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Teledyne Continental IO-360 Series Overhaul Manual X30594A - TCM Aircraft Engine PDF

Teledyne Continental IO-360 Series Overhaul Manual X30594A – TCM Aircraft Engine PDF

Name: Teledyne Continental IO-360 Series Overhaul Manual X30594A - TCM Aircraft Engine PDF
SKU: TCM-IO360-OH-X30594A-HD
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Complete Teledyne Continental Motors overhaul manual for IO-360 series aircraft engines. Covers disassembly, inspection, repair, assembly, testing, and preservation for IO-360-A, AB, C, CB, D, DB, ES, G, GB, H, HB, J, JB, K, KB models. Instant PDF download.

SKU: TCM-IO360-OH-X30594A-HD Category: Aircraft Engine Manuals Tags: continental io-360 engine overhaul, io-360 series aircraft engine manual, tcm io-360 service manual pdf, teledyne continental io-360 overhaul manual Vendor: ServicePDFs

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Description

Teledyne Continental IO-360 Series Overhaul Manual X30594A

This is the complete Teledyne Continental Motors Overhaul Manual for the IO-360 Series aircraft engine, published under Form X30594A. It covers every phase of a major engine overhaul, from initial disassembly through cleaning, inspection, repair, reassembly, testing after overhaul, and engine preservation. The manual is written for A&P mechanics and overhaul facilities working on IO-360-A, IO-360-AB, IO-360-C, IO-360-CB, IO-360-D, IO-360-DB, IO-360-ES, IO-360-G, IO-360-GB, IO-360-H, IO-360-HB, IO-360-J, IO-360-JB, IO-360-K, and IO-360-KB engines.

File Details

Manual Type: Overhaul Manual
Brand / Publisher: Teledyne Continental Motors
Models Covered: IO-360-A, AB, C, CB, D, DB, ES, G, GB, H, HB, J, JB, K, KB
Document Number: Form X30594A
Publication Date: June 1992
Language: English
File Format: PDF
Page Count: 322
Format Standard: GAMA (General Aviation Manufacturers Association) format

Chapters Covered

Chapter 1 – Introduction: Scope, related publications, service bulletins, 100% replacement parts, definitions and abbreviations, engine model code, basic design features, special tools, products and sealants
Chapter 4 – Airworthiness Limitations: Mandatory replacement times, mandatory inspection intervals, distribution of changes
Chapter 5 – Time Limits / Maintenance Checks: Time limits and inspection program, scheduled maintenance, preflight inspection, 50-hour inspection, 100-hour inspection, unscheduled maintenance
Chapter 70 – Standard Practices: Lockwire procedure, crankcase threading procedure, application of adhesives, installation of gaskets, cylinder leakage check
Chapter 72 – Engine Reciprocating: General engine description, disassembly, cleaning/repair/replacement, inspection (visual, magnetic particle, ultrasonic, fluorescent penetrant, dimensional), specific inspections, assembly of subassemblies, final assembly, testing after overhaul, engine preservation
Chapter 73 – Engine Fuel System: Fuel injection system operation, set-up procedure, naturally aspirated engine adjustments, fuel system troubleshooting chart
Chapter 74 – Ignition: TCM ignition system (magneto installation, harness assembly installation), Slick ignition system (magneto installation, harness maintenance), ignition troubleshooting
Chapter 75 – Air: Induction system components and air flow
Chapter 76 – Engine Controls: Cruise control by performance curve, cruise control by E.G.T., performance charts
Chapter 77 – Engine Indicating: Operating limits, engine troubleshooting chart
Chapter 78 – Exhaust: General exhaust system information
Chapter 79 – Oil: Approved oil products, lubricating system troubleshooting chart
Chapter 80 – Starting: Prestarting, starting, ground warm-up, pre-takeoff check, flooded engine, cold weather operation, preheating, hot weather operation, ground operation at high altitude airports

This Teledyne Continental IO-360 Series overhaul manual gives the technician the full factory procedure for returning a IO-360 engine to service. It opens with a complete introduction to the engine family, the GAMA-standard numbering system, tooling requirements, and the 100% replacement parts list that applies at every major overhaul. From there, the disassembly chapter walks through every system — ignition, fuel injection, accessory case, induction, oil sump, oil cooler, alternator, starter adapter, oil pump, cylinders, pistons, crankcase, camshaft, and crankshaft group. Cleaning, repair, and replacement procedures follow, including cylinder work, valve guide installation, helical coil insert installation, stud replacement, crankshaft assembly, and more. The inspection chapter covers visual inspection, magnetic particle inspection, crankshaft ultrasonic inspection, fluorescent penetrant inspection, dimensional inspection, and a complete table of limits with new-part and service-limit values for the crankcase, crankshaft, connecting rods, camshaft, pistons, rings, cylinders, and gears. Specific inspection chapters then go component by component. Assembly of subassemblies, final assembly, testing after overhaul (including standard acceptance test, oil consumption determination, and overhaul test run), and engine preservation procedures round out the manual.

What This Manual Enables You To Do

With the Teledyne Continental IO-360 Series Overhaul Manual X30594A, an A&P mechanic or overhaul shop has the complete factory procedure for a major engine overhaul on any IO-360 series powerplant. The manual supports:

Complete engine disassembly in the correct sequence for every IO-360 model
Cleaning, inspection, and repair of every reciprocating engine component
Magnetic particle, ultrasonic, fluorescent penetrant, and dimensional inspection of critical parts
Use of the Table of Limits to determine new-part dimensions and service limits for the crankcase, crankshaft, connecting rods, camshaft, cylinders, pistons, and gears
Cylinder reconditioning, valve guide replacement, and valve seat refacing
Helical coil insert installation for spark plug holes and stud holes
Crankshaft and counterweight bushing replacement
Assembly of subassemblies and final engine assembly with correct torque values
Fuel injection system set-up and troubleshooting
Magneto installation and timing for both TCM and Slick ignition systems
Overhaul test run, oil consumption determination, and test flight procedures
Flyable, temporary, and indefinite storage preservation procedures

Correct torque values, clearances, fits, and inspection limits are all included, along with special tool references, sealant and lubricant application charts, and troubleshooting guides for the fuel, ignition, and lubrication systems. The manual also includes the engine specifications, operating limits, and performance charts needed to verify the engine meets its rated output after overhaul.

Why This Manual Matters

An IO-360 is a certified aircraft engine, and every overhaul must be done to the manufacturer’s published fits, limits, and procedures. Using the wrong clearance or torque value, skipping a required inspection, or reusing a part that the manufacturer specifies for 100% replacement can compromise the airworthiness of the engine and the safety of the aircraft. This manual gives the correct procedure the first time — whether you are measuring a crankshaft journal, setting magneto timing, adjusting fuel pump pressure, checking cylinder leakage, or torquing through bolts in the correct sequence.

The overhaul manual is also written to work with the IO-360 Series Parts Catalog (Form X30595A), the Maintenance and Operators Manual (Form X30617), and the Fuel Injection Manual (Form X30593A). Service bulletins referenced throughout the text cover updates issued after the original June 1992 publication date.

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the “Teledyne Continental IO-360 Series Overhaul Manual X30594A – TCM Aircraft Engine PDF” are as follows:

X30594A – IO-360 OVERHAUL MANUAL – MODELS IO-360-A, AB, C, CB, D, DB, ES, G, GB, H, HB, J, JB, K, KBp. 1

CURRENT STATUS OF PAGESp. 2

WARNINGp. 3

NOTICEp. 4

INTRODUCTIONp. 5

TABLE OF CONTENTSp. 6

LIST OF ILLUSTRATIONSp. 12

1-10-04 – THREE QUARTER RIGHT FRONT VIEW OF THE IO-360 SERIES ENGINEp. 30

1-10-04 – THREE QUARTER LEFT FRONT VIEW OF THE IO-360-ES ENGINEp. 30

1-10-04 – INSTALLATION DRAWING IO-360 SERIES ENGINEp. 31

1-20-01 (1) – STRAP WRENCHp. 40

1-20-01 (2) – OIL FILTER CAN CUTTERp. 40

1-20-01 (3) – CYLINDER BASE NUT WRENCHESp. 41

1-20-01 (4) – CYLINDER BASE NUT WRENCHp. 41

1-20-01 (5) – PISTON PIN REMOVERS 8121 SERIESp. 42

1-20-01 (6) – CYLINDER HONEp. 42

1-20-01 (7) – HOLDING FIXTURE ADAPTERSp. 43

1-20-01 (8) – UNIVERSAL CYLINDER HOLDING FIXTUREp. 43

1-20-01 (9) – VALVE GUIDE CLEANER 122p. 44

1-20-01 (10) – SEAL SEAT CUTTERp. 44

1-20-01 (11) – SPRING CHECKERp. 44

1-20-01 (12) – VALVE GUIDE REMOVERSp. 44

1-20-01 (13) – VALVE GUIDE REPLACERSp. 45

1-20-01 (14) – ROCKER ARM BUSHING REMOVER/INSTALLER SETp. 45

1-20-01 (15) – PISTON RING COMPRESSORSp. 45

1-20-01 (16) – PISTON RING COMPRESSORSp. 45

1-20-01 (17) – FLOATING HOLDERp. 46

1-20-01 (18) – VALVE SPRING COMPRESSORp. 46

1-20-01 (19) – PUSH ROD SPRING COMPRESSORp. 46

1-20-01 (20) – FLARING TOOL FOR PUSH ROD HOUSINGp. 46

1-20-01 (21) – VALVE GUIDE REMOVERp. 46

1-20-01 (22) – VALVE SEAT INSERT REMOVER AND REPLACERp. 47

1-20-01 (23) – INSTALLER VALVE SEAT INSERTSp. 47

1-20-01 (24) – VALVE GUIDE TO VALVE SEAT ALIGNMENT SYSTEMp. 48

1-20-01 (25) – VALVE STEM HOLE REAMERSp. 49

1-20-01 (26) – BORING BARSp. 49

1-20-01 (27) – BORING BARSp. 49

1-20-01 (28) – EXPANDING GUIDE BODIESp. 49

1-20-01 (29) – VALVE SEAT INSERT CUTTERSp. 50

1-20-01 (30) – STEP SIDE CUTTERSp. 50

1-20-01 (31) – ROSAN STUD REMOVERp. 50

1-20-01 (32) – CONNECTING ROD REAMING AND ALIGNMENT CHECKING FIXTUREp. 51

1-20-01 (33) – ADAPTER KITSp. 51

1-20-01 (34) – REAMERS, CONNECTING ROD BUSHINGp. 51

1-20-01 (35) – UNIVERSAL CONNECTING ROD BUSHING REMOVER AND INSTALLER SETp. 52

1-20-01 (36) – COMMON DRIVE HANDLE AND PILOTSp. 52

1-20-01 (37) – NEEDLE BEARING INSTALLERp. 53

1-20-01 (38) – HYDRAULIC CRANKSHAFT DAMPENER BUSHING REMOVER/REPLACER SETp. 53

1-20-01 (39) – COUNTER WEIGHT BUSHING REMOVER/INSTALLERp. 53

1-20-01 (40) – ALL POSITION ENGINE STANDp. 54

1-20-01 (41) – TORQUE BAND TENSION ADJUSTERp. 54

1-20-01 (42) – GENERATOR DRIVE HOLDERSp. 54

1-20-01 (43) – CYLINDER HEATING STANDp. 55

1-20-01 (44) – STARTER CLUTCH SHAFT BEARING PULLERSp. 55

1-20-01 (45) – DIFFERENTIAL PRESSURE GAUGEp. 56

1-20-01 (46) – DIFFERENTIAL PRESSURE CYLINDER CHECKERp. 56

1-20-01 (47) – BELT TENSION GAUGEp. 56

1-20-01 (48) – HYDRAULIC VALVE LIFTER TESTERp. 56

1-20-01 (49) – IN AIRCRAFT ALTERNATOR GENERATOR TESTERp. 57

1-20-01 (50) – ENGINE TIMING DISCp. 57

1-20-01 (51) – PULLEY HOLDERp. 57

1-20-01 (53) – VACUUM PUMPp. 58

1-20-01 (52) – PULLEY ALIGNMENT GAGE BARp. 57

1-20-01 (54) – GENERATOR PULLEY PULLERp. 58

1-20-01 (55) – SPARK PLUG INSERT REPLACERp. 59

1-20-01 (56) – THRU-BOLT BORE STEP CUTTERSp. 59

1-20-01 (57) – SPARK PLUG INSERT TAPp. 59

1-20-01 (58) – SPARK PLUG INSERT REMOVERp. 59

1-20-01 (59) – SLIDE HAMMERp. 59

1-20-01 (60) – SPARK PLUG TAPp. 59

1-20-01 (61) – ROSAN LOCK RING INSTALLERp. 60

1-20-01 (62) – STUD DRIVERSp. 60

1-20-01 (63) – CRANKCASE SPLITTER SETp. 60

1-20-01 (64) – PROPELLER SHAFT OIL SEAL INSTALLERp. 62

1-20-01 (65) – OIL PRESSURE RELIEF SPOT FACERSp. 62

1-20-01 (66) – RUNOUT BLOCK SETp. 62

1-20-01 (67) – POLISHING TOOLS FOR CRANKSHAFT BEARINGSp. 62

1-20-01 (68) – INJECTOR NOZZLE REMOVER AND INSTALLERp. 13

1-20-01 (69) – CRANKCASE THRU-BOLT REMOVERSp. 13

1-20-01 (70) – HEX DRIVE FOR HEX TUBE NUTSp. 13

1-20-01 (71) – ROTABROACH CUTTERSp. 13

1-20-01 (72) – PULLERSp. 63

1-20-01 (73) – PULLERSp. 63

1-20-01 (74) – PULLERSp. 63

1-20-01 (75) – PULLERSp. 63

1-20-01 (76) – OUTSIDE MICROMETERSp. 64

1-20-01 (77) – DIAL BORE GAGESp. 64

1-20-01 (78) – BLADE MICROMETERSp. 65

1-20-01 (79) – SCREW THREAD MICROMETERp. 65

1-20-01 (80) – DEPTH MICROMETERSp. 65

1-20-01 (81) – REAMERS, ROCKER SHAFT SUPPORT BOSSp. 66

1-20-01 (82) – REAMERS, VALVE GUIDE BOSSp. 66

1-20-01 (83) – VALVE GUIDE STEM HOLE REAMERSp. 67

1-20-01 (84) – ADAPTER, SQUARE SHANK REAMERSp. 67

1-20-01 (85) – PLUG GAUGES VALVE STEM HOLEp. 67

1-20-01 (86) – DIAL THICKNESS GAGEp. 68

1-20-01 (87) – PRECISION VERNIER CALIPERSp. 68

1-20-01 (88) – INSIDE MEASURING INSTRUMENTSp. 68

1-20-01 (89) – ALTERNATOR ANALYZERp. 69

1-20-01 (90) – ALTERNATOR/REGULATOR/BATTERY TESTERp. 69

1-20-01 (91) – MULTIPLE VOLTAGE & CIRCUIT TESTERp. 69

1-20-01 (92) – AIRCRAFT MAGNETO TIMING LIGHTp. 70

1-20-01 (93) – AIRCRAFT TIMING INDICATORp. 70

1-20-01 (94) – COLD CYLINDER TESTERp. 70

1-20-01 (95) – HI-VOLTAGE CABLE TESTERp. 71

1-20-01 (96) – MASTER ORIFICE TOOLp. 71

1-20-01 (97) – ALCOR PORTABLE DIGITAL EGT UNITp. 72

1-20-01 (98) – ALCOR PORTABLE DIGITAL CHT UNITp. 72

70-10-00 – LOCKWIRE PROCEDUREp. 95

70-20-00 – PERMATEX, THREADING PROCEDURE & GASKET MAKERp. 96

70-50-01 – MASTER ORIFICE ASSEMBLY TOOLp. 98

70-50-02 – CYLINDER STATIC SEAL & DYNAMIC SEALp. 98

70-50-03 – DIFFERENTIAL PRESSURE TESTERp. 100

70-50-04 – DYNAMIC SEAL CHECKp. 102

72-00-03 – CRANKSHAFT NUMBERINGp. 112

72-00-09 – GEAR TRAIN DIAGRAMp. 115

72-00-10 – LUBRICATION SYSTEMp. 116

72-00-11 – HYDRAULIC LIFTERp. 117

72-00-14 – WIRING DIAGRAM (HARNESS)p. 118

72-10-05 – EXPLODED VIEW OF IGNITION SYSTEMp. 123

72-10-06A – FUEL INJECTION SYSTEMp. 125

72-10-06B – FUEL INJECTION SYSTEM, IO-360-ESp. 127

72-10-07 – ACCESSORY CASEp. 129

72-10-08A – INDUCTION SYSTEMp. 131

72-10-08B – INDUCTION SYSTEM, IO-360-ESp. 133

72-10-09 – OIL SUMPp. 134

72-10-10 – OIL COOLERp. 135

72-10-11 – ALTERNATOR ASSEMBLYp. 137

72-10-12A – STARTER AND STARTER DRIVE ADAPTER, IO-360-A,AB,D,DB,H,HB,J,JB,K,KB,ESp. 139

72-10-12B – STARTER AND STARTER DRIVE ADAPTER, IO-360-C,CB,G,GBp. 141

72-10-13 – OIL PUMP ASSEMBLYp. 143

72-10-14 – CYLINDER AND PISTON ASSEMBLYp. 145

72-10-15A – CRANKCASE STUDDING ASSEMBLYp. 147

72-10-15B – CRANKCASE ASSOCIATED PARTSp. 149

72-10-15C – CRANKCASE ATTACHING PARTSp. 151

72-10-16 – CAMSHAFT ASSEMBLYp. 152

72-10-17 – CRANKSHAFT GROUPp. 153

72-10-18 – INTERCYLINDER AIR BAFFLES IO-360-ESp. 154

72-10-19 – OPTIONAL ACCESSORIESp. 156

72-20-12A – CRANKCASE AND ACCESSORY CASE STUD SETTING HEIGHTSp. 161

72-20-12B – STANDARD & OVERSIZED STUD IDENTIFICATIONp. 162

72-20-14A – PRYING SPARK PLUG HELICAL COIL FROM CYLINDERp. 164

72-20-14B – REMOVING SPARK PLUG HOLE HELICAL INSERTp. 164

72-20-14C – INSTALLING SPARK PLUG HOLE HELICAL INSERTp. 164

72-20-14D – EXPANDING SPARK PLUG HOLE HELICAL INSERTp. 164

72-20-15A – CYLINDER ASSEMBLY DIMENSIONSp. 165

72-20-15B – INTAKE VALVE SEAT REFACINGp. 166

72-20-15C – EXHAUST VALVE SEAT REFACINGp. 166

72-20-15D – INTAKE VALVE REFACINGp. 167

72-20-17 – VALVE, ROCKER BUSHING DIMENSIONSp. 164

72-20-18 – HYDRAULIC LIFTERp. 169

72-20-20 – CONNECTING ROD AND BUSHING DIMENSIONSp. 170

72-20-27 – IGNITION WIRING DIAGRAMp. 171

72-30-04 – CRANKSHAFT ULTRASONIC INSPECTING PROCEDUREp. 180

72-40-07A – INSPECTION RING SIDE CLEARANCEp. 195

72-40-07B – MEASURING RING GAP IN CYLINDERp. 195

72-40-13A – SPARK PLUGSp. 198

72-40-13B – REVERSE SPARK PLUG PROCEDUREp. 198

72-50-10A – FUEL MANIFOLD VALVE FITTING ORIENTATION ESp. 216

72-50-10B – FUEL MANIFOLD VALVE FITTING ORIENTATIONp. 217

72-50-10C – FUEL PUMP FITTING LOCATIONSp. 218

72-50-10D – FUEL PUMP FITTING LOCATIONS (ES)p. 219

72-60-02A – RIGHT SIDE OF CRANKCASE ON STANDp. 224

72-60-02B – ALIGNMENT OF TIMING MARKSp. 225

72-60-02C – LEFT CRANKCASE AND SUPPORTp. 225

72-60-02D – TORQUING SEQUENCEp. 226

72-60-03A – INSTALLATION NO. 5 CYLINDERp. 227

72-60-03B – TIGHTENING CYLINDER BASE NUTp. 227

72-60-03C – CYLINDER FLANGE TORQUE SEQUENCE FOR SINGLE CYLINDER INSTALLATIONp. 228

72-60-04 – TORQUING THRU BOLTSp. 228

72-60-10 – INSTALLING PUSHROD HOUSINGp. 231

72-60-11 – BOTTOM VIEW, VALVE MECHANISMp. 231

73-00-00 – FUEL SYSTEM DIAGRAMp. 255

73-00-01 – THROTTLE AND METERING UNITp. 256

73-00-02 – FUEL INJECTION NOZZLEp. 256

73-00-03 – FUEL SYSTEM SCHEMATIC (ES)p. 256

74-00-01 – COATING INSULATING SLEEVEp. 263

74-00-02 – INSTALLATION OF ELBOW CLAMPp. 263

LIST OF CHARTSp. 16

1-10-04 – ENGINE DIMENSIONSp. 16

1-20-01 – SPECIAL TOOLS PROCUREMENT SOURCESp. 34

1-20-01 – IDENTIFICATION CODE FOR TOOLSp. 35

1-20-01 – SPECIAL TOOL INDEXp. 36

1-30-00 – APPLICATION CHART SEALANTS/LUBRICANTSp. 73

70-50-05 – CYLINDER LEAKAGE CHECKp. 97

72-20-12A – CRANKCASE AND ACCESSORY CASE STUD SETTING HEIGHTSp. 161

72-20-12B – STANDARD AND OVERSIZE STUD IDENTIFICATIONp. 162

72-20-12C – MISCELLANEOUS STUD SETTING HEIGHTSp. 162

72-30-03 – MAGNETIC PARTICLE INSPECTIONp. 177

72-30-08 – TABLE OF LIMITS CHART (1)p. 181

72-30-08 – TABLE OF LIMITS CHART (2)p. 182

72-30-08 – TABLE OF LIMITS CHART (3)p. 184

72-30-08 – TABLE OF LIMITS CHART (4)p. 186

72-30-08 – TABLE OF LIMITS CHART (5A)p. 187

72-30-08 – TABLE OF LIMITS CHART (5B)p. 188

72-30-09 – CRITICAL NEW PART DIMENSIONSp. 189

72-40-15 – INSPECTION CHARTp. 199

72-50-01A – GENERAL USE – TIGHTENING TORQUESp. 211

72-50-01B – TABLE OF TIGHTENING TORQUESp. 212

72-50-01C – PIPE PLUGSp. 213

72-50-01D – HYDRAULIC LINE FITTINGSp. 213

72-50-10A – FUEL MANIFOLD VALVE FITTING LOCATIONS (ES)p. 216

72-50-10B – FUEL MANIFOLD VALVE FITTING LOCATIONp. 217

72-50-10C – FUEL PUMP FITTING LOCATIONSp. 218

72-70-14 – STANDARD ACCEPTANCE TESTp. 240

72-70-14 – OIL CONSUMPTION DETERMINATIONp. 241

72-70-14 – TEST OPERATING LIMITSp. 242

73-10-02 – FUEL INJECTION SYSTEM TROUBLESHOOTING CHARTp. 259

74-00-03 – COUPLING NUT TORQUE VALUES (TCM)p. 264

74-10-01 – COUPLING NUT TORQUE VALUES (SLICK)p. 267

74-20-00 – IGNITION TROUBLESHOOTINGp. 268

76-30-00 – PERFORMANCE CHARTSp. 276

77-10-00 – OPERATING LIMITSp. 296

77-20-00 – ENGINE TROUBLESHOOTINGp. 298

79-10-00 – APPROVED OIL PRODUCTSp. 311

79-20-00 – LUBRICATION SYSTEM TROUBLESHOOTINGp. 312

CHAPTER 1 – INTRODUCTIONp. 17

1-00-00 – SCOPEp. 19

1-00-01 – RELATED PUBLICATIONSp. 19

1-00-02 – SERVICE BULLETINSp. 20

1-00-03 – SERVICE REPORTS AND INQUIRIESp. 20

1-00-04 – 100% REPLACEMENT PARTSp. 21

1-10-00 – DEFINITIONS & ABBREVIATIONSp. 23

1-10-01 – ABBREVIATIONS / SYMBOLSp. 23

1-10-02 – DEFINITIONSp. 24

1-10-03 – DESCRIPTION OF ENGINE MODEL CODEp. 29

1-10-04 – BASIC DESIGN FEATURESp. 29

1-20-00 – TOOLSp. 33

1-20-01 – SPECIAL TOOLSp. 33

1-30-00 – PRODUCTSp. 73

1-30-01 – PRODUCT LISTp. 73

CHAPTER 4 – AIRWORTHINESS LIMITATIONSp. 79

4-00-00 – AIRWORTHINESS LIMITATIONSp. 79

CHAPTER 5 – TIME LIMITS/MAINTENANCE CHECKSp. 81

5-00-00 – GENERALp. 83

5-10-00 – TIME LIMITS/INSPECTION PROGRAMp. 85

5-20-00 – SCHEDULED MAINTENANCEp. 87

5-20-01 – PREFLIGHT INSPECTIONp. 87

5-20-02 – 50 HOUR INSPECTIONp. 87

5-20-03 – 100 HOUR INSPECTIONp. 88

5-50-00 – UNSCHEDULED MAINTENANCEp. 91

CHAPTER 70 – STANDARD PRACTICESp. 93

70-00-00 – GENERALp. 94

70-10-00 – LOCKWIRE PROCEDUREp. 95

70-20-00 – CRANKCASE THREADING PROCEDUREp. 96

70-30-00 – APPLICATION OF ADHESIVESp. 97

70-40-00 – INSTALLATION OF GASKETSp. 97

70-50-00 – CYLINDER LEAKAGE CHECKp. 97

70-50-01 – LEAKAGE CHECKSp. 99

70-50-02 – EQUIPMENTp. 99

70-50-03 – PERFORMING THE CHECKp. 100

CHAPTER 72-00 – ENGINE RECIPROCATINGp. 105

72-00-00 – GENERALp. 108

72-00-01 – INTRODUCTIONp. 111

72-00-02 – CRANKCASEp. 111

72-00-03 – CRANKSHAFTp. 111

72-00-04 – CONNECTING RODSp. 112

72-00-05 – CAMSHAFTp. 113

72-00-06 – PISTONSp. 113

72-00-07 – LIFTERSp. 113

72-00-08 – CYLINDERSp. 113

72-00-09 – GEAR TRAINp. 114

72-00-10 – LUBRICATION SYSTEMp. 114

72-00-11 – VALVE MECHANISMp. 117

72-00-12 – INDUCTION SYSTEMp. 117

72-00-13 – EXHAUST SYSTEMp. 118

72-00-14 – IGNITION SYSTEMp. 118

CHAPTER 72-10 – DISASSEMBLYp. 119

72-10-01 – GENERALp. 121

72-10-02 – EXTENT OF DISASSEMBLYp. 122

72-10-03 – PARTS TO BE DISCARDEDp. 122

72-10-04 – PRELIMINARY CLEANINGp. 122

72-10-05 – IGNITION SYSTEMp. 122

72-10-06 – FUEL INJECTION SYSTEMp. 124

72-10-07 – ACCESSORY CASEp. 128

72-10-08 – INDUCTION SYSTEMp. 130

72-10-09 – OIL SUMPp. 134

72-10-10 – OIL COOLERp. 135

72-10-11 – ALTERNATOR ASSEMBLYp. 137

72-10-12 – STARTER AND STARTER DRIVE ADAPTERp. 138

72-10-13 – OIL PUMP ASSEMBLYp. 142

72-10-14 – CYLINDERS AND PISTONSp. 144

72-10-15A – CRANKCASE STUDDING ASSEMBLYp. 146

72-10-15B – CRANKCASE ASSOCIATED PARTSp. 148

72-10-15C – CRANKCASE ATTACHING PARTSp. 150

72-10-16 – CAMSHAFT ASSEMBLYp. 152

72-10-17 – CRANKSHAFT GROUPp. 152

72-10-18 – INTER CYLINDERS BAFFLESp. 154

72-10-19 – OPTIONAL ACCESSORIESp. 155

CHAPTER 72-20 – CLEANING, REPAIR AND REPLACEMENTp. 157

72-20-01 – GENERALp. 159

72-20-02 – CYLINDERSp. 159

72-20-03 – PISTONSp. 159

72-20-04 – VALVESp. 160

72-20-05 – ROCKER SHAFTSp. 160

72-20-06 – PUSHRODS, VALVE ROCKERS AND SMALL STEEL PARTSp. 160

72-20-07 – CAMSHAFT AND CRANKSHAFTp. 160

72-20-08 – CRANKCASEp. 160

72-20-09 – GEARSp. 160

72-20-10 – SHEET METAL PARTS AND INTAKE MANIFOLDp. 160

72-20-11 – CASTINGSp. 161

72-20-12 – STUD REPLACEMENTp. 161

72-20-13 – HELICAL COIL INSERT INSTALLATIONp. 163

72-20-14 – SPARK PLUG HOLE HELICAL COIL INSERTSp. 163

72-20-15 – FIN REPAIRSp. 168

72-20-16 – VALVE GUIDESp. 168

72-20-17 – VALVE ROCKERSp. 169

72-20-18 – HYDRAULIC VALVE LIFTERSp. 169

72-20-19 – CONNECTING RODSp. 169

72-20-20 – PISTON PIN BUSHING REPLACEMENTp. 169

72-20-21 – CRANKSHAFT ASSEMBLYp. 170

72-20-22 – MAGNETO GEAR SUPPORT SHAFTp. 170

72-20-23 – MAGNETO AND ALTERNATOR DRIVE COUPLINGp. 171

72-20-24 – TACHOMETER DRIVE HOUSINGp. 171

72-20-25 – STARTER DRIVE ADAPTERp. 171

72-20-26 – OIL PUMP ASSEMBLYp. 171

72-20-27 – IGNITION CABLESp. 171

CHAPTER 72-30 – INSPECTIONp. 173

72-30-01 – GENERALp. 175

72-30-02 – VISUAL INSPECTIONp. 176

72-30-03 – MAGNETIC PARTICLE INSPECTIONp. 176

72-30-04 – CRANKSHAFT ULTRASONIC INSPECTIONp. 178

72-30-05 – FLOURESCENT PARTICLE INSPECTIONp. 180

72-30-06 – DIMENSIONAL INSPECTIONp. 180

72-30-07 – DIMENSIONAL LIMITSp. 180

72-30-08 – TABLE OF LIMITSp. 181

72-30-09 – CRITICAL NEW PART DIMENSIONp. 189

72-30-10 – PROTECTIVE COATINGp. 189

72-30-11 – APPLICATION OF ANODIZINGp. 190

72-30-12 – REPAIR OF ALODIZED SURFACESp. 190

72-30-13 – ENAMEL COATINGSp. 190

CHAPTER 72-40 – SPECIFIC INSPECTIONSp. 191

72-40-01 – CRANKCASEp. 193

72-40-02 – CRANKSHAFTp. 193

72-40-03 – CRANKSHAFT AND COUNTERWEIGHT PINS AND BUSHINGSp. 193

72-40-04 – CAMSHAFTp. 194

72-40-05 – CONNECTING RODSp. 194

72-40-06 – GEARSp. 194

72-40-07 – PISTONS AND RINGSp. 194

72-40-08 – CYLINDERSp. 196

72-40-09 – HYDRAULIC VALVE LIFTERSp. 196

72-40-10 – INTAKE TUBESp. 197

72-40-11 – LUBRICATION SYSTEMp. 197

72-40-12 – FUEL INJECTION SYSTEMp. 197

72-40-13 – IGNITION SYSTEMp. 197

72-40-14 – EXHAUST SYSTEMp. 9

72-40-15 – INSPECTION CHARTp. 199

CHAPTER 72-50 – ASSEMBLY OF SUBASSEMBLIESp. 209

72-50-01 – GENERALp. 211

72-50-02 – OIL PUMP ASSEMBLYp. 213

72-50-03 – STARTER AND STARTER ADAPTERp. 214

72-50-04 – CYLINDER ASSEMBLYp. 214

72-50-05 – PISTON AND RING ASSEMBLIESp. 215

72-50-06 – PUSHROD HOUSINGp. 215

72-50-07 – CRANKSHAFT AND CONNECTING RODSp. 215

72-50-08 – CAMSHAFTp. 215

72-50-09 – CRANKCASEp. 216

72-50-10 – FUEL INJECTION, AIR THROTTLE AND METERING ASSEMBLYp. 216

CHAPTER 72-60 – FINAL ASSEMBLYp. 221

72-60-01 – GENERALp. 223

72-60-02 – CRANKCASEp. 223

72-60-03 – CYLINDERS AND PISTONSp. 227

72-60-04 – ACCESSORY CASEp. 228

72-60-05 – FUEL PUMPp. 229

72-60-06 – STARTER DRIVE ADAPTERp. 229

72-60-07 – ALTERNATOR ASSEMBLYp. 229

72-60-08 – OIL COOLERp. 230

72-60-09 – VALVE MECHANISMp. 230

72-60-10 – INTERCYLINDER AIR BAFFLESp. 230

72-60-11 – OIL SUMPp. 232

72-60-12 – INDUCTION SYSTEMp. 232

72-60-13 – FUEL INJECTION SYSTEMp. 232

72-60-14 – IGNITION SYSTEMp. 233

72-60-15 – EXHAUST SYSTEMp. 233

72-60-16 – OPTIONAL ACCESSORIESp. 234

CHAPTER 72-70 – TESTING AFTER OVERHAULp. 235

72-70-01 – TEST STANDp. 237

72-70-02 – TEST CLUBp. 237

72-70-03 – COOLING AIR SCOOPp. 237

72-70-04 – INDUCTION AIR INTAKEp. 237

72-70-05 – EXHAUST SYSTEMp. 237

72-70-06 – CONTROLSp. 237

72-70-07 – ELECTRICAL WIRINGp. 237

72-70-08 – INSTRUMENTSp. 237

72-70-09 – BREATHERp. 238

72-70-10 – FUEL SYSTEMp. 238

72-70-11 – GOVERNOR PAD COVERp. 238

72-70-12 – ENGINE TESTp. 238

72-70-13 – STARTING PROCEDUREp. 239

72-70-14 – OVERHAUL TEST RUNp. 240

72-70-15 – TEST FLIGHTp. 243

CHAPTER 72-80 – ENGINE PRESERVATIONp. 245

72-80-01 – GENERALp. 247

72-80-02 – FLYABLE STORAGEp. 247

72-80-03 – TEMPORARY STORAGEp. 248

72-80-04 – INDEFINITE STORAGEp. 249

CHAPTER 73-00 – ENGINE FUEL SYSTEMp. 253

73-00-00 – ENGINE FUEL SYSTEMSp. 255

73-10-00 – SET-UP PROCEDUREp. 258

73-10-01 – NATURALLY ASPIRATED ENGINEp. 258

73-10-02 – FUEL SYSTEM TROUBLESHOOTING CHARTp. 259

CHAPTER 74 – IGNITIONp. 261

(TCM IGNITION SYSTEM)p. 262

74-00-00 – GENERALp. 262

74-00-01 – MAGNETO INSTALLATIONp. 262

74-00-02 – HARNESS ASSEMBLY INSTALLATIONp. 263

(SLICK IGNITION SYSTEM)p. 265

74-10-00 – GENERALp. 265

74-10-01 – MAGNETO INSTALLATIONp. 265

74-10-02 – HARNESS ASSEMBLY MAINTENANCEp. 266

74-20-00 – IGNITION TROUBLESHOOTINGp. 268

CHAPTER 75 – AIRp. 269

75-00-00 – GENERALp. 271

CHAPTER 76 – ENGINE CONTROLSp. 273

76-00-00 – GENERALp. 275

76-10-00 – CRUISE CONTROL BY PERFORMANCE CURVEp. 275

76-20-00 – CRUISE CONTROL BY E.G.T.p. 275

76-30-00 – PERFORMANCE CHARTSp. 276

CHAPTER 77 – ENGINE INDICATINGp. 293

77-00-00 – GENERALp. 295

77-10-00 – OPERATING LIMITSp. 296

77-20-00 – ENGINE TROUBLESHOOTING CHARTp. 298

CHAPTER 78 – EXHAUSTp. 305

78-00-00 – GENERALp. 307

CHAPTER 79 – OILp. 309

79-00-00 – GENERALp. 311

79-10-00 – APPROVED OIL PRODUCTSp. 311

79-20-00 – LUBRICATING SYSTEM TROUBLESHOOTING CHARTp. 312

CHAPTER 80 – STARTINGp. 313

80-00-00 – GENERALp. 315

80-00-01 – PRESTARTINGp. 315

80-00-02 – STARTINGp. 315

80-00-03 – GROUND WARM-UPp. 316

80-00-04 – PRE-TAKEOFF CHECKp. 317

80-00-05 – FLOODED ENGINEp. 318

80-00-06 – COLD WEATHER OPERATIONp. 319

80-00-07 – PREHEATINGp. 319

80-00-08 – HOT WEATHER OPERATIONp. 321

80-00-09 – GROUND OPERATING AT HIGH ALTITUDE AIRPORTSp. 322

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