1977-1986 Cessna 172 Series Aircrafts OEM Service & Repair Manual

Cessna ATextron Company Service Manual 1977 Thru 1986 MODEL 172 SERIES Member of GAMA FAA APPROVAL HAS BEEN OBTAINED ON TECHNICAL DATA IN THIS PUBLICATION THAT AFFECTS AIRPLANE TYPE DESIGN. THIS REPRINT CONSISTS OF THE BASIC MANUAL, DATED 20 MARCH 1985, AND INCORPORATES REVISION 2, DATED 1 MAY 1992. AND REVISION 3, DATED 1 JULY 1995. COPYRIGHT 1995 CESSNA AIRCRAFT COMPANY 20 MARCH 1985 WICHITA, KANSAS. USA D2065-3-13 REVISION 3 1 JULY 1995 (RGI-200-10/00)

TEMPORARY REVISION NUMBER 5 DATED 7 January 2000 MANUAL TITLE MODEL 172 SERIES 1977 THRU 1986 SERVICE MANUAL MANUAL NUMBER - PAPER COPY D2065-3-13 AEROFICHE D2065-3-13AF TEMPORARY REVISION NUMBER PAPER COPY D2065-3TR5 AEROFICHE N/A MANUAL DATE 20 MARCH 1985 REVISION NUMBER 3 DATE 1 JULY 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 18 6A Added 18 6B Added REASON FOR TEMPORARY REVISION 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 Draw a line, with a permanent red ink marker, through any superceded information.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 This will be a visual identifier that the information on the frame (page) is no longer valid and the Temporary Revision should be referenced.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

TEMPORARY REVISION NUMBER 4 DATED 16 FEBUARY 1996 MANUAL TITLE MODEL 172 SERIES 1977 THRU 1986 SERVICE MANUAL MANUAL NUMBER - PAPER COPY D2065-3-13 AEROFICHE D2065-3-13AF TEMPORARY REVISION NUMBER - PAPER COPY D2065-3TR4-13 AEROFICHE N/A MANUAL DATE 20 MARCH 1985 REVISION NUMBER 3 DATE 1 JULY 1995 This Temporary Revision consists of the following pages, which affect and replace existing pages in the paper cc- manual and supersede aerofiche information. CHAPTER/ CHAPTER/ SECTION/ AEROFICHE SECTION/ AEROFICHE SUBJECT PAGE FICHE/FRAME SUBJECT PAGE FICHE/FRAME 11 11-11 2B19 11-15 2B23 REASON FOR TEMPORARY REVISION To change torque values for engine mount-to-fuselage bolts. FILING INSTRUCTIONS FOR THIS TEMPORARY REVISION For Paper Publications: File this cover sheet behind the publication's title page to identify inclusion of the temporary revision in the manual. Insert the new pages in the publication at the appropriate locations and remove and discard the superseded pages. For Aerofiche Publications: Draw a line, with a 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 1.996 CESSNA AIRCRAFT COMPANY WICHITA, KANSAS, USA

MODEL 172 SERIES SERVICE MANUAL LIST OF EFFECTIVE PAGES INSERT LATEST REVISED PAGES. DESTROY SUPERSEDED PAGES. NOTE The portion of the text affected by the revision is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by miniature pointing hands. Original 0 20 March 1985 Revision 1 20 October 1985 Revision 2 1 May 1992 Revision 3 1 July 1995 TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 652. *The asterisk indicates pages changed, added, or deleted by the current change Page Revision Page Revision No. No. No. No. *Title ........... ........... . 3 3-21 thru 3-22 ... .............. 1 *A thru C .................... 3 3-22A ....................... 1 *i thru iv .. ..... . . . .... . ..... . 3 3-22B ..... ... ... ... .. . .. .... 0 *1-1 ................. ..... . 3 3-23 ........................ 1 1-2 thru 1-18 .................. 1 3-24 ........................ 0 1-19 thru 1-26 ................. 2 3-25 thru 3-27 ................. 1 2-1 ......................... 2 3-2 8 ........................ 0 - 2-2 thru 2-4 ................... 0 4-1 ......................... 1 2-5 thru 2-6 ................... 1 4-2 thru 4-10 .................. 0 2-7 thru 2-10 .. . ........... 0 4-10A ....................... 0 2-11 ........................ 1 4-10B Blank ................. 0 2-12 ............. ........... 0 4-11 thru 4-12 ................. 0 2-13 thru 2-34 ..... ............ 1 5-1 ................... ...... 1 2-35 thru 2-38 . ................ 2 5-2 ........................ 3 *2-39 thru 2-50 . ............... 3 5-3 thru 5-6 .................. 0 2-51 thru 2-54 . ................ 2 *5-7 ........................ 3 *2-55 thru 2-77 . .......... 3 5-8 thru 5-20 .................. 0 2-78 Blank ................... 2 5-20A ....................... 0 3-1 thru 3-2 .................. 1 5-20B Blank .................. 0 3-3 ...................... .. 0 5-21 thru 5-23 ................. 0 3-4 . . .. .... ................. 1 * 5 -24 ....................... 3 3-4A ........................ 1 5-25 thru 5-38 ................. 0 3-4B Blank ............. 1 5-39 ........................ 1 3-5 thru 3-7 . . .................. 1 *5-40 ....................... 3 3-8 thru 3-12 .................. 0 5-41 ........................ 0 3-12A thru 3-12F ............... 0 *5-42 ....................... 3 3-13 thru 3-14 . ........... 1 5-43 ........................ 0 3-15 thru 3-17 ................. 0 5-44 Blank ................... 0 3-18 . ...................... 1 6-1 ......................... 2 3-19 thru 3-20 . ........... 0 A Revision 3

MODEL 172 SERIES SERVICE MANUAL LIST OF EFFECTIVE PAGES Page Revision Page Revision No. No. No. No. 6-2 thru 6-7 . .................. 0 *12-17 ..................... 3 6-8 ......... ......... ...... 2 12-18 thru 12-22 .............. 0 6-9 thru 6-12 .......... ........ 0 12-23 ..................... 3 7-1 ... ............ ....... .. 1 12-24 thru 12-33 .............. 0 7-2 thru 7-7 ................... 0 12-34 Blank ................. 0 *7-8 ................... . ... . 3 13-1 1 7-9 thru 7-12 .................. 0 13-2 .......... ... 3 8-1 .. 1.................. .. 8-5 . ...................... . 8- ..................... 0 14-1 ....................... 3 *8-7 ........................ 3 14-2 thru 14-6 ................ 0 8-8 ......................... 0 *15-1 ...................... 3 9-1 ........................ 1 15-2 thru 15-20 ............... 0 9-2 thru 9-10 .................. 0 15-20A thru 15-20C ............ 0 10-1 ......................... 1 15-20D ..................... 1 10-2 thru 10-10 ................ 0 15-21 ......... 0 11-1 thru 11-2 ................. 15-22 ....... 3 11-2A . .1 15-23 thru 15-26 .............. 0 11-2B Blank ................... 1* 15-2 thru 51-2 .................... *11-15 3 15-29 thru 15-31 .............. 0 11-36 ................... .... 16-1 thru ................ 1 11-37 thru 11-38 .............. 0-thru 16-6 ................. 0 11-1 thru 11A-2...................... 1- . . .... 0 11-13 thru 11-15 ............... 0 1- Blank ................. 0 *11-16 ....................... 16-7 thru 16-40 ............... 11-18 thru 11-31 .............. 01-3 ................ 11A-20 thru 11A-2 ............... 1 16-B6A tak ................ 0 11-3 thru 11A- 1 .............. 0 16-41 thru 16-50 .............. 0 11A-1 ...................... 3. 12-2 ............. .. 0 *16-51 ............... 3 *12-3 . .3 16-52 thru 16-54 .. 0 11A-41 ....................... 016 12-4A 0 .............................. 0 16-55 thru 16-60 ................ 11A-18 thru 11A-19 ............. 0. ... . . ... 12-4B Blank.0 16-60A ................ 0 11A-20 Blank .................. 016-0 ..................... B B a n k 0 12-.1 1 16-41 thru 16-50 .............. 0 12-21 ........................ 3 12-4 ........................ 016-5 thru 16-54 .............. 0 12-4 ........................ 016-55 thru 16-72 ............ 0 12- .0... 16- thru 16-1 .............. 0 12- 7 .............. .......... 0 16-72A ........ ............. 0 *12-8 ........................ 3 16-72B Blank ............ 0 12-9 thru 12-16 ................ 16-73 thru 16-75 . ..... ...... 0 Revision 3 B

MODEL 172 SERIES SERVICE MANUAL LIST OF EFFECTIVE PAGES Page Revision Page Revision No. No. No. No. 16-76 ....... ........ .... 1 20-58A thru 20-58B ............ 1 18-1 thru 18-2 ................ 1 20-59 thru 20-62 .............. 0 18-3 thru 18-18 .............. 0 20-62A . ............. 0 18-19 ...................... 2 20-62B Blank ................ 0 18-20 thru 18-42 .............. 0 20-63 ...................... 1 19-1 ....................... 1 20-64 thru 20-66 . ......... 0 19-2 thru 19-8 ................ 0 20-66A . ............. 1 20-1 thru 20-3 ................ 1 20-66B Blank . ........... 1 20-4 thru 20-57 ............... 0 20-67 thru 20-94 . ......... 0 2 0 -5 8 ...................... 1 Upon receipt of a revision to this book, personnel responsible for maintaining this publication in current status should ascertain that all previous revisions havebeen received and incorporated. C Revision 3

MODEL 172 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 ...................... 1B11/2-1 3. FUSELAGE ............................................ 1F9/3-1 4. WINGS AND EMPENNAGE ............................. 1H5/4-1 5. LANDING GEAR AND BRAKES ......................... 111/5-1 5. AILERON CONTROL SYSTEM .......................... 1K5/6-1 7. WING FLAP CONTROL SYSTEM ........................ 1K21/7-1 8. ELEVATOR CONTROL SYSTEM ........................ 1L13/8-1 9. ELEVATOR TRIM TAB CONTROL SYSTEM ............. 2A3/9-1 10. RUDDER CONTROL SYSTEM .......................... 2A17/10-1 11. ENGINE (MODEL O-320-H2AD) ......................... 2B7/11-1 11A. ENGINE (MODEL O-320-D2J AND MODEL O-360-A4N) .................................... 2D3/11A-1 12. FUEL SYSTEM ......................................... 2E3/12-1 13. PROPELLERS AND PROPELLER GOVERNORS .......... 2F19/13-1 14. SYSTEMS .............................................. 2G3/14-1 15. INSTRUMENTS AND INSTRUMENT SYSTEMS .......... 2G13/15-1 16. ELECTRICAL SYSTEMS ...................... ......... 217/16-1 17. ELECTRICAL SYSTEMS (DELETED) 18. STRUCTURAL REPAIR ................................. 3A3/18-1 19. PAINTING ............................................. 3C3/19-1 20. WIRING DIAGRAMS ................................... 3C171/20-1 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. Revision3 i

MODEL 172 SERIES SERVICE MANUAL CROSS REFERENCE LISTING OF POPULAR NAME VS. MODEL NUMBERS AND SERIALS All aircraft, regardless of manufacturer, are certified under model number designations. 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 publication unless the popular name is necessary to differentiate between versions of the same basic model. The following table provides a listing of popular name, model number and serial number. MODEL SERIAL POPULAR NAME YEAR MODEL BEGINNING ENDING SKYHAWK,SKYHAWK II 1977 172N 17261445,17267585 17069309 1978 172N 17261578,17269310 17271034 (except 17270050) 1979 172N 17271035 17272884 1980 172N 17270050,17272885 17274009 1981 172P 17274010 17275034 1982 172P 17275035 17275759 1983 172P 17275760 17276079 1984 172P 17276080 17276259 1985 172P 17276260 17276516 1986 172P 17276517 17276654 REIMS/CESSNA F172 1977 F172N F17201515 F17201639 SKYHAWK, SKYHAWK II 1978 F172N F17201640 F17201749 1979 F172N F17201750 F17201909 1980 F172N F17201910 F17202039 1981 F172P F17202040 F17202134 1982 F172P F17202135 F17202194 1983 F172P F17202195 F17202216 1984 F172P F17202217 F17202233 1985 F172P F17202234 F17202238 1986 F172P F17202239 F17202254 CUTLASS, CUTLASS II 1983 172Q 17275869 17276054 1984 172Q 17276101 17276211 1985 172Q NONE ii Revision 3

MODEL 172 SERIES SERVICE MANUAL INTRODUCTION This manual contains factory-recommended procedures and instructions for ground handling, servicing, and maintaining Cessna 172 Series airplanes. Besides serving as a reference for the experienced mechanic, this manual also covers step-by-step procedures for the less experienced. If properly used, it will better enable the mechanic to maintain Cessna 172 Series airplanes and thereby establish a reputation for reliable service. This service manual is designed for aerofiche presentation. To facilitate the use of the aerofiche, refer 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 Letters, Service Bulletins, Sup- plier 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 information available at Cessna Authorized Service Stations or 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 var- ious 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., REC- OMMENDED BY CESSNA ARE SOLELY BASED ON THE USE OF NEW, REMANU- FACTURED, OR OVERHAULED CESSNA APPROVED PARTS. IF PARTS ARE DE- SIGNED, 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, RE- PLACEMENT TIME LIMITS, OVERHAUL TIME LIMITS, THE METHOD OF INSPEC- TION, 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 publication as required, and include only pages that require updating. 2. REISSUE. Manual is reissued to dealers as required, and is a complete manual incorporating all the latest information and outstanding revisions/changes. It supersedes and replaces previous issue(s). REVISIONS/CHANGES and REISSUES can be purchased from your Cessna Dealer or directly from the Cessna Parts Distribution, (CPD 2) Dept. 701, Cessna Aircraft Company, 5800 East Pawnee, Wichita, Kansas 67201. All supplemental service information concerning this manual is supplied to all appropriate Cessna Dealers so that they have the latest authoritative recommendations for servicing these Cessna aircraft. Therefore, it is recommended that Cessna owners utilize the knowledge and experience of the factory-trained Dealer Service Or- ganization. Revision 3 iii

MODEL 172 SERIES SERVICE MANUAL CUSTOMER CARE SUPPLIES AND PUBLICATIONS CATALOG A Customer Care Supplies and Publications Catalog is available from your Cessna Dealer or directly from the Cessna Parts Distribution, (CPD 2), Dept. 701, Cessna Aircraft Company, 5800 East Pawnee, Wichita, Kansas 67201. The Supplies and Publications catalog lists all publications and Customer Care Supplies available from Cessna for prior year models as well as new products. SUPPLEMENTAL TYPE CERTIFICATE INSTALLATIONS Inspection, maintenance and parts requirements for supplemental type certificate (STC) installations are not in- cluded 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 comments you wish to make. iv Revision 3

1977-1986 Cessna 172 Series Aircrafts OEM Service & Repair Manual

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