advance throttle to decrease.
to full (rated) power setting to check pump outlet
pressure and fuel flow. j. When setting up full throttle fuel flow on a hot
day (above 60 0 F) the system should be set towards the
With approximately 2233 RPM, full throttle, and 39.0 lower flow limit. On a cold day (below 60F) the
in. Hg. manifold pressure, set fuel flow at 255 to 265 system should be set towards the higher flow limit.
C-7-18 OCTOBER 1980

Overhaul Manual FOR Gtsio-520 Series Aircraft Engines: Faa Approved MARCH 1981 FORM X-30045A

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Overhaul Manual FOR Gtsio-520 Series Aircraft Engines: Faa Approved MARCH 1981 FORM X-30045A

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OVERHAUL MANUAL

MODELS GTSIO-520-C, D, H, K, L, M and N

II. SPECIFICATIONS, LIMITS AND CHARTS A-2- 1

III GENERAL DESCRIPTION A-3-1

V SPECIAL TOOLS AND EQUIPMENT A-5-1

VI UNPACKING AND PREPARATION FOR SERVICE, STORAGE OR SHIPMENT A-6-1

VII DISASSEMBLY A-7-1

X REPAIR AND REPLACEMENT A-10-1

XII FINAL ASSEMBLY A-12-1

XIII REPAIR AND TESTING OF ACCESSORIES A-13-1

Figure No. Title Page

Figure No. Title Page

CHAPTER B (TABLE OF LIMITS)

Table No. Page

Figure No. TITLE Page

II. DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-520-D C-2-1

V. DIFFERENCE DATA SECTION FOR THE MODEL GTSIO 520-L C-5-1

VI. DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-520-M C-6-1

VII. DIFFERENCE DATA SECTION FOR THE MODEL GTSIO-520N C-7-1

Figure No. Title Page

Figure No. Tide Page

1-1. SCOPE. 1-6. DEFINITION OF TERMS. Front, rear, left

OCTOBER 1980 A-1-1

A-1-2 MARCH 1981

Accessory Qty. Indicated Condition Minimum Maximum

IGNITION SYSTEM DETAILS PRESSURE LIMITS

Feature Value Indication Minimum Maximum

Firing order (cylinder numbers) 1-4- OIL VISCOSITY GRADES

CHARACTERISTICS AND DIMENSIONS All Temperatures 15W - 50,

June 1980 A-2-1/A-2-2

3. The crankcase interior is ventilated by a e. CRANKSHAFT. The six-throw steel alloy

i. TAPPETS. The barrel-type hydraulic b. LUBRICATION SYSTEM. Figure A-4-9

A-3-2 MARCH 1981

FIGURE A4-1. CYLINDER NUMBERING DIAGRAM

FIGURE A-4-3. LEFT REAR VIEW - GTSIO-520-D

FIGURE A-4-5. LEFT FRONT VIEW - GTSIO-520-K

FIGURE A-4-7. RIGHT SIDE VIEW - GTSIO - 520-M

FIGURE A4-8. GEAR TRAIN DIAGRAM

1. Crankshaft Gear 13. Idler Gear Support Pin

1. Nut, Hex 13. Gasket

FIGURE A4-12. OIL SUMP

AND CUT AS SHOWN.

OTTER PIN HEAD IN SLOT

FIGURE A4-13. ALTERNATOR ASSEMBLY

1. Nut, Hex 8. Key, Woodruff

FIGURE A-4-14. OIL COOLER

1. Nut, Hex 11. Washer, Plain

FIGURE A-4-15. STARTER ADAPTER

FIGURE A4-16. OIL PUMP ASSEMBLY

FIGURE A-4-17. CYLINDER AND PISTON ASSEMBLY

Note: Current production engines are built with

1. Screw, Fillister 18. Packing, Push Rod Housing 3 5. Ring, Compression

A-4-14 MARCH 1981

FIGURE A-4-19. CAMSHAFT ASSEMBLY

1. Gear, Bevel, Governor Drivcn

FIGURE A-4-20. CRANKSHAFT ASSEMBLY.

A-4-18 OCTOBER 1980

FIGURE A-4-22. INSPECTION RING SIDE CLEARANCE

June 1980 A-4-19