Lycoming Direct Drive Aircraft Engine Overhaul Manual – 4, 6 & 8 Cylinder Models (60294-7-13) PDF Download

This is the official Lycoming Direct Drive Engine Overhaul Manual (document 60294-7-13) covering all 4, 6 and 8 cylinder horizontally opposed, air-cooled aircraft engines. It provides comprehensive overhaul procedures for every major component, from cylinder and piston assemblies to crankshaft, camshaft, accessory housing, ignition system, lubrication system, fuel induction, and test procedures. This is the essential factory-level resource for aircraft maintenance professionals and experienced owner-mechanics working on Lycoming direct drive engines.

File Details

• Manual Type: Official Factory Overhaul Manual
• Brand: Lycoming (Avco Corporation)
• Applicable Models: O-235, O-290, O-320, O-340, O-360, O-435, O-540, IO-320, IO-360, IO-540, TIO-360, TIO-540, AIO-320, AIO-360, IO-720, VO-360, IVO-360, and many variations
• Language: English
• Page Count: 151 pages (including Table of Limits)
• File Format: PDF
• Document Number: 60294-7-13
• Includes: Full Table of Limits (SSP-1776) with clearances, torques, and specifications

Chapters Covered

• 1. Introduction – manual scope and usage
• 2. General Description – cylinders, valve operation, hydraulic tappets, crankcase, crankshaft, counterweights, accessory housing, connecting rods, pistons, lubrication, cooling, induction, turbocharger controls, ignition
• 3. General Overhaul Procedures – cleaning, degreasing, carbon removal, inspection (bearing surfaces, gears, corrosion, magnetic inspection), repair and replacement, reassembly, pre-lubrication, oilite bushings, pitch alignment, table of limits
• 4. Ignition System – magnetos, impulse coupling, retard breaker, firing order, harnesses, spark plugs, removal, disassembly, inspection, repair, reassembly, installation, timing
• 5. Accessory Housing – disassembly, cleaning, inspection, repair, reassembly, dual drives, fuel pumps, oil filter, oil cooler bypass valve
• 6. Cylinders, Pistons and Valve Train – removal, disassembly, cleaning, inspection (cylinders, pistons, rockers, push rods, valves, hydraulic tappets, springs), modifications, repair, replacement, reassembly, cylinder painting, intercylinder baffles
• 7. Crankcase, Crankshaft and Reciprocating Parts – removal of accessories, disassembly, cleaning, inspection (bearings, crankcase, crankshaft, camshaft, main bearing clearance, connecting rods, counterweight bushings, piston cooling oil jets), repair and replacement, reassembly (sludge tubes, expansion plug, propeller flange bushings, gear, counterweight, connecting rods, camshaft, crankcase, propeller governor drive, oil seal, hydro control valve, generator drive belt, crankshaft idler gears)
• 8. Oil Sump and Fuel Induction – disassembly, cleaning, inspection, repair, replacement, reassembly (induction housing, flow dividers, intake pipes, nozzle assembly)
• 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 adjustment, preservation and storage
• 10. Table of Limits – complete SSP-1776 with all clearances, torques, specifications for direct drive engines

What This Manual Enables You to Do

This manual provides everything needed to perform a complete major overhaul of Lycoming direct drive engines. With detailed step-by-step instructions, exploded views, and precise specifications, you can confidently disassemble, inspect, repair, and reassemble every component to factory standards. Avoid costly mistakes and ensure airworthiness with the correct torque values, clearances, and procedures directly from the manufacturer. The instant PDF download allows you to access the manual on any device, print necessary pages, and work side-by-side with the manual in your workshop.