Cessna 152 Service maintenance manual D2064-1-13

Cessna A Textron Company SERVICE MANUAL 1978 thru 1985 MODEL 152 SERIES Member of GAMA FAA APPROVAL HAS BEEN OBTAINED ON TECHNICAL DATA IN THIS PUBLICATION THAT AFFECTS AIRPLANE DESIGN. REVISION 1 INCORPORATES TEMPORARY REVISION 1. DATED 3 OCTOBER 1994. COPYRIGHT 1995 WICHITA. KANSAS. USA 7 FEBRUARY 1985 (RGI-100-4/02) REVISION 1 2 OCTOBER 1995 (RGI-100-4/02)

Cessna A Textron Company TEMPORARY REVISION NUMBER 3 DATE 10 March 2003 MANUAL TITLE Model 152 Series 1978 Thru 1985 Service Manual MANUAL NUMBER - PAPER COPY MANUAL NUMBER - AEROFICHE TEMPORARY REVISION NUMBER MANUAL DATE 7 February 1985 D2064-1-13 D2064-1-13AF D2064-1 TR3 REVISION NUMBER 1 DATE 2 October 1995 This Temporary Revision consists of the following pages, which affect and replace existing pages in the paper copy manual and supersede aerofiche information. AEROFICHE SECTION PAGE FICHE/FRAME 12 12-7 AEROFICHE SECTION PAGE FICHE/FRAME 2/A08 REASON FOR TEMPORARY REVISION 1. To add a note to Figure 12-3, Detail A that provides a description of the vent valve tube position in the fuel tank. FILING INSTRUCTIONS FOR THIS TEMPORARY REVISION 1. For Paper Publications, file this cover sheet behind the publication's title page to identify the inclusion of the Temporary Revision into the manual. Insert the new pages into the publication at the appropriate locations and remove and discard the superseded pages. 2. For Aerofiche Publications, draw a line with permanent red ink marker, through any aerofiche frame (page) affected by the Temporary Revision. This will be a visual identifier that the information on the frame (page) is no longer valid and the Temporary Revision should be referenced. For "added" pages in a Temporary Revision, draw a vertical line between the applicable frames. Line should be wide enough to show on the edges of the pages. Temporary Revisions should be collected and maintained in a notebook or binder near the aerofiche library for quick reference. COPYRIGHT 0 2003 CESSNA AIRCRAFT COMPANY WICHITA, KANSAS, USA

TEMPORARY REVISION NUMBER 2 DATED 7 January 2000 MANUAL TITLE MODEL 152 SERIES 1978 THRU 1985 SERVICE MANUAL MANUAL NUMBER - PAPER COPY D2064-1-13 AEROFICHE D2064-1-13AF TEMPORARY REVISION NUMBER PAPER COPY D2064-1TR2 AEROFICHE N/A MANUAL DATE 7 FEBRUARY 1985 REVISION NUMBER 1 DATE 2 OCTOBER 1995 This Temporary Revision consists of the following pages, which affect existing pages in the paper copy manual and supersede aerofiche information. AEROFICHE AEROFICHE SECTION PAGE FICHE/FRAME SECTION PAGE FICHE/FRAME 2 38A Added 2 42A Added 17 4A Added 17 6A Added REASON FOR TEMPORARY REVISION To include the inspection requirements of Cessna Service Bulletin SEB99-18. To provide additional information for the stop drilling of cracks that originate at the trailing edge of control surfaces with corrugated skins. FILING INSTRUCTIONS FOR THIS TEMPORARY REVISION For Paper Publications: File this cover sheet behind the publication's title page to identify the inclusion of the Temporary Revision into the manual. Insert the new pages into the publication at the appropriate locations. Draw a line, with a permanent red ink marker, through any superceded information. For Aerofiche Publications: Draw a line through any aerofiche frame (page) affected by the Temporary Revision with a permanent red ink marker. This will be a visual identifier that the information on the frame (page) is no longer valid and the Temporary Revision should be referenced. For "added" pages in a Temporary Revision, draw a vertical line between the applicable frames which is wide enough to show on the edges of the pages. Temporary Revisions should be collected and maintained in a notebook or binder near the aerofiche library for quick reference. COPYRIGHT 2000 CESSNA AIRCRAFT COMPANY WICHITA, KANSAS, USA

MODEL 152 SERIES SERVICE MANUAL LIST OF EFFECTIVE PAGES INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES. NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by miniature pointing hands. Original . . . 0 . .. 1 February 1985 Revision . . . 1 . . . 2 October 1995 *The asterisk indicates pages changed, added, or deleted by the current change. TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 504, CONSISTING OF THE FOLLOWING: Page Revision Page Revision No. No. No. No. * T itle ............................ 1 * 4-1 ............................. 1 * A thru B ........................ 1 4-2 thru 4-6 .................... . 0 C Blank ........................ 0 * 4-6A thru 4-6B .................. 1 * i thruiv ......................... 1 4-7thru 4-8 ..................... 0 *1-1 .......................... * 4-8A ............................ 1 1-2thru 1-5 ..................... 0 * 4-8B Blank ...................... 1 1-6 B lank ....................... 0 * 4-9 ............................. 1 * 2-1 ............................. 1 4-10thru 4-12 ................... 0 2-2 thru 2-5 .................... 0 * 5-1 ............................. 1 2-6 ............................. 1 5-2thru 5-4 ..................... 0 * 2-6A ............................ 1 * 5-5 ............................. 1 * 2-6B Blank ..................... 1 5-6 thru 5-14 .................... 0 * 2-7thru 2-10 .................... 1 * 5-15thru 5-16 ................... 1 2-11 ............................ 0 5-17 ............................ 0 * 2-12 ............................ 1 * 5-18thru 5-19 ................... 1 * 2-12A thru 2-12B ................ 1 5-20 thru 5-34 ................... 0 * 2-13 thru 2-14 ............ ...... 1 * 5-35 thru 5-37 ................... 1 2-15 ............................ 0 5-38 ............................ 0 * 2-16 ............................ 1 * 5-39thru 5-41 ................... 1 2-17thru2-18 ................... 0 5-42 ............................ 0 * 2-18A .......................... 1 * 5-43 ............................ 1 2-18B ........................... 0 5-44 Blank ...................... 0 2-19 ............................ 0 * 6-1 ........................ 1 * 2-20 ............................ 1 6-2 thru 6-9 ..................... 0 * 2-21 ............................ 1 * 6-10thru 6-11 ................... 1 2-22 ............................ 0 6-12 B lank ...................... 0 * 2-23 thru 2-27 ................... 1 * 7-1 ............................. 1 2-28 thru 2-35 ................... 0 7-2 thru 7-5 ..................... 0 * 2-36 thru 2-38 ................... 1 7-6 ....... ...................... 1 2-39 thru 2-40 ................... 0 7-7thru 7-11 .................... 0 * 2-41 thru 2-42 ................... 1 * 7-12 thru 7-14 ................... 1 * 3 -1 .................. .......... 1 * 8 -1 ............................. 1 3-2 thru 3-4 ..................... 0 8-2 thru 8-6 ..................... 0 * 3-5 thru 3-7 ..................... 1 * 8-7 .................. .......... 1 3-8 ............................. 0 8-8 .... .... .............. ... 0 3 -9 ............................. 1 8-8 A ............................ 0 3-10 thru 3-25 ................... 0 8-8B Blank ....... ........ 0 3-26 Blank ...................... 0 8-9 thru 8-10 .................... 0 A Revision 1

MODEL 152 SERIES SERVICE MANUAL Page Revision Page Revision No. No. No. No. * 9 1 ............................. 1 15-14 thru 15-18 ................. 0 9-2 ............................. 0 * 15-19 thru 15-20 ................. 1 * 9-3 ............................. 1 15-20A thru 15-20B .............. 0 9-4 thru 9-7 ..................... 0 * 15-20C thru 15-20D .............. 1 * 9-8 thru 9-9 0 1 * 15-21 ........................... 1 9-10 thru 9-11 ................... 0 15-22 thru 15-24 ................. 0 * 9-12 ............................ 1 * 15-25 thru 15-26 ................. 1 * 10-1 ............................ 1 * 15-26A ......................... 1 10-2 thru 10-10 ................. 0 * 15-26B Blank ................... 1 * 11-1 thru 11-2 ................... 1 15-27 thru 15-30 ................. 0 11-3 thru 11-4 ................... 0 * 16-1 thru 16-2 ................... 1 * 11-5 ...................... ...... 1 16-3 thru 16-6 ................... 0 11-6 ............................ 0 * 16-7 thru 16-8 ................... 1 * 11-6A thru 11-6B ................ 1 * 16-8A .......................... 1 * 1-7 thru 11-8 ................... 1 * 16-8B Blank .................... 1 11-9 thru 11-10 ................. 0 * 16-9 ............................ 1 * 11-10A ......................... 1 16-10 thru 16-18 ................. 0 * 11-10B Blank ................... 1 * 16-19 ........................... 1 * 11-11 .......................... 1 16-20 thru 16-22 ................. 0 11-12thru 11-15 ................ 0 * 16-23 ................... ...... 1 * 11-16 .......................... 1 16-24thru 16-25 ................. 0 * 11-16A ......................... 1 * 16-26thru 16-27 ................. 1 * 11-16B Blank ................... 1 16-28 thru 16-29 ................. 0 11-17 thru 11-19 ................ 0 * 16-30 ................... 1.... .. 1 * 11-20 .......................... 1 16-31thru 16-32 ................. 0 11-21 thru 11-24 ................ 0 * 16-33 thru 16-34 ................. 1 11-24A ......................... 0 * 16-34A ....................... 1 * 11-24B ......................... 1 * 16-34B Blank ................... 1 11-25 ............... 0 16-35 thru 16-36 ................. 0 * 11-26 .......................... 1 16-36A thru 16-36B .............. 0 11-27 thru 11-29 ................ 0 16-37 thru 16-38 ................. 0 * 1i-30 .......................... 1 16-38A ......................... 0 * 11-30A ......................... 1 16-38B Blank ................... 0 * 11-30B Blank ................... 1 16-39 thru 16-46 ................. 0 11-31 thru 11-41 ................ 0 16-46A thru 16-46B .............. 0 11-42 Blank ................... 0 16-47 thru 16-48 ................ 0 12- thru 12-4 .................. 0 16-48A ......................... 0 * 12-5 thru 12-7 ................... 1 16-48B Blank ................... 0 12-8 thru 12-15 ................. 0 16-49 thru 16-51 ................. 0 12-16 Blank .................... 0 * 16-52 .......................... 1 * 13-1 ............................ 1 16-53 thru 16-55 ................. 0 13-2 thru 13-3 ......... 0.......... * 16-56 ........................... 1 134 Blank ..................... 0 16-57 thru 16-59 ................. 0 14-1 thru 14-5 ................... 0 16-60 Blank ..................... 0 14-6 Blank ..................... 0 17-1 thru 17-51 .................. 0 : 15-1 ............................ 1 17-52 Blank ..................... 0 15-2 ............................ 0 * 1 8-1 ............................ 1 15-2A .......................... 0 18-2 thru 18-8 ................... 0 15-2B Blank .................... 0 * 19-1 ............................ 1 15-3 thru 15-11 ................. 0 19-2 thru 19-38 .................. 0 15-12 .......................... 1 19-38A ......................... 0 * 15-12A ......................... 1 19-38B Blank ................... 0 * 15-12B Blank ................... 1 19-39 thru 19-43 ................. 0 * 15-13 .......................... 1 19-44 Blank ..................... 0 Revision 1 B/(C blank)

MODEL 152 SERIES SERVICE MANUAL TABLE OF CONTENTS SECTION PAGE NO. Aerofiche/Manual 1. GENERAL DESCRIPTION .......................................... 1A9/1-1 2. GROUND HANDLING, SERVICING, CLEANING, LUBRICATION, AND INSPECTION ............................... 1A15/2-1 3. FUSELAGE ....................................................... 1C18/3-1 4. WINGS AND EMPENNAGE ........................................ 1D22,4-1 5. LANDING GEAR AND BRAKES .................................... E16/5-1 6. AILERON CONTROL SYSTEM ..................................... 1G14/6-1 7. WING FLAP CONTROL SYSTEM ................................... 1H4/7-1 8. ELEVATOR CONTROL SYSTEM ................................... 1H22/8-1 9. ELEVATOR TRIM TAB CONTROL SYSTEM .................. .......... 11139-1 10. RUDDER CONTROL SYSTEM ......... ............................. J7/10-1 11. ENGINE .......................................................... 1J19/11-1 12. FUEL SYSTEM . ................ ............................. 2A2/12-1 13. PROPELLER ...................................................... 2A20/13-1 14. UTILITY SYSTEMS ................................................ 2B5/14-1 15. INSTRUMENTS AND INSTRUMENT SYSTEMS ..................... 2B15/15-1 16. ELECTRICAL SYSTEMS ........................................... 2D9/16-1 17. STRUCTURAL REPAIR ............................................ 2G11/17-1 18. PAINTING ........................................................ 212118-1 19. WIRING DIAGRAMS ............................................... 2J11/19-1 WARNING When performing any inspection or maintenance that requires turning on the master switch, installing a battery, or pulling the propeller through by hand, treat the propeller as if the ignition switch were ON. Do not stand. nor allow anyone else to stand within the arc of the propeller, since a loose or broken wire, or a component malfunction, could cause the propeller to rotate. Revision I

MODEL 152 SERIES SERVICE MANUAL CROSS REFERENCE LISTING OF POPULAR NAME VS. MODEL NUMBERS AND SERIALS All aircraft, regardless of manufacturer, are certified under model number degnations. However, popular names are often used for marketing purposes. To provide a consistent method of referring to these aircraft, the model number will be used in this pblication unless the popular name is necessary to differentiate between ver- sions of the same basic model. The following table provide a listing of popular name, model number, and serial number. MODEL SERIAL POPULAR NAME YEAR MODEL BEGINNING ENDING 152 1978 152 15279406 15282031 15211 1979 152 15282032 15283591 1980 152 15283592 15284541 1981 152 15284542 15285161 1982 152 15285162 15285594 1983 152 15285595 15285833 1984 152 15285834 15285939 1985 152 15285940 15286033 REIMS/CESSNA F152 1978 F152 F15201449 F15201528 REIMS/CESSNA F15211 1979 F152 F15201529 F15201673 1980 F152 F15201674 F15201808 1981 F152 F15201809 F15201893 1982 F152 F15201894 F15201928 1983 F152 F15201929 F15201943 1984 F152 F15201944 F15201952 1985 F152 - F15201953 F15201965 1986 F152 F15201966 F15201980 152AEROBAT 1978 A152 A1500433, A1520735 A1520808 1979 A152 681, A1520809 A1520878 1980 A152 A1520879 A1520948 1981 A152 A1520949 A1520983 1982 A152 A1520984 A1521014 1983 A152 A1521015 A1521025 1984 A152 A1521026 A1521027 1985 A152 A1521028 A1521049 REIMS/CESSNA F152 1978 FA152 FA1520337 FA1520347 AEROBAT 1979 FA152 FA1520348 FA1520357 1980 FA152 FA1520358 FA1520372 1981 FA152 FA1520373 FA1520377 1982 FA152 FA1520378 FA1520382 1983 FA152 FA1520383 FA1520387 1984 FA152 NONE 1985 FA152 FA1520388 FA1520415 1986 FA152 FA1520416 FA1520425 ii Revision 1

MODEL 152 SERIES SERVICE MANUAL INTRODUCTION This manual contains factory-recommended procedures and instructions for ground handling, servicing, and maintaining Cessna 152 Series Models. Besides serving as a reference for the experienced mechanic, this manual also covers step-by-step procedures for the less experienced. This service manual is designed for aerofiche presentation. To facilitate the use of the aerofiche, re- fer to the aerofiche header for basic information. KEEPING CESSNA PUBLICATIONS CURRENT The information in this publication is based on data available at the time of publication and is updated, supplemented, and automatically amended by all information issued in Service News Let- ters, Service Bulletins, Supplier Service Notices, Publication Changes, Revisions, Reissues and Temporary Revisions. All such amendments become part of and are specifically incorporated within this publication. Users are urged to keep abreast of the latest amendments to this publication through the Cessna Product Support subscription services. Cessna Service Stations have also been supplied with a group of supplier publications which provide disassembly, overhaul, and parts breakdowns for some of the various supplier equipment items. Suppliers publications are updated, supplemented, and specifically amended by supplier issued revisions and service information which may be reissued by Cessna; thereby automatically amending this publication and is communicated to the field through Cessna's Authorized Service Stations and/or through Cessna's subscription services. WARNING ALL INSPECTION INTERVALS, REPLACEMENT TIME LIMITS, OVERHAUL TIME LIMITS, THE METHOD OF INSPECTION, LIFE LIMITS, CYCLE LIMITS, ETC., RECOMMENDED BY CESSNA ARE SOLELY BASED ON THE USE OF NEW, REMANUFACTURED, OR OVERHAULED CESSNA APPROVED PARTS. IF PARTS ARE DESIGNED, MANUFACTURED, REMANUFACTURED, OVERHAULED, PURCHASED, AND/OR APPROVED BY ENTITIES OTHER THAN CESSNA, THEN THE DATA IN CESSNA'S MAINTENANCE/SERVICE MANUALS AND PARTS CATALOGS ARE NO LONGER APPLICABLE AND THE PURCHASER IS WARNED NOT TO RELY ON SUCH DATA FOR NON-CESSNA PARTS. ALL INSPECTION INTERVALS, REPLACEMENT TIME LIMITS, OVERHAUL TIME LIMITS, THE METHOD OF INSPECTION, LIFE LIMITS, CYCLE LIMITS, ETC., FOR SUCH NON-CESSNA PARTS MUST BE OBTAINED FROM THE MANUFACTURER AND/OR SELLER OF SUCH NON-CESSNA PARTS. 1. REVISIONS/CHANGES. These are issued to the dealers by Cessna Aircraft Company for this publications required, and include only pages that require updating. 2. REISSUE. Manual is reissued to dealers as required, and is a complete manual incorpo- rating all the latest information and outstanding revisions/changes. It supersedes and re- places previous issue(s). REVISIONS/CHANGES and REISSUES can be purchased from a Cessna Service Station or directly from Cessna Parts Distribution (CPD 2), Dept. 701, Cessna Aircraft Company, P. O. Box 949, Wichita, Kansas 67201. All supplemental service information concerning this manual is supplied to all appropriate Cessna Service Stations so that they have the latest authoritative recommendations for servicing these Cessna aircraft. Therefore, it is recommended that Cessna owners utilize the knowledge and exper- ience of the factory-trained Service Station Organization. Revision 1 iii

MODEL 152 SERIES SERVICE MANUAL CUSTOMER CARE SUPPLIES AND PUBLICATIONS CATALOG A Customer Care Supplies and Publications Catalog is available from a Cessna Service Station or I directly from Cessna Parts Distribution, Dept. 701, Cessna Aircraft Company, 5800 East Pawnee, Wichita, Kansas 67201. This catalog lists all publications and Customer Care Supplies available from Cessna for prior year models as well as new products. To maintain this catalog in a current status, it is revised quarterly and issued on Aerofiche with the quarterly Service Information Sum- maries. A listing of all available publications is issued periodically by the Cessna Propeller Prod- uct Support Department. SUPPLEMENTAL TYPE CERTIFICATE INSTALLATIONS Inspection, maintenance, and parts requirements for supplemental type certificate (STC) installations are not included in this manual. When an STC installation is incorporated on the airplane, those portions of the airplane affected by the installation must be inspected in accordance with the inspection program published by the owner of the STC. Since STC installations may change systems interface, operating characteristics, and component loads or stresses on adjacent structures, Cessna provided inspection criteria may not be valid for airplanes with STC installations. CUSTOMER COMMENTS ON MANUAL Cessna Aircraft Company has endeavored to furnish you with an accurate, useful, up-to-date manual. This manual can be improved with your help. Please use the return card, provided with your manual, to report any errors, discrepancies, and omissions in this manual as well as any general comments you wish to make. iv Revsion 1

MODEL 152 SERIES SERVICE MANUAL SECTION 1 GENERAL DESCRIPTION Page No. TABLE OF CONTENTS Aerofiche/ Manual GENERAL DESCRIPTION ..... A9/1-1 Aircraft Specification ....... 1A9/1-1 Model 152 and F152 ......... IA9/1-1 Stations ................... 1A9/1-1 Description ................ 1A9/1-1 Bolt Torques ............... 1A12/1-4 Model A152 and FA152 ...... 1A9/1-1 Description ................ 1A9/1-1 1-1. GENERAL DESCRIPTION. 1-2. MODEL 152 AND F152 SERIES. 1-3. DESCRIPTION. Cessna Model 152 and F152 Series aircraft described in this manuaL are high-wing monoplanes of all-metal semimonocoque construction They are equipped with fixed tubular spring-steel main gear struts and a steerable nose gear. The nose gear has an air/hydraulic fluid shook strut. Two-place seating is standard, and a double-width, fold-up auxiliary rear seat is optional. Also featured is a "wrap-around" rear window and a swept- back fin and rudder. Powering these aircraft is a four-cylinder. horizontally-opposed. air- cooled Lycoming "Blue Streak" engine, driving an all-metal fixed-pitch propeller. 1-4. MODEL A152 AND FA52 SERIES. 1-5. DESCRIPTION. Aerobat Model A152 and FA152 Series aircraft are a modified version of the current production Model 152. The strucure has been beefed-up" in some areas to meet requirements set forth in Acrobatic Category, CAR, Part 3. In addition, quick-relese cabin doors. two-strap shoulder harnesses, and aerbatic paint design are standard Removable seat and back cushions are provided to allow occupants to use either seat-pack or back-pack type parachutes for arobatic maneuvers. The FA152 is powered by a Rolls Royce built, four-cylinder, horizontally-opposed, air-cooled Lycoming engine. 1-6. AIRCRAFT SPECIFICATIONS. Leading particulars of these aircraft. with dimensions based on gross weight, are given in figure 1-1. If these dimensions are used for constructing a hangar or computing clearances, remember that such factors as nose gear strut inflation. tire pressures, tire sizes and load distribution may result in some dimensions that are considerably different from those listed. 1-7. STATIONS. Station diagrams are shown in figures 1-2 and 1-3 to assist in locating equipment when a written description is inadequate or impractical. Revision 1 1-1

Cessna 152 Service maintenance manual D2064-1-13

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