Lycoming aircraft engine overhaul manual direct drive 4 6 8

A Textron Company 652 Oliver Street Williamsport, PA. 17701 U.S.A. 570/323-6181 TECHNICAL PUBLICATION REVISION REVISION NO. PUBLICATION PUBLICATION NO. PUBLICATION DATE Direct Drive 60294-7-9 Overhaul Manual 60294-7 December 1974 The page(s) furnished herewith are intended to replace the corresponding page(s) of the pub ication indicated above. Previous revisions to this publication This revision consists of April 1966 June 2002 5-3, 5-6; 8-5 7-10B July 1967 5-8; 6-1 thru 6-18, 6-23, deleted pages 6-25 thru 6-32 April 1968 4-2 thru 4-8 December 1968 Section 11 replaced Special Tool Catalog *- January 1970 i, ii, deleted pages iv and v; 1-1, 1-2, deleted pages 1-3; 2-1 thru 2-6, deleted pages 2-7 thru 2-12; 3-1 thru 3-5; 4-1; 9-1, 9-2, 9-4, deleted page 9-7; 10-1 thru 10-36, deleted pages 10-37 thru 10-47 January 1971 i, ii; 6-19 thru 6-24; 7-1 thru 7-19; 9-3, 9-5, 9-6 May 1972 Added page 2-7; 3-1, 3-5; 5-1, 5-2, 5-3, 5-4, 5-5, 5-6, 5-7, 5-8, 5-9, 5-10, 5-11, deleted pages 5-12, 5-13, 5-14; 6-1, 6-17, 6-18, 6-22, 6-13; 8-1, 8-2, 8-3, 8-4, 8-5, 8-6, deleted pages 8-7, 8-8; 9-3 October 1973 i, ii, iii; 1-1; 3-3, 34, 3-5; 4-1, 4-3, 4-4, 4-5, 4-6, 4-7, 4-8; 5-1, 5-5, 5-6, 5-7, 5-9, 5-10; 6-2, 6-7, 6-10, 6-11, 6-12, 6-13, 6-17, 6-20, 6-21, 6-22, 6-23; 7-4, 7-16, 7-17, 7-18, 7-19, 9-1, 9-2 February 1992 i June 1993 7-10, added pages 7-10A, 7-10B, 7-10C, 7-10D, 7-12, 7-12A/B June 1996 i June 1999 7-4

Lycoming TECHNICAL PUBLICATION REVISION REVISION NO. PUBLICATION PUBLICATION NO. PUBLICATION DATE Direct Drive Overhaul 60294-7-8 Manual 60294-7 December 1974 The page(s) furnished herewith are intended to replace the corresponding page(s) on the publication indicated above. Previous revisions to this publication This revision consists of: April 1966 June 1999 5-3, 5-6; 8-5 7-4 July 1967 5-8; 6-1 thru 6-18, 6-23, deleted pages 6-25 thru 6-32 April 1968 4-2 thru 4-8 December 1968 Section 11 replaces Special Service Tool Catalog January 1970 I, ii, deleted pages iv and v; 1-1, 1-2, deleted page 1-3; 2-1 thru 2-6, deleted pages 2-7 thru 2-12; 3-1 thru 3-5; 4-1; 9-1, 9-2, 9-4, deleted page 9-7; 10-1 thru 10-36, deleted pages 10-37 thru 10-47 January 1971 Iii; 6-19 thru 6-24; 7-1 thru 7-19; 9-3, 9-5, 9-6 May 1972 Added page 2-7; 3-1, 3-5; 5-1, 5-2, 5-3, 5-4, 5-5, 5-6, 5-7, 5-8, 5-9, 5-10, 5-11, deleted pages 5-12, 5-13, 5-14; 6-1, 6-17, 6-18, 6-22, 6-23; 8-1, 8-2, 8-3, 8-4, 8-5, 8-6, deleted pages 8-7, 8-8; 9-3 October 1974 i, ii, iii; 1-1; 3-3, 3-4, 3-5; 4-1, 4-3, 4-4, 4-5, 4-6, 4-7, 4-8; 5-1, 5-5, 5-6, 5-7, 5-9, 5-10; 6-2, 6-7, 6-10, 6-11, 6-12, 6-13, 6-17, 6-20, 6-21, 6-22, 6-23; 7-4, 7-16, 7-17, 7-18, 7-19; 9-1, 9-2 February 1992 I June 1993 7-10, added pages 7-10A, 710B, 7-10C, 7-10D, 7-12, 7-12A/B June 1996 i

Lycoming 652 OliverStreet Williamsport, PA 17701 U.S.A. 717/323-6181 TECHNICAL PUBLICATIONREVISION REVISION NO. 60294-7-7 PUBLICATION Direct Drive Overhaul Manual PUBLICATION NO. PUBLICATION DATE 60294-7 December 1974 The page(s) furnished herewith are intended to replace the corresponding page(s) of the publication indicated above. Previous revisions to this publication This revision consists of: April, 1966 July, 1967 April, 1968 December, 1968 January, 1970 5-3, 5-6 8-5 5-8 6-1 thru 6-18, 6-23, deleted pages 6-25 thru 6-32 4-2 thru 4-8 Section 11 replaces Special Service Tool Catalog i, ii, deleted pages iv and v 1-1, 1-2, deleted page 1-3 2-1 thru 2-6, deleted pages 2-7 thru 2-12 3-1 thru 3-5 4-1 9-1, 9-2, 9-4, deleted page 9-7 10-1 thru 10-36, deleted pages 10-37 thru 10-47 iii 6-19 thru 6-24 7-1 thru 7-19 9-3, 9-5, 9-6 Added page 2-7 3-1, 3-5 5-1, 5-2, 5-3, 5-4, 5-5, 5-6, 5-7, 5-8, 5-9, 5-10, 5-11, deleted pages 5-12, 5-13, 5-14 June 1996 i January, 1971 May, 1972

TECHNICAL PUBLICATION REVISION REVISION NO. PUBLICATION PUBLICATION NO. PUBLICATION DATE 60294-7-7 Direct Drive Overhaul 60294-7 December 1974 Manual The page(s) furnished herewith are intended to replace the corresponding page(s) of the publication indicated above. Previous revisions to this publication This revision consists of: May, 1972 6-1, 6-17, 6-18, 6-22, 6-23 (Cont.) 8-1, 8-2, 8-3, 8-4, 8-5, 8-6, deleted pages 8-7, 8-8 9-3 October, 1974 i, ii, iii 1-1 3-3, 3-4, 3-5 4-1, 4-3, 4-4, 4-5, 4-6, 4-7, 4-8 5-1, 5-5, 5-6, 5-7, 5-9, 5-10 6-2, 6-7, 6-10, 6-11, 6-12, 6-13, 6-17, 6-20, 6-21, 6-22, 6-23 7-4, 7-16, 7-17, 7-18, 7-19 9-1, 9-2 February, 1992 i June, 1993 7-10, added pages 7-10A, 7-10B, 7-10C, 7-10D, 7-12, added page 7-12A/B

Overhaul Manual Direct Drive Engine A Approved by F.A.A. Sixth Printing December 1974 Part No. 60294-7 652 Oliver Street Williamsport, PA 17701 USA

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

OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES TABLE OF CONTENTS PAGE SECTION SECTION PAGE 1 INTRODUCTION 1-1 2 GENERAL DESCRIPTION Cylinders Valve Operating Mechanism Hydraulic Tappets Crankcase Crankshaft Crankshaft Counterweights Accessory Housing Connecting Rods Pistons Lubrication System Cooling System Induction System Carbureted Fuel Injected Turbocharger Controls Ignition System 2-1 2-1 2-2 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-4 2-6 2-6 2-6 2-6 4 IGNITION SYSTEM (CONT.) Inspection Ignition Harness Magnetos Repair and Replacement Ignition Harness Magnetos Reassembly Magnetos Installation Magnetos Timing Magneto to Engine Ignition Harness 4-3 4-3 4-3 4-4 4-5 4-5 4-5 4-8 5 ACCESSORY HOUSING 3 GENERAL OVERHAUL PROCEDURES Disassembly Cleaning Inspection Repair and Replacement Reassembly Dual Drives Fuel Pumps Oil Filter Oil Cooler Bypass Valve 5-1 5-1 5-5 5-5 5-5 5-9 5-10 5-10 5-10 General Cleaning Degreasing Removal of Hard Carbon Inspection General Bearing Surfaces Gears Corrosion Screwed Fittings Magnetic Corrosion Prevention Repair and Replacement Damaged Parts Painted Parts Replacement of Studs Corrosion Prevention Reassembly Corrosion Prevention Prelubrication of Parts Oilite Bushings Pitch Alignment and Backlash in Bevel Gear Assemblies Table of Limits Oil Seals and Gaskets Arbitrary Replacement of Parts 3-1 3-1 3-1 6 CYLINDERS, PISTONS AND VALVE TRAIN 3-2 3-2 3-2 3-2 3-2 3-2 3-3 3-3 3-3 3-3 3-3 3-3 3-3 3-4 3-4 3-5 3-5 3-5 General Removal from Engine Disassembly Cleaning Inspection Cylinders Pistons Valve Rockers Push Rods Valves Hydraulic Tappets Valve Springs Modifications Repair and Replacement Spark Plug Inserts Valve Seats Valve Guides Valve Rocker Thrust Washers Valve Rocker Shaft Bushing Plain Steel Cylinder Barrels Nitrided Cylinder Barrels Chrome Plated Cylinder Barrels Valve Repair Warped Exhaust Flanges Reassembly Assembly of Pistons Assembly of Cylinders Installation of Pistons Installation of Cylinders Cylinder Head Fin Stabilizers Cylinder Painting Intercylinder Baffles 6-1 6-7 6-7 6-7 6-8 6-9 6-10 6-10 6-10 6-11 6-13 6-13 6-13 6-14 6-15 6-17 6-17 6-18 6-19 6-20 6-20 6-20 6-20 6-20 6-21 6-21 6-21 6-23 6-24 6-24 4 IGNITION SYSTEM General Magnetos Inpulse Coupling Retard Breaker Engine Firing Order Ignition Harnesses Spark Plug Removal and Disassembly Ignition Harness Magnetos 4-1 4-1 4-1 4-1 4-1 4-1 4-1 4-1 ii Revised October 1974

OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES TABLE OF CONTENTS (CONT.) PAGE SECTION SECTION PAGE 7 CRANKCASE, CRANKSHAFT AND RECIPROCATING PARTS Removal of Accessories Disassembly Starter Ring Gear Support Prop. Governor Oil Line Crankcase Crankshaft Counterweights Sludge Tubes Cleaning General Piston Cooling Oil Jets Inspection Bearings Crankcase Visual Dimensional Crankshaft Visual Dimensional Camshaft Visual Dimensional Main Bearing Clearance Connecting Rods Dimensional Parallelism Check Squareness Check Crankshaft Counterweight Bushings Piston Cooling Oil Jets Repair and Replacement Crankshaft Bearing Surfaces Straightening Flange Oil Seal Surface Counterweight Bushings Counterweight Bushings Connecting Rod Bushings Crankshaft and Gear Assy. Starter Ring Gear Crankcase Oil Relief Valve Sleeve Oil Pressure Relief Valve Crankcase Crankshaft Idler Gear Shaft Recess Reassembly Crankshaft Sludge Tubes Expansion Plug Propeller Flange Bushings Gear Counterweight Assembly Connecting Rods Camshaft Crankcase Propeller Governor Drive 7 CRANKCASE, CRANKSHAFT AND RECIPROCATING PARTS (CONT.) 7-1 7-1 7-1 7-1 7-1 7-3 7-3 Crankshaft Oil Seal Hydro Control Valve Generator or Alternator Drive Belt Crankshaft Idler Gears 7-17 7-17 7-17 7-18 8 OIL SUMP AND FUEL INDUCTION 7-3 7-3 7-4 7-4 7-4 7-4 7-4 7-5 7-5 7-5 7-6 7-6 7-6 7-6 7-6 7-7 7-7 7-8 7-9 7-10 7-10 7-10 7-10 7-10 7-11 7-12 7-12 7-12 7-12 7-12 7-12 7-12 7-12 7-14 7-14 7-15 7-15 General Disassembly Intake Pipes Carburetor or Fuel Injector Induction Housing Oil Sump Cleaning Oil Sump Carburetor Fuel Injector Injector Nozzles Inspection Oil Sump Carburetor Fuel Injector Nozzle Assembly Repair and Replacement Intake Pipes Carburetor Fuel Injector Reassembly Induction Housing Flow Dividers Intake Pipes Nozzle Assembly 8-1 8-1 8-1 8-1 8-1 8-1 8-1 8-1 8-1 8-1 8-2 8-2 8-2 8-3 8-3 8-3 8-4 8-6 8-6 8-6 9 TEST PROCEDURES General Test Limits Turbocharged Engines Pressure Carburetors Run-in Procedure Run-in Schedule Oil Consumption Run Oil Pressure Relief Valve Idle Speed and Mixture Adjust- ment Preservation and Storage (Engine) Preservation- Run Preservation and Storage Carburetors and Fuel Injec- tors 9-1 9-2 9-3 9-3 9-3 9-3 9-4 9-4 9-4 9-5 9-6 9-6 10 TABLE OF LIMITS Revised October 1974 iii

OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 1 Introduction SECTION 1. INTRODUCTION 1-1. This manual contains the necessary information for the major overhaul of the Avco Lycoming horizon- tally installed direct drive engines. Unless otherwise noted, all information and data in the manual will ap- ply equally to all models; those portions of the text ap- plying to any one particular model or series will be so identified. 1-2. The main portion of the text is divided into sections corresponding to the basic engine components. Additional sections are provided for general description, general overhaul and inspection procedures, preservation and storage information, and other items of a non-specific nature. 1-3. The tools required for overhauling the engines (excludingthe ordinary mechanic's tools found inmost overhaulshops) are listed inSSP-2172 SpecialService Tools. Inspection gages are also listed in the same section. Any special information required concerning these tools may be obtained by writing to the Service Department, Avco Lycoming Division, Williamsport, Pennsylvania, 17701. When requesting information concerninganyofthesetools, refer to thetool by name and part number and not merely by name. 1-4. Parts catalogs, for specific models, may be or- dered from the department listed in paragraph 1-3. Because this manual covers the entire series of engines, it is almost impossible to call out attaching parts for specific models. Therefore, it is recom- mended that the parts catalogs be used in conjunction with the manual, when reassembling the engine. 1-5. Service bulletins, service instructions and service letters are issued from time totime whenever the engine is modified or overhaul procedures revised. When received, these publications should be inserted in the rear of this manual or maintained in a separate file for ready reference. 1-6. The followingprocedure should be followed if, for any reason, parts are to be returned to the factory. You may obtain from, but preferably have your dis- tributor complete, the applicable warranty or rework form. These forms must include the engine model and serial numbers, number of hours in service, the reason for the parts being returned and any other pertinent facts concerning the parts. 1-7. In this manualall references to locations of various components will be designated when viewing the engine from the rear. The power take off end is con- sideredthe front and the accessory drive end the rear. The oil sump is considered the bottom. Cylinders are numbered from front to rear with odd numbered cylinders on the right side. 1-8. The direction of rotation of the crankshaft, as viewed from the rear, is clockwise on all models with the following exception. The direction of rotation of the crankshaft, as viewed from the rear is counter- clockwise on all models withthe letter L in the model prefix. (Example - LIO-320-B1A). All references to direction of rotation of the various accessory drives are as viewed facing the accessory drive mounting pad. Figure 1-1. Typical 4 Cylinder Engine Revised October 1974 1-1

OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Figure 1-2. Typical 6 Cylinder Engine Figure l-3. Typical 6 Cylinder Engine 1-2 Revised January, 1970

Lycoming aircraft engine overhaul manual direct drive 4 6 8

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