Lycoming Tg St Ste

~n"\’cO LYCON1ING VVILLIANISPORT DIV1510N

652 Oliver Street, Williamsport, Pennsylvania 17707

L~AVCO LYCOMING ENGINE GROUP

SPECIAL SERVICE TOOLS FOR AVCO

LYCOMING PISTON ENGINES

JSSP384 JAN.1985

EBs.ao

REALIZING THE WEALTH OF INFORMATION IN THE FIELD,WE WELCOME ANY AND ALL COMMENTS AM) ADDITIONS TO THIS GUIDE.

THIS BOOKLET IS MADE TO HELP ALL SERVICE PERSONNEL AND

MECHANICS. THE MORE COMPLETE WE MAKE IT, THE MORE HELPFUL

IT WILL BE. WE LOOK FORWARD TO HEARING FROM YOU AND HOPE

TO MAKE THE 1976 EDITION BIGGER AND BETTER. PLEASE ADDRESS

YOUR COMMENTS TO:

AVCO LYCOMING WILLIAMSPORT DIVISION

AVCO CORPORATION

WILLIAMSPORT, PA. 17701

E. L. TYLER, MANAGER

PROMOTION Sr TRAINING

AVCO LYCOMING SERVICE TOOLS

INTRODUCTION

This catalog replaces Tool Catalog SSP578 dated November, 1978.

This catalog contains information relative to tools used for modification and maintenance of Avco Lycomingopposed aircraft engines. It consists of four sections: The first is an alphabetical index and the second a

numerical pictorial listing with brief descriptions. The third is a Service Publication Cross Reference Index and

the fourth is a listing of obsolete tools.

The illustrations used in this catalog show the general appearance of the tools but are not related according to

size. In some cases, a single illustration has been used to cover a number of tools similar in appearance, with dif-

ferent tool numbers; therefore it is necessary, when ordering tools, to note carefully the descriptions and tool

numbers in the text. Any tool described as being applicable to engines with "crosswise accessories" or

"crosswise accessory housings" do not include VO-435-B1A and TVO-435-F1A helicopter engines and TIG-541

and TIGO-541 integral accessory drive engines; tools applicable to these engines are specifically designated byengine model.

PRICES

This catalog does not list prices. A separate numerically arranged parts and tool price list is available and is

supplied to distributors of Avco Lycoming engines.

HOW TO ORDER

Tools must be ordered by or through authorized Avco Lycoming distributors. A tool must be designated by a

tool number together with a name sufficiently descriptive to identify the tool. It is not necessary to write the full

catalog description of the tool. Do not enter price of the tool on the order. Be sure to give definite shipping in-

structions.


ALPHABETICAL INDEX

A C (Cont.)

Adapter- Club -test- 64773, 64783, 64801, 64802, 64803,

dynafocal mounts -64898, ST-88 64807, 64988, 64990, ST-241, ST-297, ST-298, ST-351,engine overhaul assembly ST-165, ST-240 ST-456

hand drive ST-63 Compressorhydraulic tappets 64899 piston ring 64529, 64559, 64712

overhaul stand 64917 valve spring ST-25, ST-266, ST-419

propeller shaft flange 64836 Counterbore

sludge tube removal 64866 crankcase "o" ring recess 64904, ST-323

test club 64840, 64979, 64980, 64981, 64989, 64991, cylinder heads ST-199

ST-242, ST-455 Counterbore

Adapter 5/8-18 NC-2 thread to 16 MM x 2 intake pipe bore salvage ST-228, ST-274

thread ST-333 spark plug pad ST-370

Adapter, Puller Countersink-

check valve retainer 64752 intake pipe bore salvage ST-273

crankshaft front oil plug 64735 oil relief valve ST-248, ST-439

crankshaft rear oil tube 64737, 64831 Crimping tool and wire stripper 64861

crankshaft sludge tube 64784 Cutter

starter jaw 64748 salvage fretted crankcases ST-145, ST-269

Arbor shroud tube relief ST-363

connecting rod slave bolts ST-236, ST-237 oil pump housing 64868

counterweight balancing ST-96 valve seat ST-50, ST-51, ST-52, ST-53, ST-54,finish pilot bushing 64590 ST-55, ST-56, ST-57, ST-58

B D

Ba11s- sizing- ST-147-1, ST-147-2, ST-300-1, ST-300-2, Drift-

ST-300-3 bushing installation ST-276, ST-230

Bar, boring connecting rod bushing removal 64535

accessory housing cover bushing 64884 connecting rod bushing replacement 64536

cross shaft in accessory housing 64877 crankshaft,~ front plug ST-234

generator drive bushing 64870 crankshaft, oil plug 64647, 64754, ST-46, ST-295,Basket valve parts, cleaning 64553 64770

Blade, Counterweight- 64603-7 crankshaft, oil tubes -64548, 64648, ST-44

Blade, Valve Adjusting ST-418-3 crankshaft pilot bushing 64588

Block crankshaft spline bushing ST-170

cylinder holding 64526, 64526-1, 64526-2 exhaust valve guide 64923

thrust nut 64607 intake pipe bore salvage ST-230

vee 64545 magneto coupling sleeve 64741

Bolt magneto drive idler bushing 64743

propeller 64982, 64983, 64984 main bearing oil tubes 64649

Bracket engine lifting 64758 oil pump drive shaft bushing 64747

Burnisher- oil seal plug- 64770

connecting rod bushing 64580 outer rocker shaft bushing 64815, 64824

magneto drive idler gear 64887 rocker shaft bushing 64814, 64825, 64816

valve rocker bushing 64541 starter drive adapter bushing 64745

Bushing valve guide 64505, 64796, ST-302, ST-303, ST-304

oil relief valve ST-243, ST-245 valve seat ST-64, ST-65

Drill-

C crankcase thru-stud dowel ST-124

dowel hole in crankcase ST-379

Cable engine lifting 1240, 64834, ST-220 piloted, exhaust valve guide conversion 64939

Cap protector, propeller shaft thread 72762 plate, turbocharger ST-135


ALPHABETICAL INDEX

D (Cont.) F (Cont.)

reduction gear housing ST-10 tapper body magnaflux ST-387

Drill Jig- turbocharger, holding ST-133

accessory housing assembly ST-17, ST-19 valve guides, replace 64501, 64644, 64714

crankcase mounting bushing 64771 valve guide hole ST-179

crankcase bearing oil drain ST-372 valve rocker 64540

Drive Assembly test 64894 valve seat ST-250, ST-232

Driver Former oil relief valve seat ST-340

bearing dowel ST-291, ST-305, ST-306, ST-307,

ST-378 Gcounterbore, intake pipe ST-275

counterweight bushing ST-92Gage

crankcase thru stud ST-316, ST-317belt tension ST-131

crankshaft plug 64681connecting rod bolt stretch 64945

crankshaft rear spline bushing ST-168

dowel crankcase ST-332 connecting rod bushing 64767

connecting rod parallelism and squareness 64530intake pipe bore salvage ST-253

counterweight bushing ST-94oil relief valve ST-215, ST-249

valve seat cutters ST-62 counterweight, circlip -64892

counterweight, clearance in crankcase ST-37

E countenireight- dial bore ST-73

counterweight, squareness ST-91

feeler- 64992Expander piston ring 64528, 64560, 64713

flush pin, depth ST-9Expander and staking tool 64593

fuel injector and controller ST-318Eye engine lifting -64769, ST-48

hydraulic tappet body 64909

Fintake pipe bore salvage ST-226

turbocharger ST-136

Fixture spring positions 64971

valve clearance 62700, ST-23, ST-279accessory housing bushing 64859

valve guides, bell mouthing ST-71, ST-310accessory housing cover bushing 64863

valve guides ID 64514connecting rod bushing 64597

convert carburetor cylinder ST-28 Gage, flat plug

counterweight bushing ST-93 connecting rod bushing 64537

crankcase fretting salvage ST-144, ST-252 rocker shaft bushing 64613

crankshaft counterweight holes ST-280 valve guide ID ST-81

crankshaft flange ST-256 Gage, plugcrankshaft gear drill ST-390 by-pass valve ST-140, ST-141

crankshaft oil seal retainer ST-40, ST-105 rocker arm bushing 64542

crankshaft rear spline bushing ST-169 rocker shaft bushing 64810, 64811, 64823, ST-191

cylinder shroud tube ST-364 valve guide ID 64901, 64927, ST-26, ST-155

drill bearing dowel hole ST-377 Gagefuel injector ST-319 valve guide ID ST-314

grind bushing 64878 valve guide OD ST-89, ST-89-1, ST-89-2, ST-89-3,

hydraulic lifters ST-233 ST-89-4, ST-89-5, ST-259, ST-259-1, ST-259-2,intake pipe bore salvage ST-227, ST-277

ST-259-3, ST-259-4, ST-259-5, ST-429, ST-429-1,locating and reaming ST-149

ST-429-2, ST-429-3, ST-429-4, ST-429-5, ST-431,oil seal cap ST-39

ST-431-1, ST-431-2, ST-431-3, ST-431-4, ST-431-5plug type, drill generator housing ST-20, ST-21

Gage, plug and depth ST-126, ST-331propeller, shaft locknut assembly ST-329

reduction gear housing ST-8 Gage block

reduction gear housing, drive plate dowel 64827 crankcase counterveight bushing ST-212

shroud tube adapter ST-357 turbocharger ST-138

III


ALPHABETICAL INDEX

H P (Cont.)

Handle engine mounting ST-47

cylinder base nut wrench 64711 impeller nut 64715

offset spark plug wrench ST-345 torque hold-down ST-222

Holder, accessory drive shaft ST-173, ST-174 PlugHolder, shroud tube barrel springs ST-37~ bearing 64906

Hub Assembly 64774 crankshaft counterweight ST-280-10, ST-280-ii

Hub and Cone Assembly ST-415 Pointer ignition timing 64697

Protector thread -475-B, 72762, ST-86, ST-87

I Puller

compressor pulley ST-321

Indicator Expander ST-24 crankcase thru stud ST-271

Inserting Tool 64594 crankshaft spline bushing 64772

Installer, seal ST-443 crankshaft counterweight bushing 64872

cylinder head insert ST-356

J generator and alternator ST-158

generator drive countershaft 64728

Jaws, slide hammer puller 64886 magneto drive shaft sleeve 64766

Jig magneto gear 64976

supercharger shaft gear 64780 oil seal ST-172

welding, by-pass valve ST-139 pinion cage 64698

Jig, drill 64599 piston pin 64843

slide hammer 64782

K valve guide ST-49

Kit R

engine overhaul ring mounting ST-239

helicoil repair ST-184 Reamer-

valve train removal ST-368 accessory housing oil transfer tube ST-435, ST-436

counterweight bushing hole 64874, 64875, 64876,

M ST-210, ST-211

crankcase, body fit thru studs 64902, 64903

Mount crankcase, thru stud dowel ST-125, ST-328-2,

engine maintenance ST-460, ST-461 ST-366-5, ST-366-1

crankshaft flange ST-254, ST-255

P crankshaft, pilot bushing 64589

cylinder head shroud tube ST-362

Pilot intake pipe bore salvage ST-231

bar, rocker arm ST-160 oil relief valve ST-244, ST-246

crankcase ST-324 oil temperature by-pass valve seat ST-388

counterbore, intake bore salvage ST-229 pinion cage ST-150-1, ST-150-2, ST-299-1, ST-299-2,

spark plug pad ST-369 ST-299-3

valve seat ST-66, ST-66-1, ST-66-2, ST-66-3, propeller shaft bearing dowel ST-380

ST-66-4, ST-66-5, ST-67, ST-67-1, ST-67-2, ST-67-3, reduction gear bolt 64891, 64891-1, 64891-2, 64893,

ST-67-4, ST-67-5, ST-68, ST-68-1, ST-68-2, ST-68-3, 64893-1, 64893-2

ST-68-4, ST-68-5, ST-257, ST-257-1, ST-257-2, reduction gear housing, dowel hole 64828, 64829,

ST-257-3, ST-257-4, ST-257-5 ST-12, ST-13, ST-14, ST-15

Pin, locating ream pinion cage ST-149-9 rocker shaft bushing ID 64819, 64820, 64821,

Pin, locating valve guide hole in cylinder head fixture 64822, 64826

ST-179-3 rocker shaft bushing hole 64812, 64813, 64838,

Plate 64839, ST-427

bushing 64856, ST-123, ST-270, ST-327 shroud tube adapter ST-354

crankcase ST-122 valve guide ID 64684, 64900, 64925, ST-27,

IV


ALPHABETICAL INDEX

R (Cont.) T (Cont.)

ST-113-1, ST-113-2, ST-143-1, ST-143-2, ST-181-1, crankcase, thru stud high compression 64907

ST-181-2, ST-267, ST-309-1, ST-309-2, ST-315, spark plug, hell-coil insert 18MM 64596-1

91‘-338 Thermocouple Probe, Deck Temperature ST-264-Bvalve guide OD ST-90-1, ST-90-2, ST-90-3, ST-90-4, ST-264-C

ST-90-5, ST-180, ST-258-1, ST-258-2, ST-258-3, Thermocouple Extension ST-265

ST-258-4, ST-258-5, ST-430-1, ST-430-2, ST-430-3, Tool-

ST-430-4, ST-430-5, ST-432-1, ST-432-2, ST-432-3, baffle installation 64885

ST-432-4, ST-432-5 crankcase separator ST-389

Removing Tool hell-coil insert 64595 crankshaft countenveight plug 64603

Ring engine mounting 64759, ST-161, ST-272, crankshaft oil seal ST-383

ST-285, ST-286, ST-287 crimping ST-22, ST-78, ST-198, ST-301

Mount, Rubber test stand 64975 density controller adjusting ST-260

flare cylinder head shroud tube adapter ST-365S hydraulic tappet assembly 64941, ST-440, ST-474

fuel injector oil filter 64914Shroud cooling -64612, 64857, 64867, 64888, peening, crankshaft spline bushing ST-171

64944, ST-45, ST-114, ST-128, ST-164, ST-352pressure controller lock ST-284

Skid overhaul ST-278propeller flange bushing ST-115

Sleeve roll pin spreader 64864connecting rod and gage 64530-9, 64530-10,

shroud tube holes 6497464530-11

shroud tube assembly and disassembly ST-361tubocharger piston ST-129

spinner, cylinder base nut 64987Socket-

valve adjusting ST-418connecting rod nut ST-251

injector nozzle ST-190-2

oil pressure screen ST-80

spark plug wrench ST-288Universal Drill, high compression crankcase 64908

Spacer-pinion cage ST-148

Wsupercharger impeller 64704

Spinner cylinder base nuts 64987

Spinning Tool crankshaft oil tubes 64910 Weight counterweight balancing ST-95

Spring Holder shroud tube ST-376Wrench accessory drive shaft nut 64709

WrenchSpotfacer

pilot and driver reduction gear modification ST-112 c’ankshaft flange ST-313

rocker shaft bushing 64862 crankshaft spline 1225-B, ST-38

Stand cylinder -64700, 64701, 64942, 64943, ST-83, ST-84

overhaul- ST-162, 64916 ST-322, ST-374, ST-375

test, engine 64765, ST-43 engine timing ST-235

work 64947 exhaust head manifold 64933

Stop, drill and reamer ST-156 exhaust pipe flange ST-163, ST-213

Stop Collar fuel flow adjustment ST-29, ST-30

crankcase- 64905, ST-325 impeller -64778

reduction gear housing seal ST-11 injector 64932, 64970

holder crankcase ST-146 magneto- 64977, ST-79

Stud, crankcase plate ST-122-2 oil pump drive ST-416

Swaging Tool oil plug ST-107

intake pipe 64781, 64948, ST-289 oil screen 64946

turbocharger exhaust pipes ST-223 pressure controller, differential ST-283

propeller ST-320

T propeller flange spanner 64721

propeller shaft sleeve nut 64719

Tap reduction gear housing ST-108


ALPHABETICAL INDEX

W (Cont.)

shroud tube ST-142

tee bar ST-345

thrust bearing lock nut 40714

timing -64729, 64764

turbocharger ST-134

turbocharger impeller ST-177

vacuum pump 64934

weatherhead fittings ST-104

VI


Ref. Tool No. Nomenclature and Description

1 475-B Protector, Crankshaft Propeller Nut Thread-All propeller shafts with No. 20 spline2 1225-B Wrench, Crankshaft No. 20 Spline All propeller shafts with no. 20 spline (See ST-38 for No. 30)3 1240 Cable, Engine Lifting All engines employing two lifting straps4 40714 Wrench, Thrust Bearing Lock Nut All reduction gear housing employing a thrust bearing lock

nut

5 62700 Gage, Valve Clearance 0-235, 0-290-D Series solid tappets only6 64501 Fixture, Valve Guide Replacement All 4-3/8" and 4-7/8" bore cylinder assemblies

7 64505 Drift, Valve Guide Installation All (flange) intake valve guides and all (flange) exhaust valve

guides incorporating the .404/.405 guide hole I.D.

8 64514 Gage, Valve Guide ID All intake valve guides and all exhaust valve guides incorporating the

.404/.405 valve guide hole (See 64684 for Reamer)9 64526 Block, Cylinder Holding All cylinder assemblies with 4-3/8" bore

10 64526-1 Block, Cgrlinder Holding All cylinder assemblies with 4-7/8" bore

11 64526-2 Block, Cylinder Holding All cylinder assemblies with 5-1/8" bore

12 64528 Expander, Piston Ring All cylinder assemblies with 4-7/8" bore

13 64529 Compressor, Piston Ring All cylinder assemblies with 4-7/8" bore

14 64530 Gage, Connecting Rod Parallelism and Squareness All engines15 64530-9 Sleeve, Tapered, Connecting Rod Parallelism and squareness gage. Detail of 64530. Used on

2.4205/2.4210 bearing bores

16 64530-10 Sleeve, Tapered, Connecting Rod Parallelism and squareness gage. Detail of 64530. Used on


17 64530-11 Sleeve, Tapered, Connecting Rod Parallelism and squareness gage. Detail of 64530. Used on


18 64535 Drift, Connecting Rod Bushing Removal All engines19 64536 Drift, Connecting Rod Bushing Replacement All engines

4 6

1

5

PS_3~FZ’

9-10-11

806 o~ 15 16 -17

ce~pas,



20 64537 Gage, Flat Plug Connecting Rod Bushing Rejection All engines

21 64540 Fixture, Rebushing Valve Rocker All engines except 76 Series

22 64541 Burnisher, Valve Rocker Bushing All engines except 76 Series (Use with 64826)

23 64542 Gage, Plug, Valve Rocker Bushing ID (Finish)- All engines except 76 Series

24 64545 Block, Vee Check Crankshaft Run All engines25 64548 Drift, Replace Crankshaft Oil Tubes (Sludge Tubes) All four cylinder direct drive engines

employing sludge tubes

26 64553 Basket, Valve Parts, Cleaning All engines27 64559 Compressor, Piston Ring All cylinder assemblies with 4-3/8" bore

28 64560 Expander, Piston Ring All cylinder assemblies with 4-3/8" bore

29 64580 Burnisher, Connecting Rod Bushing All engines30 64588 Drift, Crankshaft Pilot Bushing All geared engines31 64589 Reamer, Crankshaft Pilot Bushing Finish All geared engines

32 64590 Arbor, Crankshaft Pilot Bushing Reamer All geared engines33 64593 Expanding and Staking Tool, 18 MM Spark Plug Hell-Coil Insert All engines (Includes long

reach plugs)34 64594 Inserting Tool, 18 MM Spark Plug Hell-Coil Insert All engines (Including long reach spark

plugs)

20 22

25

26

~I24

28

a umnuin~

29

30

27

cr~32

33

34



35 64595 Removing Tool, 18 MM Spark Plug Heei-Coil Insert All engines (Includes long reach plugs)36 64596-1 Tap, 18 MM Heli-Coil Spark Plug Bottoming Tap .010 o/s All engines (Includes long reach

plugs)37 64597 Fixture, Remove, Replace, Burnish Connecting Rod Bushing All engines38 64597-10 Spacer, Use under detail 1 or detail 9 to hold connecting rod level with fixture. Use with connec-

ting rods with 1.271bearing cap width (detail of 64597)

1.273

39 64597-11 Spacer, Use under detail 1 or detail 9 to hold connecting rod level with fixture. Use with connec-

ting rods with 1.331 bearing cap width (detail of 64597)1.333

40 64599 Jig, Generator Mounting Bushing Drill for Dowel Pin GO-435-C2 Series, GO-480-B1C, -C1D6,

-G1D6, -G1F6, -G2D6, -G2F6, -C2 Series, -F Series

41 64603 Tool, Crankshaft Counterweight Plugs, Removal and Replacement All Counterweightsemploying threaded plugs

42 64603-7 Blade, Counterweight Removal and Replacement Plug Detail of 64603

43 64607 Block, Thrust Nut in Thrust Plate Assembly Installation All reduction gear housings employ-ing a thrust bearing locknut

44 64612 Shroud, Cooling All four cylinder engines employing parallel valve cylinder except VO-360 and

IVO-360

45 64613 Gage, Rocker Shaft Bushing Rejection All engines except 76 Series

46 64644 Fixture, Valve Guide Replacement All angle head cylinder assemblies

47 64647 Drift, Crankshaft Front Oil Plug All geared engines except IGO-540, IGSO-540 and TIGO-541

48 64648 Drift, Crankshaft Oil Tubes Replacement (Sludge Tubes) All six cylinder vertical engines and

all geared engines employing sludge tubes

49 64649 Drift, Rear Main Bearing Oil Tubes GO-435-C2 Series, GO-480-B Series, -G1A6, -G1C6, -C1D6,

-G1D6, -G1F6, -G2D6, -G2F6, -C2 Series, -F Series

36 37 38 39

4035

42

41

43

i~´•,g I46

J49

47

48


Ref. ToolNo. Nomenclature and Description

50 64681 Driver, Crankshaft Welch Plug All direct drive except VO-435 and VO-540

51 64684 Reamer, Valve Guide ID All intake valve guides and all exhaust valve guides incorporating the

.404/.405 ID valve guide hole (See 64514 for Plug Gage)52 64697 Pointer, Ignition Timing All direct drive except TIG-541

53 64698 Puller, Pinion Cage All geared engines except TIGO-541

54 64700 Wrench, (9/16" Spline) Cylinder base nut All engines employing 68515 nut (See 64701 for 3/4"

Wrench)55 64701 Wrench, (3/4" Spline) Cylinder base nut All engines employing 68514 nut (See 64700 for 9116"

wrench)56 64704 Spacer, Supercharger Impeller (This spacer is used as a tool in setting up impeller in super-

charger housing assembly to obtain tool box clearance) All supercharger engines57 64709 Wrench, Accessory Drive Shaft Nut All crosswise accessory housing58 64711 Handle, Cylinder Base Nut Wrench Use with 64700 and 64701

59 64712 Compressor, Piston Ring All 5-1/8" bore cylinder assemblies

60 64713 Expander, Piston Ring All 5-1/8" bore cylinder assemblies

61 64714 Fixture, Valve Guide Replacement All 5-1/8" bore parallel valve cylinder assemblies

62 64715 Plate, Impeller Nut All supercharged engines63 64719 Wrench, Propeller Shaft Sleeve Nut All reduction gears employing nut PIN 67729

64 64721 Wrench, Propeller Flange Spanner All engines with flanged propeller shaft less bushings ex-

cept TIGO-541 (See ST-313)

50 52

54 55 57

56

60

53

r,::b59

4~-

62

63



65 64728 Puller, Generator Drive Countershaft GO-480-B

66 64729 Wrench, Timing All engines equipped for hand starters

67 64735 Adapter, Puller, Crankshaft Front Oil Plug P/N 70432 VO-435, TVO-435, VO-540, TIVO-540

68 64737 Adapter, Puller, Crankshaft Rear Oil Tube P/N 69844 VO-435, TVO-435, GO-480-D Series,

-C1B6, -G1B6, -G1E6, GSO-480 Series, IGSO-480 Series, IGO-540 Series, IGSO-540 Series,VO-540 Series, TIVO-540 Series

69 64741 Drift, Magneto Coupling Sleeve Removal All engines with crosswise accessory housings70 64743 Drift, Magneto Drive Idler Gear Hub Bushing All engines with crosswise accessory housings71 64745 Drift, Starter Drive Adapter Bushing Ah engines with crosswise accessory housings72 64747 Drift, Oil Pump Drive Shaft Bushing Removal All engines with crosswise accessory housings73 64748 Adapter, Puller, Starter Jaw All engines with crosswise accessory housings74 64752 Adapter, Puller, Check Valve Retainer All engines with crosswise accessory housings75 64754 Drift, Crankshaft Oil Plug Installation VO-435, TVO-435, VO-540, TIVO-540

76 64758 Bracket, Engine Lifting GO-435-C2A, -C2B, VO-435-A Series

77 64759 Ring, Engine Mounting All engines except turbochargq equipped and 10-720 series. (Use

adapters 64898 or ST-88 with 4 cylinder engines. Use engine mounts ST-460 and ST-461 on

applicable 6 cylinder direct drive engines). Use with ST-278, ST-162, and ST-165 as re-

quired.78 64764 Wrench, Timing All engines with crosswise accessory housing not employing hand starters ex-

cept VO-435-B1A and TVO-435-F1A

79 64765 Stand, Test-Helicopter Engines All six cylinder vertical engines80 64766 Puller Magneto Drive Shaft Sleeve All engines employing crosswise accessory housing with

rear mounted magnetos

81 64767 Gage, Connecting Rod Bushing ID Finish All engines82 64769 Eye, Engine Lifting VO-435, TVO-435, VO-540, IVO-540 and TIVO-540

83 64770 Drift, Oil Seal Plug Installation 0-235, 0-290, 0-320, 10-920, 0-340, 0-360, 10-960 and HIO-360

(Plug Size 1.753/1.755) PIN 61510

~iBPs,

86 s7 68

-65

6970 71 72

76

W73 75

74

82

80 8377



84 64771 Drill, Jig, Mounting Bushing Crankcase 0-320

85 64772 Puller, Crankshaft Spline Bushing Rear All engines with crosswise accessory housings

86 64772-1 Nut, Splined 13 Teeth Detail of 64772

87 64772-5 Nut, Splined 14 Teeth Detail of 64772

88 64773 Club, Test, GO-435-C2, VO-435, TVO-435, VO-540, IVO-540 and TIVO-540 (Use with 64774)

89 64774 Hub and Cone Assembly, Test Club (4 Blade) All No. 20 spline propeller shafts with

2.365/2.367 OD

90 64778 Wrench, Impeller GSO-480 Series, IGSO-480 Series and IGSO-540 Series

91 64780 Jig, Holding Supercharger Shaft Gear GSO-480, IGSO-480, IGSO-540 Series

92 64781 Swaging Tool, Intake pipe Engines employing intake pipe connections PIN 69602, 71699,

78914 with 1.672/1.696 ID

93 64782 Puller, Slide Hammer Medium Used with the following tools: 64735, 64737, 64748, 64752,

64784, 64831, 64866, ST-172 and ST-333

94 64783 Club, Test (4 Blade)- GO-480-B, -C1, -D, -F2, -F4A6, -G1 Series; GSO-480-A1, -B1 Series;

IGSO-480; IGO-540 and IGSO-540

95 64784 Adapter, Puller, Crankshaft Sludge Tube VO-435; TVO-435; VO-540; TIVO-540; 10-720 and

all geared engines96 64796 Drift, Valve Guide Installations All (Flange) valve guides with .4371.438, .43751.4385 ID valve

guide hole

97 64801 *Club, Test 0-235 with AS-127 type 2 prop flange 0-290-D, 0-320-A, -C, -E series and IO-320-

A, -D, -E series, AIO-320-A, -B, -C. Use with 64979 or 64980

98 64802 Club, Test 0-320-B, -D series, IO-320-B, -C series, 0-340-A, -B. Use with 64980

99 64803 Club, Test 0-360; VO-360; 10-360; AIO-360; TIG-360; MO-360; HIO-360; IMO-360; 0-540;

10-540; TIG-540 and TIG-541 (Use with 64981)100 64807 Club, Test GO-480-C2, -F6, -F1A6, -F3A6, -F3B6, -G2D6, -G2F6 series; GSO-480-A2A6, -B2

series (Use with 64840)

AS-127 Type 2 propeller flange can be identified by measuring from one prop attaching

bushing across the center of the crankshaft to the opposite bushing. The center to center

measurement is 4-3/4 inches.

85-86-87

84

88-94-97 THRU 199

90

89

93

95

92

se



101 64810 Gage, Plug, Rocker Shaft Bushing Hole in Cylinder Head All engines except 76 Series

102 64811 Gage, Plug,.005 ols, Rocker Shaft Bushing Hole in Cylinder Head All engines except 76

Series (See ST-191 for .010 ols)

103 64812 Reamer, .005 ols Outer Rocker Shaft Bushing Hole in Cylinder Head All engines employing

angle valves

104 64813 Reamer, .010 o/s Outer Rocker Shaft Bushing Hole in Cylinder Head All engines employing

angle valves

105 64814 Drift, Rocker Shaft Bushing Removal All engines except 76 Series

106 64815 Drift, Outer Rocker Shaft Bushing Installation All engines employing angle valves

107 64816 Drift, Inner Rocker Shaft Bushing Installation All engines employing angle valves

108 64819 Reamer, Semi-Finish, Outer Rocker Shaft Bushing ID All engines employing angle valves

109 64820 Reamer, Semi-Finish, Inner Rocker Shaft Bushing ID All engines employing angle valves

110 64821 Reamer, Finish Outer Rocker Shaft Bushing ID All engines employing angle valves

111 64822 Reamer, Finish Inner Rocker Shaft Bushing ID All engines employing angle valves

112 64823 Gage, Plug Rocker Shaft Bushing ID All engines except 76 Series

113 64824 Drift, Outer Rocker Shaft Bushing Installation All engines employing parallel valves except

76 Series

114 64825 Drift, Inner Rocker Shaft Bushing Installation All engines employing parallel valves except

76 Series

115 64826 Reamer, Finish Inner and Outer Rocker Shaft Bushings All engines employing parallel valves

except 76 Series (Use with 64541)

116 64827 Fixture, Drill Drive Plate Dowel in Reduction Gear Housing GO-480-F Series, -C2 Series,

-G2D6, -G2F6 and GSO-480-B2D6

117 64828 Reamer, Drive Plate Dowel Hole in Reduction Gear Housing GO-480-C2 Series, -F Series,

-G2D6, -G2F6 and GSO-480-B2D6

118 64829 Reamer, Reduction Gear Housing Dowel Hole GO-480-C2 Series, -F Series, -G2D6, -G2F6 and

GSO-480-B2D6

101-102-112 103-104 105

107- 114

106-113

108 110109 111

115

117 118 116



119 64831 Adapter, Puller, Crankshaft Rear Oil Tube 0-435-A, GO-435-C2 Series, GO-480-B, -C2, -F

Series, -C1D6, -G1A6, -G2D6, -G1F6, -G2F6, -G1G6

120 64834 Cable, Engine Lifting All engines not employing lifting eyes

121 64836 Adapter, Propeller Shaft Flange GO-480-C2 Series, -F6, -F1A6, -F3A6, -F3B6, -G2D6, -G2F6

122 64838 Reamer,.005 ols Inner Rocker Shaft Hole in Cylinder Head (Used with 64812 reamer for anglehead cylinder. Used for both shaft holes in parallel valve cylinders except 76 Series)

123 64839 Reamer, .010 ols Inner Rocker Shaft Hole in Cylinder Head (Used with 64813 reamer for anglehead cylinder. Used for both shaft holes in parallel valve cylinders except 76 Series)

124 64840 Adapter, Test Club GO-480-C2 Series, -F6, -F1A6, -F3A6, -F3B6 Series, -G2 Series, GSO-480-

A2A6, -B2 Series

125 64843 Puller, Piston Pin All engines126 64856 Bushing Plate, Crankcase and Accessory Housing Drill All engines with crosswise accessory

housings127 64857 Shroud, Cooling All six cylinder angle valve cylinders employing down draft exhaust except

TIO and TIGO-541

128 64859 Fixture, Bore Accessory Housing Bushing All engines with crosswise accessory housings129 64861 Crimping Tool and Wire Stripper All 7MM ignition harnesses (See ST-198 for 5MM)130 64862 Spotfacer, Inner Rocker Shaft Bushing All engines employing angle head valves

"~4

119 122 123

121

124

125

~gra

z´•9-~ I;~1

126127

kI~~T 129

129

130128



131 64863 Fixture, Bore Bushing in Accessory Housing Cover All engines with crosswise accessory hous-

ings132 64864 Tool, Roll Pin Spreader (Connecting Rod) All engines employing roll pins133 64866 Adapter, Sludge Tube Removal 0-540, 10-540 (P/N 60449)

134 64867 Shroud Cooling All six cylinder parallel valve cylinders employing down draft exhaust

135 64868 Cutter, Oil Pump Housing (Convert to Large Capacity Filter) All crosswise accessory housingsnot equipped with large filter

136 64870 Bar, Boring, Generator Drive Bushing and Annulus in Accessory Housing All engines with

crosswise accessory housings137 64872 Puller, Remove and Install Crankshaft Counterweight Bushings All engines with

counterweight bushings138 64874 Reamer,.005 ols Counterweight Bushing Holes All engines with counterweights (See ST-210

for.0075 ols)139 64875 Reamer,.010 ols Counterweight Bushing Holes All engines with counterweights (See ST-211

for.0125 o/s)140 64876 Reamer,.015 ols Counterweight Bushing Holes All engines with counterveights141 64877 Bar, Boring, Cross Shaft in Accessory Housing All engines with crosswise accessory housings142 64878 Fixture, Grind Bushings in Dynamic Counterweight All engines with counterweight bushings143 64884 Bar, Boring Accessory Housing Cover Bushings All engines with crosswise accessory hous-

ings144 64885 Tool, Baffle Installation All engines with cooling baffles

145 64886 Jaw, Slide Hammer Puller (Small Diameter) All engines (Use with 64782)

146 64887 Burnisher, Magneto Drive Idler Gear (Hub Assembly)- All engines with crosswise accessory

housings

133

132

135 137

136

,,_134 :*p-i~

´•´•I;--´•’´• "i~

141

142

138 139 140

146

143 145

144



147 64888 Shroud Cooling (Permanent Installation) All six cylinder down draft exhaust engines exceptIGO and IGSO-540, TIO and TIGO-541)

148 64891 Reamer, Body Fit Bolts Reduction Gear "Service" (STD) All geared engines in which PIN

71184 body fit bolts are to be installed in reduction gear housing149 64891-1 Reamer, BodyFit Bolts Reduction Gear "Service" (.010 o/s) All geared engines in which PIN

71184 body fit bolts are to be installed in reduction gear housing150 64891-2 Reamer, Body Fit Bolts Reduction Gear "Service" (.020 ols) All geared engines in which P/N

71184 body fit bolts are to be installed in reduction gear housing151 64892 Gages, Check Circlips in Counterweights All engines with counterweights that employ circlips

152 64893 Reamer, Body Fit Bolts Reduction Gear (STD) All geared engines in which P/N 68364 body fit

bolts are to be installed in reduction gear housing153 64893-1 Reamer, Body Fit Bolts Reduction Gear (.010 ols) All geared engines employing P/N

68364-P10 body fit bolts in reduction gear housing154 64893-2 Reamer, Body Fit Bolts Reduction Gear (.020 ols) All geared engines in which P/N 68364-P20

body fit bolts are to be installed in reduction gear housing

155 64894 Drive Assembly, Test All six cylinder, vertical engines (Use 74822 gasket)156 64894-1 Nut, Slotted 3/8-16 thread (detail of 64894)

157 64894-3 Bearing, 2.001 OD x 1.377 ID x 1.19 long (detail of 64894)

158 64894-4 Spacer, Tapered 1.0 diameter x .150 thick (detail of 64894)

159 64894-5 Shim, Lamina~ed 7.13 OD x 4.63 ID x .060 thick (detail of 64894)

160 64894-6 Screw, Sholder -.500 diameter x 1.42 long 3/8-16 thread (detail of64894)

161 64894-7 Nut, 3/8-24 x 2.25 long 9116 hex (detail of 64894)162 64894-13 Pad, Access hole cover (detail of 64894)

163 64894-16 Screw, Sholder .500 diameter x 1.72 long 3/8-16 thread (detail of 64894)

148 149 150 152 153 154

158

157

156

160

163161

155 9~

n<sI162

159

10



164 64898 Adapter, Dynafocal Mounts (Test Stand and Mounting Ring)- All engines employing 300

mounts

165 64899 Adapter, Magnetic Particle Inspection of Hydraulic Tappets All engines except 0-235,

0-290-D, 76 Series, TIG-541 and TIGO-541 (Use with ST-387)

166 64900 Reamer, Valve Guide ID (Exhaust) All valve guides with.43751.4385 ID valve guide hole (See

64901 for Plug Gage)167 64901 Gage, Plug Valve Guide ID (Exhaust) All valve guides with .4375/.4385 ID valve guide hole

(See 64900 for Reamer)

168 64902 Reamer, Rework High Compression Crankcase (Rough) 0-320, 0-340, 0-360, VO-360 and 0-540

Series To incorporate Body Fit Thru Studs (PIN 72698)

169 64903 Reamer, Rework High Compression Crankcase (Final)- 0-320, 0-340, 0-360, VO-360 and 0-540

Series To incorporate Body Fit Thru Studs (PIN 72698)

170 64904 Counterbore, Rework High Compression Crankcase "O" Ring Recess 0-320, 0-340, 0-360,

VO-360 and 0-540 Series To incorporate Body Fit Thru Studs (P/N 72698)

171 64905 Stop Collar, Use with 64902 and 64903 Reamers High Compression Crankcase 0-320, 0-340,

0-360, VO-360 and 0-540 Series To incorporate Body Fit Thru Studs (PIN 72698)

172 64906 Plug, Bearing, High Compression Crankcase 0-320, 0-340, 0-360, VO-360 and 0-540 Series To

incorporate Body Fit Thru Studs (P/N 72698)

173 64907 Tap,.007 ols for 1/2" Thru-Stud, High Compression Crankcase, 0-320, 0-340, 0-360, VO-360 and

0-540 Series To incorporate Body Fit Thru Studs (PIN 72698)

174 64908 Universal, Drill 1/2" Rework High Compression Crankcase 0-320, 0-340, 0-360, VO-360 and

0-540 Series To incorporate Body Fit Thru Studs (PIN 72698)

175 64909 Gage, Reject Hydraulic Tappet Bodies All engines except 0-235, 0-290-D, 76 Series, TIG-541

and TIGO-541

176 64910 Spinning Tool, Crankshaft Oil Tube Replacement (Sludge Tubes) All engines employing

sludge tubes

o.

167165 166

164

170

168 169 171

174

173

172 176

175

11


Ref. ToolNo. Nomenclature andDescription

177 64914 Tool, Remove Fuel Injector Oil Filter 1GSO-480 Series

178 64916 Stand, Overhaul All engines available from (B.K. Sweeney Mfg. Co., 6300 East 44th Ave.,Denver 16, Colorado)

179 64917 Adapter, Overhaul All engines available from (B.K. Sweeney Mfg. Co., 6300 East 44th Ave.,Denver 16, Colorado)

180 64923 Drift, Exhaust Valve Guide Installation All engines employing 1/2" (Flange) exhaust valve

guides181 64925 Reamer, Valve Guide ID (Brass) (Exhaust)- Pilot dia..48881.4893, Finished ID .49851.4995 (Not

used on Ni-Resist guides) (See 64927 for Plug Gage)182 64927 Gage, Plug, Valve Guide ID (Exhaust)- All valve guides with .49851.4995 ID valve guide hole

(See 64925 for Reamer)183 64932 Wrench, Offset Alien, Simmonds Injector Pump Installation 1GSO-540-B

184 64933 Wrench, 1/2" Top Exhaust Head Manifold Removal Tool 10-540 Series, IGO-540-B Series,IGSO-540-B Series, IO-720-B Series

185 64934 Wrench, 7116" Dry Vacuum Pump Installation All engines employing 3P-194 Pesco Vacuum

Pump186 64939 Piloted Drill, Install 1/2" Diameter Exhaust Valve Guide All angle head engines to be con-

verted from 7/16" to 1/2" exhaust valves

187 64941 Tool, Remove Hydraulic Tappet Assemblies All engines except 0-235, 0-290-D, 76 Series,TIG-541 and TIGO-541

188 64942 Wrench, (1/2" Alien) Cylinder Base Nut All engines employing PIN 71133 Nut (See 64943 for

3/8" wrench)

189 64943 Wrench, (3/8" Alien) Cylinder Base Nut All engines employing P/N 71134 Nut (See 64942 for

1/2" wrench)190 64944 Shroud, Cooling (Updraft Exhaust)- IO-540-B Series, IGO-540-B, IGSO-540-B Series, TIO-

540-A Series

181

177

180

184

183

178 179

188 189 186182

C--"

;iP

190

12



191 64945 Gage, Connecting Rod Bolt Stretch All engines employing stretch bolts in connecting rods

192 64945-7 Dial Indicator Detail of 64945

193 64945-9 Set Master 2.1255 Length Detail of 64945

194 64945-10 Set Master 2.2555 Length Detail of 64945

195 64945-11 Gage Assembly and Set Masters Less dial indicator

196 64946 Wrench, Offset, (1-5116") Change Oil Screen in Aero Commander IGO-540, IGSO-540

197 64947 Stand, Work- IGO-540, IGSO-540

198 64948 Swaging Tool, Intake Pipe, 0-235, 0-290, 0, IO, AEIO-320, 0-340, 0-360, 10-360, MO-360

engines employing intake pipe connections P/N 61376, 61377, 62115, 70482 with

1.422/1.446 ID

199 64970 Wrench, Adjust Bendix Injector (Idle Speed) on Aero Commander IGO-540 Series

200 64971 Gage, Check Switch and Retard Terminal Contact Springs Positions (200 Series Magnetos)All engines employing 200 series magnetos

201 64974 Tool, Rework Shroud Tube Holes in Cylinder Head All engines employing angle head valves

202 64975 Rubber Mount, Test Stand (64765)- All six cylinder, vertical engines203 64976 Puller, Gear, Magneto Assembly (PIN 60971) All engines employing low tension magnetos

204 64977 Wrench, Special, Gears on Low Tension Magnetos (PIN 60971)- All engines employing low ten-

sion magnetos

196

200191 THRU 195

197

199

198

o

203

204

202

13



205 64979 *Adapter, Test Club All engines with AS-127 Type 2 propeller flange with bushings for 3/8

inch propeller attaching bolts (See ST-455 for AS-127 Type 1 propeller flange)

206 64980 *Adapter, Test Club All engines with AS-127 Type 2 propeller flange with bushings for 7116

inch propeller attaching bolts

207 64981 *Adapter, Test Club All engines with AS-127 Type 2 propeller flange with bushings for 1/2

inch propeller attaching bolts

208 64982 Bolt, Propeller 3/8-24 Drilled Hex Head Use with Adapter 64979

209 64983 Bolt, Propeller 7116-20 Drilled Hex Head Use with Adapter 64980

210 64984 Bolt, Propeller 1/2-30 Drilled Hex Head Use with Adapter 64981

211 64987 Spinner, Cylinder Base Nut All engines employing hex head cylinder base nuts

212 64988 Club, Test- 10-720

213 64989 Adapter, Test Club 10-720

214 64992 Gage, Feeler to Set Simmonds 580 Injector IGSO-540-B Series

215 72762 Protector, Crankshaft Propeller Nut Thread All propeller shafts with No. 30 spline216 ST-8 Fixture, Counterboring PIN 72572 Reduction Gear Housing Seal IGO and 1GSO-540

217 ST-9 Depth Gage, Flush Pin, Counterbore Oil Passage Holes for "0" Rings on Reduction Gear

Housing P/N 72572 IGO and IGSO-540

218 ST-10 Drill, 4 Flute Flat Bottom, Drill Reduction Gear Housing P/N 72572 for Seal IGO and

IGSO-540

219 ST-11 Stop Collar, 19/32" Diameter Drill Reduction Gear Housing P/N 72572 for Seal IGO and

IGSO-540

AS-127 Type 2 propeller flange can be identified by measuring from one prop attachingbushing across the center of the crankshaft to the opposite bushing. The center to center

measurement is 4-3/4 inches.

211

208 209 210

205- 206-207

~8n,he

214213

~p´•

216’

215219

~iZ- 217

218

14



220 ST-12 Reamer, Hollow Dowel Holes in Reduction Gear All GO and GSO-480 engines with flangepropeller shaft

221 ST-13 Reamer, Hollow Dowel Holes in Reduction Gear .005 ols All GO and GSO-480 engines with

flange propeller shaft





224 ST-17 Drill, Jig, Drill Hole to Pin Generator Drive Shaft Bushing in P/N 68967 Accessory HousingGO-480-B, -B1A6 and -B1E6

225 ST-19 Drill, Jig, Remove and Install Generator Drive Gear Thrust and Drive Gear Bushings PIN

69525 Accessory Housing GO-480-B1C

226 ST-20 Fixture, Plug Type Drill, Generator Housing Assembly GO-435 and GO-480 Series

227 ST-21 Fixture, Plug Type Drill, Generator Housing Assembly GO-435 and GO-480 Series

228 ST-22 Tool, Crimping, Crimp Burndy Hy-Rings on Low Tension Harness

229 ST-23 Gage, Valve Clearance .028 .080 All engines requiring a valve clearance between .028 -.080

230 ST-24 Indicator, Expander, Check alignment between crankshaft bore in accessory housing and the

accessory drive GSO-480, IGSO-480 and IGSO-540 Series

231 ST-25 Compressor, Valve Spring and Bar All engines except 76 Series and TIG-541 Series (See St-266

and St-419)232 ST-26 Gage, Plug, Valve Guide ID (Exhaust) All valve guides with.437/.438 ID valve guide hole (See

ST-27 for Reamer)233 ST-27 Reamer, Valve Guide ID (Exhaust) All valve guides with .4371.438 ID valve guide hole (See

ST-26 for Plug Gage)234 ST-28 Fixture, Drill Jig used to convert carburetor cylinders to fuel injection cylinders All 0-360,

0-540 cylinders which are to be converted to 10-360, 10-540

235 ST-29 Wrench, Injector Fuel Flow Adjustment (Simmonds No. 580 Injector)- IGSO-540-B1A

236 ST-30 Wrench, Injector Fuel Flow Adjustment (Simmonds No. 580 Injector)- IGSO-540-B1A

220 THRU 223

224

1~ 225 226

227228

229

232

231

235 236 234

233

15



237 ST-37 Gage, Counterweight Clearance in Crankcase All VO-540 engines employing counterweights

238 ST-38 Wrench, Crankshaft No. 30 Spline All propeller shafts employing No. 30 spline239 ST-39 Fixture, Insert Oil Seal in Thrust Bearing Cap All geared engines240 ST-40 Fixture, Drill Four Holes in Crankshaft Oil Seal Retainer All direct drive engines with

crankcase front main bearing bore 2.566/2.567 diameter This fixture can be used only when

engine is disassembled.

241 ST-43 Stand, Engine Test VO-360 and IVO-360

242 ST-44 Drift, Install Rear Crankshaft Oil Tube All engines with crosswise accessory housings employ-

ing crankshafts with rear crankshaft oil tube (PIN 69843)

243 ST-45 Shroud, Cooling VO-360 and IVO-360

244 ST-46 Drift, Install Crankshaft Oil Plug 0-540, 10-540 and TIG-540 (Plug size 1.38011.382 PIN 71640)

245 ST-47 Plate, Engine Mounting VO-435, TVO-435, VO-540, IVO-540 and TIVO´•540 Series

246 ST-48 Eye, Lifting All vertical engines247 ST-49 Puller, Valve Guide All engines248 ST-49-4 Hex Head Cap Screw, Valve Guide Puller (Detail of ST-49)- All engines249 ST-50-1 Cutter, Valve Seat (Intake) (.010 ols)- All cylinder heads with 2.307 valve seat hole

250 ST-50-2 Cutter, Valve Seat (Intake) (.020 ols)- All cylinder heads with 2.307 valve seat hole

251 ST-50-3 Cutter Valve Seat (Intake) (.030 ols) All cylinder heads with 2.307 valve seat hole

31.

j23~ 242

iY~TD

239

240

243

241249 THRU 251

B

B

244

~ib,,245

247

246

248

16



252 ST-51-1 Cutter, Valve Seat (Intake) (.010 ols) All cylinder heads with 2.281 valve seat hole



255 ST-52-1 Cutter, Valve Seat (Exhaust) (.010 ols) All cylinder heads with 1.734 valve seat hole

256 ST-52-2 Cutter, Valve Seat (Exhaust) (.020 ols)- All cylinder heads with 1.734 valve seat hole






262 ST-54-2 Cutter, Valve Seat (Exhaust) (.020 ols) All cylinder heads with 1.927 valve seat hole



265 ST-55-2 Cutter, Valve Seat (Intake) (.020 o/s)- All cylinder heads with 2.160 valve seat hole

266 ST-55-3 Cutter, Valve Seat (Intake) (.030 o/s)- All cylinder heads with 2.160 valve seat hole

267 ST-56-1 Cutter, Valve Seat (Intake) (.010 o/s) All cylinder heads with 1.919 valve seat hole






273 ST-58-1 Cutter, Valve Seat (Exhaust) (.010 o/s)- All cylinder heads with 1.995 valve seat hole


275 ST-58-3 Cutter, Valve Seat (Exhaust) (.030 o/s) All cylinder heads with 1.995 valve seat hole

276 ST-62 Driver, Special Length for Use with Valve Seat Cutters All cutters in ST series only277 ST-63 Adapter, Hand Drive Use with ST-62 Driver

278 ST-64 Drift, Valve Seat Replacement All valve seats with dimensions between 1.870 and 2.040 ID

279 ST-65 Drift, Valve Seat Replacement All valve seats with dimensions between 1.575 and 1.710 ID

252 THRU 269 270 THRU 275

276278 279

17


Ref. ToolNo. Nomenclatureand Description

280 ST-66 Pilot, Valve Seat Cutter (Standard) All cylinder heads with .5913 valve guide hole

281 ST-66-1 Pilot, Valve Seat Cutter (.010 ols) All cylinder heads with.5913 valve guide hole

282 ST-66-2 Pilot, Valve Seat Cutter (.020 ols)- All cylinder heads with .5913 valve guide hole

283 ST-66-3 Pilot, Valve Seat Cutter (.030 o/s)- All cylinder heads with .5913 valve guide hole



286 ST-67 Pilot, Valve Seat Cutter (Standard)- All cylinder heads with .6613 valve guide hole




290 ST-67-4 Pilot, Valve Seat Cutter (.040 o/s) All cylinder heads with .6613 valve guide hole

291 ST-67-5 Pilot, Valve Seat Cutter (.005 ols) All cylinder heads with .6613 valve guide hole

292 ST-68 Pilot, Valve Seat Cutter (Standard) All cylinder heads with.6247 valve guide hole






298 ST-71 Gage, Check Bell-Mouthing of Exhaust Valve Guides All parallel valve engines (See ST-310 for

Angle Valves)299 ST-71-8 Adapter (Post), Check Bell-Mouthing of 1/2" Exhaust Valve Guides All parallel valve engine

(Detail of ST-71)300 ST-73 Gage, Counterweight Dial Bore (.7485/.7505 ID of Bushings) Replace Bushings in

Counterweights All engines equipped with counterweights employing bushings exceptcounterweight PIN 77002

301 ST-78 Tool, Crimping Connecting Rod Nut and Ring Gear Plate Nut All engines using crimp nuts

302 ST-79 Wrench, (Spanner) To Hold Magneto Gear All four cylinder engines303 ST-80 Socket, (Special) (1-5116") Remove Oil Press~re Screen IGSO-540 Series

304 ST-81 Gage, Flat Plug Rejection (Intake Valve Guide ID) All engines305 ST-83 Wrench, Break Loose Cylinder Base Nuts All engines employing 1/2" Alien head cylinder base

nuts (P/N 71133)306 ST-84 Wrench, Break Loose Cylinder Base Nuts All engines employing 3/8" Alien head cylinder base

nuts (P/N 71134)

"IW´•s,Ja

f4 299

280 THRU 297

298

301

300

302 303

304 305 306

18

AVCO LYCOMINC SERVICE TOOLS

Ref. Tool No. Nomenclature and Description307 ST-86 Protector, Thread No. 20 Spline Shaft This tool must be used when changing propeller in order

to keep from damaging propeller shaft threads

308 ST-87 Protector, Thread No. 30 Spline Shaft This tool must be used when changing propeller in order

to keep from damaging propeller shaft threads

309 ST-88 Adapter, Dynafocal Mounts All engines employing 180 mounts

310 ST-89 Gage, Plug Valve Guide OD (Exhaust) (Standard) All valve guides with .62471.6257 valve

guide hole in cylinder head

311 ST-89-1 Gage, Plug Valve Guide OD (Exhaust) (.010 o/s) All valve guides with .62471.6257 valve guidehole in cylinder head

312 ST-89-2 Gage, Plug Valve Guide OD (Exhaust) (.020 ols)- All valve guides with.6247/.6257 valve guidehole in cylinder head

313 ST-89-3 Gage, Plug Valve Guide OD (Exhaust) (.030 o/s) All valve guides with .62471.6257 valve guidehole in cylinder head

314 ST-89-4 Gage, Plug Valve Guide OD (Exhaust) (.040 ols)- All valve guides with .62471.6257 valve guidehole in cylinder head

315 ST-89-5 Gage, Plug Valve Guide OD (Exhaust) (.005 ols) All valve guides with .6247/.6257 valve guidehole in cylinder head

316 ST-90-I Reamer, Valve Guide OD (Exhaust) (.010 ols) All valve guides with .62471.6257 valve guidehole in cylinder head

317 ST-90-2 Reamer, Valve Guide OD (Exhaust) (.020 o/s) All valve guides with .6247/.6257 valve guidehole in cylinder head

318 ST-90-3 Reamer, Valve Guide OD (Exhaust) (.030 ols) All valve guides with .62471.6257 valve guidehole in cylinder head

319 ST-90-4 Reamer, Valve Guide OD (Exhaust) (.040 o/s)- All valve guides with .6247/.6257 valve guidehole in cylinder head

320 ST-90-5 Reamer, Valve Guide OD (Exhaust) (.005 ols)- All valve guides with .62471.6257 valve guidehole in cylinder head

321 ST-91 Gage, Counterweight Squareness (Check Parallel and Squareness of Finished Inside Diameterof Bushing Hole) All engines equipped with counterweights employing bushings exceptCounterweight PIN 77002

322 ST-92 Driver, Counterweight Bushing (Remove and Install Bushings) All engines equipped with

counterweights employing bushings except Counterweight P/N 77002

323 ST-93 Fixture Assembly, Counterweight (Install Bushings in Counterweights) All engines equippedwith counterweights employing bushings except Counterweight PIN 77002

324 ST-93-3 Spacer, Control Depth of Bushing .370 thick (detail of ST-93)325 ST-93-5 Spacer, Control Depth of Bushing .440 thick (detail of ST-93)

ii 310 THRU 315

309

307 308322

316 THRU 320 321

323 THRU 325

19



326 ST-94 Gage, Counterweight Bushing Location (Check Hole Location After Grinding) All engines

equipped with counterweights employing bushings except Counterweight P/N 77002

327 ST-95 Weight, Counterweight Balancing (.004 pound Check Balance of Counten~eight after

kebushing) All engines equipped with counterveights employing bushings except

Counterweight P/N 77002

328 ST-96 Arbor, Counterweight Balancing (Check Balance of Counterweights after Rebushing) All

engines equipped with counterweights employing bushings except Counterweight P/N

77002

329 ST-104 Wrench, Install and Remove Weatherhead Fittings All engines with crosswise accessory hous-

ings330 ST-105 Fixture, Drill Four Holes for Crankshaft Oil Seal Retainer All direct drive engines with a

2.375 Crankshaft seal diameter This fixture can be used only when the engine is assembl-

ed.

331 ST-107 Wrench, Front Oil Plug Remove and replace front oil plug (controllable pitch propeller)332 ST-108 Wrench, Offset to Torque Nuts on Reduction Gear Housing All geared engines except

TIGO-541

333 ST-112 Back Spotfacer, Pilot and Driver Modify all flanged reduction gear housings for use of body fit

bolts

334 ST-113-1 Reamer, Valve Guide ID Exhaust (Ni-Resist) Pilot Dia..48281.4833 Finished ID .49851.4995

for large ID valve guide replacement (See 64927 for Plug Gage)335 ST-113-2 Reamer, Valve Guide ID Exhaust (Ni-Resist) Pilot Dia..47781.4783 Finished ID .4985/.4995

for small ID valve guide replacement (See 64927 for Plug Gage)336 ST-114 Shroud, Cooling IO-720-B1A Up Draft Exhaust

337 ST-115 Tool, Install and Remove Propeller Flange Bushings All flanged propeller shafts employing

bushings

ba328il~ll-

327

326

332331

330

329

333

334 335

337

336

20



338 ST-122 Plate, Crankcase Separates and draws together doweled crankcase halves All engines employ-

ing crankcase thru stud dowels

339 ST-122-2 Stud, Crankcase Plate -(Detail of St-122)

340 ST-122-3 Nut, (Detail of ST-122)

341 ST-122-4 Washer, (Detail of ST-122)

342 ST-123 Plate, Bushing (Crankcase) Drill and ream crankcase for standard thru stud dowels All

engines to employ crankcase standard thru stud dowels, except large cylinder base flange

crankcases (See ST-270)

343 ST-124 Drill, Crankcase (Standard) Thru Stud Dowel All engines to employ crankcase standard thru

stud dowels

344 St-125 Reamer, Crankcase (Standard)- Thru Stud Dowel All engines to employ crankcase standard

thru stud dowels

345 ST-126 Gage, Plug and Depth (Standard)- Crankcase Thru Stud Dowel All engines to employ

crankcase standard thru stud dowels

346 ST-128 Shroud, Cooling 10-720 A1A (Down Draft Exhaust)

347 ST-129 Sleeve, This tool is used to install AiResearch Piston (PIN 475515) into bypass cylinder All

T-1108 and T-1112 turbochargers

348 ST-131 Gage-Belt, Tension Dial All direct drive engines

349 ST-133 Fixture-Holding Turbocharger All T-1108 and T-1112 turbochargers Use with St-135

350 ST-134 Wrench, Turbocharger Wrench is used to remove back plate nut after it has been drilled and

cracked All T-1108 and T-1112 turbochargers

351 ST-135 Drill, Plate, Turbocharger Drill plate is used to drill back plate nut in order that is may be

cracked with a chisel. Use drill plate with holding fixture ST-133 All T-1108 and T-1112

turbochargers352 ST-136 Gage, Special Turbocharger (This gage is used for checking radial bearing play.) All T-1108 and

T-1112 turbochargers

343

342

344

346

338 THRU 341

347

345

348349

350

351 352

21



353 St-138 Gage, Block, Turbocharger This block is used to set up vernier height gage and oval indicatorto measure impeller tip height All T-1108 and T-1112 turbochargers

354 ST-139 Jig, Welding Single Butterfly Exhaust Bypass Valve All turbochargers single butterfly ex-

haust bypass valve

355 ST-140 Gage, Plug Exhaust Bypass Valve (Wire Type for size up to .125 dia.) This is the clearancebetween the butterfly and the housing in the closed position All turbocharger exhaust

bypass valves356 STL141 Gage, Plug, Double Exhaust Bypass Valve This is the clearance between the butterfly and the

housing in the open position All turbocharger exhaust bypass valves used on TIG-541

engines357 ST-142 Wrench, Shroud Tube All engines employing lock type shroud tubes358 ST-143-1 Reamer, Valve Guide ID Exhaust (Ni-Resist) Pilot Dia..48281.4833 Finished ID .49951.5005

for large ID valve guide replacement (See ST-155 for Plug Gage)359 ST-143-2 Reamer, Valve Guide ID Exhaust (Ni-Resist) Pilot Dia..47781.4783 Finished ID .49951.5005

for small ID valve guide replacement (See ST-155 for Plug Gage)360 ST-144 Fixture, Salvage Fretted Crankcase Used on four and six cylinder engines with conventional

crankcases. Use this tool with ST-145 and ST-146. (See ST-252 for crankcases with largecylinder base flanges)

361 ST-145 Cutter, Salvage Fretted Crankcase (Conventional)- See ST-144, ST-269362 ST-146 Holder, Stop Collar, Salvage Crankcase See ST-144 and ST-252363 ST-147-I Balls, Sizing Pinion Cage, Balls are used to burnish pinion shaft holes to proper size All stan-

ST-147-2 dard reduction gears (Tools ST-148, ST-149, ST-150 are used in conjunction with this tool)All engines with standard planitary reduction gears

364 ST-148 Spacer, Adjustable, Pinion Cage -Spacer is used inside of pinion cage to keep it from collapsingwhen sizing balls are pushed thru pinion cage -All engines with planitary reduction gears

355 356

353

358 359

360

361 363

362 O

364

22



365 ST-149 ’Fixture, Location and Reaming Pinion Cage Gage was designed to keep pinion shaft holes in

alignment with fixture All engines with planitary reduction gears

366 ST-149-9 Pin, Locating (Detail of ST-149)

367 ST-150-1 Reamer, Piloted Pinion Cage (.011" ols) To keep pinion shaft holes in alignment with fixture

ST-149. (ST-147, ST-148, ST-149 and are used in conjunction with this tool)

368 ST-150-2 Reamer, Piloted Pinion Cage (.022" ols) To keep pinion shaft holes in alignment with fixture

ST-149. (ST-147, ST-148, ST-149 and are used in conjunction with this tool)

369 ST-155 Gage, Plug, Valve Guide ID (Exhaust)- All cylinder heads with .49951.5005 ID valve guide hole

(See ST-143-I or ST-143-2 for Reamer)

370 ST-156 Stop, Drill and Reamer All engines to employ crankcase thru-stud dowels (Tools ST-124 and

ST-125 are used in conjunction with this tool)

371 ST-158 Puller ("V" Pulley) Generator and Alternator All direct drive engines except 0-145 and 0-435

series

372 ST-160 Pilot Bar, Assembling Rocker Arms to Cylinder Head All engines except 76 Series

373 ST-161 Ring, Engine Mounting TIG-541 and TIGO-541

374 ST-162 Stand (Engine), A-Frame, Overhaul- All engines

375 ST-163 Wrench, Remove Exhaust Pipe Flange (7/16") -TIO-541 and TIGO-541 (See ST-213 for 1/2")

376 ST-164 Shroud, Cooling TIG-541

377 ST-165 Adapter, Engine Overhaul Assembly All direct drive engines (Use with ST-278 overhaul

A-frame skid)

O369

BID Tli370

372

367 368

371

365

i376

-e

377

373

23


Ref. ToolNo. Nomenclature and Description378 ST-168 Driver, (Special Assembly) Crankshaft rear spline bushing All engines with crosswise ac-

cessory housings379 ST-169 Fixture, Drill, Crankshaft Rear Bushing All engines with crosswise accessory housings380 ST-170 Drift, Crankshaft Rear Spline Bushing Dowel All engines with crosswise accessory housings381 ST-171 Tool, Peening, Crankshaft Rear Spline Bushing Dowel All engines with crosswise accessory

housings382 ST-172 Puller Set Oil Seal All engines (Use with 64782 Slide Hammer)383 ST-172-5 For Use With STD-547 Seal (Detail of ST-172)384 ST-172-6 For Use With STD-O11 Seal (Detail of ST-172)385 ST-172-7 For Use With STD-2217 and STD-208 Seals (Detail of ST-172)386 ST-172-8 For Use With STD-213 Seal (Detail of ST-172)387 ST-172-9 For Use With LW-14260 and 61165 Seals (Detail of ST-172)388 ST-172-10 For Use With STD-1708 Seal (Detail of ST-172)389 ST-173 Holder, Accessory Drive Shaft All crosswise accessory housings employing thirteen spline ac-

cessory drive shaft assemblies390 ST-174 Holder, Accessory Drive Shaft All crosswise accessory housings employing fourteen spline ac-

cessory drive shaft assemblies391 ST-177 Wrench, Turbocharger Impeller All T-1108 and T-1112 turbochargers392 ST-179 Fixture, Reaming Valve Guide Hole in Cylinder Head All parallel valve engines converting

from 7/16" exhaust valves to 1/2" (’10019 ST-180, ST-181 and ST-199 are used in conjunctionwith this tool)

393 ST-179-2 Bushing, Reaming valve guide hole in cylinder head fixture (Detail of ST-179)394 ST-179-3 Pin, Locating Reaming valve guide hole in cylinder head fixture (Detail of ST-179)395 ST-180 Reamer, Rework Valve Guide Hole in Cylinder Head All parallel valve engines converting

7116" exhaust valves to 1/2" (Tools ST-179, ST-181 and ST-199 are used in conjunction withthis tool)

391

379378

380 381

~m, 389

393

390392

382 THRU 388

395

394

24



396 ST-181-1 Reamer, Valve Guide ID Exhaust (Ni-Resist) All parallel valve engines employing 1/2" ex-

haust valves Pilot dia..4828/.4833 Finished ID .49851.4995 For large ID valve guide

replacement (Tools ST-179, ST-180 and ST-199 are used in conjunction with this tool) (See

64927 for Plug Gage)397 ST-181-2 Reamer, Valve Guide ID Exhaust (Ni-Resist)- all parallel valve engines empoying 1/2" exhaust

valves Pilot dia..47781.4783 Finished ID .49851.4995 For small ID valve guide replace-ment (Toois ST-179, ST-180 and ST-199 are used in conjunction with this tool) (See 64927

for Plug Gage)398 ST-184 Kit, Hell-Coil Repair All engines399 ST-190-2 Socket, Injector Nozzle All TIO´•541 and TIGO-541 engines400 ST-191 Gage, Plug,.010 o/s, Rocker shaft bushing hole in cylinder head All engines except 76 Series

-See 64811 for .005 ols

401 ST-198 Tool, Crimping (Grounded Sheath) Crimp ends on (5MM) harness (See 64861 for 7MM)

402 ST-199 Counterbore, Rework Parallel Valve Cylinder Heads in Exhaust Valve Guide Flange Area All

parallel valve engines converting from 7/16" to 1/2" (flange) exhaust valves (Tools ST-179,

ST-180 and ST-181 are used in conjunction with this tool)

403 ST-210 Reamer,.0075" ols Counterweight Bushing Holes All engines equipped with counterweights

404 ST-211 Reamer,.0l25" ols Counterweight Bushing Holes All engines equipped with counterweights

405 ST-212 Gage Blocks, Crankshaft Counterweight Bushing To check parallelism of counterweight

bushing to crankshaft All engines equipped with counterweights406 ST-213 Wrench, Remove Exhaust Pipe Flange (112")- TIG-541 and TIGO-541 (See ST-163 for 7116")

407 ST-215 Driver, Sleeve, Oil Pressure Relief Valve All direct drive engines except 76 Series and ad-

justable valves. (See St-249 for driver used on adjustable valves)

408 ST-220 Sling, Engine Lifting TIG-541 and TIGO-541

409 ST-222 Plate, Torque Hold-Down All engines except 0-235 series

410 ST-222-2 Insert, Torque Hold-Down Plate, (Detail of ST-222)

396 397

400

399

401

398

J402

403 404ST-212-E

405 406

407

~q"p

408

410

25



411 ST-223 Swaging Tool, Turbocharger Exhaust Pipes All turbocharger exhaust pipes used on Avco

Lycoming engines412 ST-226 Gage, Intake Pipe Bore Salvage (Determine necessity for salvage) IO, HIO, TIO and LTIO-540

tuned induction

413 ST-227 Fixture, Intake Pipe Bore Salvage (Mount housing and fixture to radial drill press) IO, HIO,TIO and LTIO-540 tuned induction

414 ST-228 Counterbore, Intake Pipe Bore Salvage IO, HIO, TIO and LTIO-540 tuned induction

415 ST-229 Pilot, Counterbore, Intake Pipe Bore Salvage IO, HIO, TIO and LTIO-540 tuned induction

416 ST-230 Drift, Bushing Installation, Intake Pipe Bore Salvage IO, HIO, TIO and LTIO-540 tuned in-

duction

417 ST-231 Reamer,.088 .089 Pin, Intake Pipe Bore Salvage IO, HIO, TIO and LTIO-540 tuned induc-

tion

418 ST-232 Fixture, Valve Seat Replacement and Refacing All cylinder assemblies employing angle head

valves

419 ST-233 Fixture, Disassemble and assemble hydrauliclifters 76 Series, TIG-541 and TIGO-541

420 ST-234 Drift, Crankshaft, Front Plug (OD Diameter 2.010/2.011) (PIN 77416)421 ST-235 Wrench, Engine Timing (Starter Gear)- VO-435-B1A, TVO-435-F1A

422 ST-236 Arbor, Connecting Rod Slave Bolts All connecting rods with a bore diameter of 2.4205/2.4210

423 ST-237 Arbor, Connecting Rod Slave Bolts All connecting rods with a bore diameter of 2.2870/2.2875

424 ST-239 Kit, Engine Overhaul Ring Mounting (Use with ring ST-161) TIG-541 and TIGO-541

411412

413

415416

3 4414

420

419

418

-~h OC

10 ok

421j ~da

424

422 423

26



425 ST-240 Adapter, Engine Overhaul Assembly (Use with skid ST-278, overhaul stand ST-162 and ST-161

ring)- TIGO-541

426 ST-241 Club, Test (Used with adapter ST-242)- TIGO-541

427 ST-242 Adapter, Test Club TIGO-541

NOTE: The following tools, ST-243, ST-244, ST-245, ST-246, ST-248 and ST-249 are used to

modify the crankcase for use of adjustable oil pressure relief valve. See latest revision of Service

Instruction No. 1172.

428 ST-243 Bushing, Pilot, Oil Relief Valve (.001 ols) All direct drive engines429 ST-244 Reamer, Oil Relief Valve (.001 ols) All direct drive engines430 ST-245 Bushing, Pilot, Oil Relief Valve (.004 ols) All direct drive engines431 ST-246 Reamer, Oil Relief Valve (.004 o/s) All direct drive engines432 ST-248 Countersink, Oil Relief Valve (.001 .004 o/s) All direct drive engines (Use with Pilot ST-245)433 ST-249 Driver, Oil Relief Valve (.001 .004 o/s) All direct drive engines434 ST-250 Fixture, Valve Seat Replacement and Refacing All cylinder assemblies employing parallel

valves

435 ST-251 Socket, Connecting Rod Nut All engines436 ST-252 Fixture, Salvage Fretted Crankcases Used on four cylinder engines with large cylinder base

flange crankcases. Use this tool with ST-269 and ST-146. (See ST-144 for conventional

crankcases.)437 ST-253 Driver, Intake Pipe Bore Salvage IO, HIO, TIO and LTIO-540 Tuned Induction (Tools ST-226,

ST-227, ST-228, ST-229, ST-230 and ST-231 are used in conjunction with this tool.)438 ST-254 Reamer, Crankshaft Flange -.010 ols Bolt (Use with ST-256 Fixture)- All geared engines439 ST-255 Reamer, Crankshaft Flange .010 ols Bolt (use with Fixture ST-256)- All six cylinder vertical

engines

426

427

425

V~‘? 433

430

O

434

437435

436

438 439

27



440 ST-256 Fixture, Crankshaft Flange (.010 ols Bolt) Use with ST-254 and ST-255 Reamers All gearedand six cylinder vertical engines

441 ST-257 Pilot, Valve Seat Cutter (Std.) All cylinder heads with .6933 valve guide hole

442 ST-257-1 Pilot, Valve Seat Cutter (.010 o/s) All cylinder heads with .6933 valve guide hole




446 ST-257-5 Pilot, Valve Seat Cutter (.005 ols) All cylinder heads with.6933 valve guide hole


448 ST-258-2 Reamer, Valve Guide OD (Exhaust) (.020 o/s)- All valve guides with .69331.6943 valve guidehole in cylinder head



451 ST-258-5 Reamer, Valve Guide OD (Exhaust) (.005 o/s) All valve guides with .6933/.6943 valve guidehole in cylinder head

452 ST-259 Gage, Plug, Valve Guide OD (Exhaust) (STD)- All valve guides with .69331.6943 valve guidehole in cylinder head

453 ST-259-1 Gage, Plug, Valve Guide OD (Exhaust) (.010 ols) All valve guides with .69331.6943 valve guidehole in cylinder head

454 ST-259-2 Gage, Plug, Valve Guide OD (Exhaust) (.020 ols) All valve guides with .69331.6943 valve guidehole in cylinder head

455 ST-259-3 Gage, Plug, Valve Guide OD (Exhaust) (.030 ols)- All valve guides with .69331.6943 valve guidehole in cylinder head



458 ST-260 Tool, Density Controller Adjusting All engines employing a slotted head density controller ad-

justment screw

459 ST-264-B Probe, Thermocouple Deck Temperature 3/8-16 NC-3 thread

460 ST-264-C Probe, Thermocouple Deck Temperature 7116-20 NF-3 thread

461 ST-265 Extension, Thermocouple Use with ST-264-B, ST-264-C

g441 THRU 446

~p 452 THRU 457

447 THRU 451

440

459 460

461

458

28



462 ST-266 Compressor, Valve Spring and Bar TIO-541-E Series, TIGO-541-E Series (See ST-25 and

ST-419)463 ST-267 Reamer, Valve Guide ID (Ni-Resist) Pilot dia. .47781.4783 Finished ID .4980. This reamer is us-

ed only when valve guide is to be honed to size after reaming.464 ST-269 Cutter, Salvage Fretted Crankcase "Conventional and Large Cylinder Base Flange

Crankcases" See ST-252

465 ST-270 Plate, Bushing (Crankcase)- Drill and ream crankcase for standard thru-stud dowels All wide

cylinder base flange crankcase (See ST-123 for conventional crankcases)466 ST-271 Puller, Crankcase Thru-Stud All engines employing drive thru-studs

467 ST-272 Ring, Engine Mounting TIG-540 except -C1A, -E1A, -G1A, -H1A and -V2AD (Use with ST-278

and ST-162)

NOTE: The following tools, ST-273, ST-274, ST-275, ST-276 and ST-277 are used to modify the

intake pipe bore in oil sump. See latest edition of Service Instruction No. 1168.

468 ST-273 Countersink, Intake Pipe Bore IO, AEIO, HIO, LIO and LHIO-360 engines employing largecylinder base flanges

469 ST-274 Counterbore, Intake Pipe Bore IO, AEIO, HIO, LIO and LHIO-360 engines employing largecylinder base flanges

470 ST-275 Driver, Counterbore, Intake Pipe Bore IO, AEIO, HIO, LIO and LHIO-360 engines employinglarge cylinder base flanges

471 ST-276 Drift, Bushing Installation, Intake Pipe Bore IO, AEIO, HIO, LIO and LHIO-360 enginesemploying large cylinder base flanges

472 ST-277 Fixture, Intake Pipe Bore IO, AEIO, HIO, LIO and LHIO-360 engines employing largecylinder base flanges

463

462 464

466

465

468

467

469

470

29



473 ST-278 Skid (Engine A-Frame Overhaul) All engines (Use with ST-162)474 ST-279 Gage, Valve Clearance All engines requiring a valve clearance between .040 .105

475 ST-280 Fixture, Ream Crankshaft Counterweight All engines equipped with counterweights476 ST-280-3 Plug, Std. Crankshaft Counterweight For.93691.9377 hole Plug may be used with fixture

64873 or ST-280

477 ST-280-7 Plug, .005 ols Crankshaft Counterweight For .94201.9425 hole Plug may be used with fixture

64873 or ST-280

478 ST-280-8 Plug,.010 ols Crankshaft Counterweight For .94701.9475 hole Plug may be used with fixture

64873 or ST-280

479 ST-280-9 Plug,.0l5 ols Crankshaft Counterweight For .95201.9525 hole Plug may be used with fixture

64873 or ST-280

480 ST-280-10 Plug, .0075 ols Crankshaft Counterweight For.9445/.9450 hole Plug may be used with fixture

64873 or ST-280

481 ST-280-ii Plug, .0125 ols Crankshaft Counterweight For.94951.9500 hole Plug may be used with fixture

64873 or ST-280

482 ST-283 Wrench, Differential Pressure Controller Adjusting All turbochargers employing differential

pressure controllers

483 ST-284 Tool, Differential pressure controller lock All turbochargers employing differential pressure

controllers

484 ST-285 Ring, Engine Mounting TIG-360 (Use with ST-278 and ST-162)485 ST-286 Ring, Engine Mounting TIO-540-C1A and 6 cylinder direct drive engines without turbocharg-

ing (Use with ST-278, ST-162, ST-165)486 ST-287 Ring, Engine Mounting TIG-720-A (Use with ST-278 and ST-162)487 ST-288 Socket, Spark Plug Wrench 7/8 hex All engines488 ST-289 Swaging Tool, Intake Pipe IO, TIG, HIO, LTIO-540 engines employing intake pipe connec-

tions PIN 72167, 72168, 72169 and 10-720 engines employing intake pipe connections P/N

75121, 75123, 75125 with 1.54211.568 ID

489 ST-291 Driver, Main Bearing Straight Dowel All engines employing straight main bearing dowels

476 THRU 481

:I475

473~;‘of//

487

474

’~L

482

483

488 484 THRU 486 489

30



490 ST-295 Drift, Crankshaft, Oil Plug- IO, HIO, AIO, TO, TIG, LIO-360; O, TIG, LTIO-540; TIG-541 and

10-720 (plug size 1.251/1.254)491 ST-297 Club, Test (Left hand rotation) LIO-320

492 ST-298 Club, Test (Left hand rotation) LIO-360

493 ST-299-1 Reamer, Piloted Pinion Cage (.011 ols) To keep pinion shaft holes in alignment with fixture

ST-149 (ST-148, ST-149 and ST-300-1 are used in conjunction with this tool)

494 ST-299-2 Reamer, Piloted Pinion Cage (.022 ols) To keep pinion shaft holes in alignment with fixture

ST-149 (ST-148, ST-149 and ST-300-2 are used in conjunction with this tool)495 ST-299-3 Reamer, Piloted Pinion Cage (.033 0/9) To keep pinion shaft holes in alignment with fixture

ST-149 (ST-148, ST-149 and ST-300-3 are used in conjunction with this tool)496 ST-300-1 Balls, Sizing Pinion Cage, (-1, .011 o/s, -2, .022 o/s, -3, .033 ols) balls are used to burnish pinion

ST-300-2 shaft holes to proper size all heavy duty reduction gears (Tools ST-148, ST-149, ST-299 are

ST-300-3 used in conjunction with this tool) All engines with heavy duty planitary reduction gears.

497 ST-301 Tool, Crimping Crimp spark plug wire terminal on 5MM ignition harness having 5/8-24 nut

498 ST-302 Drift, Valve Guide Installation (Intake and Exhaust) All angle head engines employingflangeless valve guides

499 ST-303 Drift, Valve Guide Installation (Exhaust) All parallel head engines employing flangeless ex-

haust valve guides500 ST-304 Drift, Valve Guide Installation (Intake) All parallel head engines employing flangeless intake

valve guides501 ST-305 Driver, Bearing Dowel (Straight and Stepped) All crankcases with 2.9370 bearing bore

diameter

502 ST-306 Driver, Bearing Dowel (Straight and Stepped) All crankcases with 2.5665 bearing bore

diameter

503 ST-307 Driver, Bearing Dowel (Straight and Stepped) All crankcases with 2.8165 bearing bore

diameter

504 ST-309-1 Reamer, Valve Guide ID Exhaust (Ni-Resist) Pilot dia..48281.4833 finished ID .50001.5010 for

large ID valve guide replacement. (See ST-314 for Plug Gage)505 ST-309-2 Reamer, Valve Guide ID Exhaust (Ni-Resist) Pilot dia..47771.4783 finished ID .50001.5010 for

small ID valve guide replacement. (See ST-314 for Plug Gage)506 ST-310 Gage, Check Bell-Mouthing of Exhaust Valve Guides All angle valve engines employing 1/2"

exhaust valves with down exhaust (See ST-71 for parallel valves)

493 THRU 495490

496

497

491 492

504 505

501 THRU 503

506 498 THRU 500

31



507 ST-313 Wrench, Crankshaft Flange TIGO-541

508 ST-314 Gage, Plug, Valve Guide ID (Exhaust) All valve guides with .5000/.5010 ID valve guide hole

(See ST-315 for Reamer)509 ST-315 Reamer, Valve Guide ID (Brass) (Exhaust)- Pilot dia..48881.4893 finished ID .50001.5010, (not

used on No-Resist Guides) See ST-314 for Plug Gage510 ST-316 Driver, Crankcase Thru-Stud TIG-541 and TIGO-541

511 ST-317 Driver, Crankcase Thru-Stud All engines employing thru-studs (except TIO and TIGO-541)512 ST-318 Gage, Fuel Injector and Controller Linkage TIG-541 and TIGO-541 (Use with ST-319)513 ST-319 Fixture, Fuel Injector and Controller Linkage TIG-541 and TIGO-541 (Use with ST-318)514 ST-320 Wrench, Propeller TIGO-541

515 ST-321 Puller, Compressor Pulley All engines employing compressors516 ST-322 Wrench, (5/8" hex) Cylinder Base Nut All engines employing PIN STD-2106 nut

517 ST-323 Counterbore, Crankcase Oil Seal recess Use with ST-324, ST-325 All engines employingcrankcase thru-stud dowels

518 ST-324 Pilot, Crankcase Oil Seal Recess Counterbore Use with ST-323, ST-325 All engines employingcrankcase thru-stud dowels

519 ST-325 Stop Collar, Crankcase Oil Seal Recess Counterbore Use with ST-323, ST-324 All enginesemploying crankcase thru-stud dowels

520 ST-327 Plate, Bushing (Crankcase)- Use with ST-328-2 Ream crankcase for o/s thru-stud dowels521 ST-328-2 Reamer, Crankcase (.6350 diameter for .010 ols dowels) Use with ST-327 All engines to

employ .010 ols thru-stud dowels522 ST-329 Fixture, Propeller Shaft Locknut Assembly TIGO-541

523 ST-329-1 Fixture, Propeller Shaft Locknut (Detail of ST-329) TIGO-541524 ST-329-2 Stand, Propeller Shaft Locknut (Detail of ST-329)- TIGO-541525 ST-331 Gage, Plug and Depth .010 ols Crankcase Thru-Stud Dowel All engines to employ crankcase

.010 0/5 thru-stud dowels (See ST-126 for standard gage)526 ST-332 Driver, Dowel Crankcase Drive Press fit dowels in crankcase All engines to employ crankcase

thru-stud dowels

509507

514 510 511508 512

519 o_516

518 515

521 524 ~U 520525

523

522

526

32



527 ST-333 Adapter 5/8-18 NC-2 thread to 16 MM x 2 thread Use with Metric Slide Hammer Puller

528 ST-338 Reamer, (Short) Hand-Expansion Valve Guide ID All cylinder head with 1/2" valve guide hole

529 ST-340 Former, Oil Relief Valve Seat (Use with ST-245) All engines530 ST-345 Wrench, "T" Bar Spark Plug (Use with ST-288) All engines531 ST-351 Club, Test (Left hand rotation) (Use with 64981)- LTIO-540

532 ST-352 Shroud, Cooling All four cylinder angle valve engines533 ST-354 Reamer and Stop, Shroud Tube adapter TIO and TIGO-541-E engines Use with ST-356,

ST-357, ST-376, ST-361, ST-362, ST-363, ST-364, ST-365.

534 ST-356 Puller Insert, Shroud Tube Cylinder Head adapter All cylinder heads reworked to install

shroud tube adapter (PIN LW-13398)- Use with ST-354, ST-357, ST-361, ST-362, ST-363,

ST-364, ST-365, ST-376, ST-381, ST-382.

535 ST-357 Fixture, Shroud Tube adapter Rework shroud tube adapter (PIN 77755) on TIO and TIGO-541-

E engines Use with ST-354, ST-356, ST-376, ST-361, ST-362, ST-363, ST-364, ST-365.

536 ST-360 Reamer Set, Crankcase Bearing Dowel All crankcases to employ .2545 or .2595 o/s BearingDowel Hole

537 ST-361 Tool, Shroud Tube Barrel, Spring and Assembly TIO and TIGO-541-E Use with ST-354,

ST-356, ST-357, ST-362, ST-363, ST-364, ST-365, ST-376, ST-381, ST-382.

538 ST-362 Reamer, (Tapered) Cylinder Head Shroud Tube Hole Ream cylinder heads to install (PIN

LW-13398) adapter TIO and TIGO-541-E Use with ST-354, ST-356, ST-357, ST-361,

ST-363, ST-364, ST-365, ST-376, ST-381, ST-382.

539 ST-363 Back Relief Cutter, Pilot and Driver Cutter to relieve cylinder heads to install (PIN LW-13398)

adapter TIO and TIGO-541-E Use with ST-354, ST-356, ST-357, ST-361, ST-362, ST-364,

ST-365, ST-376, ST-381, ST-382.

540 ST-364 Fixture, Cylinder Head Shroud Tube Hole Ream cylinder head to install (P/N LW-13398)

adapter TIO and TIGO-541-E Use with ST-354, ST-356, ST-357, ST-361, ST-362, ST-363,

ST-365, ST-376.

541 ST-365 Tool, Flaring Flare cylinder head shroud tube adapter (P/N LW-13398)- TIO and TIGO-541-E

-Use with ST-354, ST-356, ST-357, ST-361, ST-362, ST-363, ST-364, ST-376, ST-381,

ST-382.

528 529 530527

531

533 534

538

535

i"

536

540

541

33



542 ST-366-5 Reamer, Piloted Crankcase (.005 ols) Ream thru-stud hole in crankcase All engines employingPIN 76220-P05 thru-stud

543 ST-366-1 Reamer, Piloted Crankcase (.010 ols)- Ream thru-stud hole in crankcase All engines employingP/N 76220-P10 thru-stud

544 ST-368 Kit, Valve Train Removal Remove valve train with a pumped up hydraulic Lifter Angle valve

cylinders545 ST-369 Pilot, Spark Plug Pad Counterbore Use with counterbore ST-370 All engines546 ST-370 Counterbore, Spark Plug Pad Use with pilot ST-369 All engines547 ST-372 Drill Jig, Crankshaft Front Oil Drain Crankcases with no thrust bearing oil drain converting to

oil lubrication stainless steel thrust bearing TIGO-541548 ST-374 Wrench, Cylinder Base Nut (9/16 hex) All engines employing P/N STD-383-B nut

549 ST-375 Wrench, Cylinder Base Nut (3/4 hex)- All engines employing P/N STD-2090 nut

550 ST-376 Spring Holder, Shroud tube (Barrel Springs) All engines employing Barrel Springs on Shroud

Tubes

551 ST-377 Drill Fixture, Relocate front propeller shaft drive gear bearing dowel hole in crankcase

-TIGO-541

552 ST-378 Driver, Bearing Dowel (Straight) Crankcases with 2.923 bearing bore diameter TIGO-541-Use with ST-377, ST-379, ST-380.

553 ST-379 Drill, Flat Bottom Propeller shaft drive bearing dowel hole in crankcase TIGO-541554 ST-380 Reamer, Propeller shaft drive gear bearing dowel in crankcase TIGO-541

555 ST-383 Tool, Crankshaft oil seal installation All engines employing stretch seals556 ST-387 Fixture, Tappet body Magnaflux All engines except 0-235, 0-290-D, 76 Series, TIO and

TIGO-541 (Use with 64899)557 ST-388 Reamer, Guide and Stop Oil temperature By-Pass Valve Seat All direct drive engines except

TIG-541

558 ST-389 Tool, Crankcase separating All doweled crankcase with drive thru-studs559 ST-390 Fixture, Drill, Crankshaft Gear TIO and TIGO-541

542 543

545547

546

544548 549

(-D

550

551 B552

555

556

557558

i-

553

559

554

34


Ref. ToolNo. Nomenclature andDescription560 ST-415 Hub and Cone Assembly, Test Club (4 Blade) All No. 30 Spline propeller shafts with

2.615/2.617 OD561 ST-415-2 Cone, Detail of ST-415562 ST-416 Wrench, Spline, Oil pump drive 76 Series engines563 ST-418 Tool, (Solid tappets) Valve adjusting 0-235, 0-290-D Series564 ST-418-3 Blade, Screwdriver Valve adjusting tool (Detail of ST-418)565 ST-419 Compressor, Valve Spring 76 Series engines566 ST-427 Reamer, (STD) Rocker Shaft Bushing Hole 0-235, 0-290 series cylinder for installation of

bushings567 ST-429 Gage, Plug Valve Guide OD (Intake and Exhaust) (STD) All valve guides with .59131.5923

valve guide hole in cylinder head568 ST-429-1 Gage, Plug Valve Guide OD (Intake and Exhaust) (.010 ols)- All valve guides with .59131.5923

valve guide hole in cylinder head569 ST-429-2 Gage, Plug Valve Guide OD (Intake and Exhaust) (.020 ols) All valve guides with .59131.5923




valve guide hole in cylinder head573 ST-430-1 Reamer, Valve Guide OD (Intake and Exhaust) (.010 ols) All valve guides with .59131.5923

valve guide hole in cylinder head574 ST-430-2 Reamer, Valve Guide OD (Intake and Exhaust) (.020 ols)- All valve guides with .59131.5923

valve guide hole in cylinder head575 ST-430-3 Reamer, Valve Guide OD (Intake and Exhaust) (.030 ols) All valve guides with .5913/.5923

valve guide hole in cylinder head576 ST-430-4 Reamer, Valve Guide OD (Intake and Exhaust) (.040 ols) All valve guides with .59131.5923

valve guide hole in cylinder head577 ST-430-5 Reamer, Valve Guide OD (Intake and Exhaust) (.005 o/s)- All valve guides with.59131.5923

valve guide hole in cylinder head

I560 561

564

563

573 THRU 577

567 THRU 572

565 566

35



578 ST-431 Gage, Plug Valve Guide OD (Exhaust) (STD) All valve guides with .66131.6623 valve guidehole in cylinder head

579 ST-431-1 Gage, Plug Valve Guide OD (Exhaust) (.010 0/9) All valve guides with .66131.6623 valve guidehole in cylinder head


581 ST-431-3 Gage, Plug Valve Guide OD (Exhaust) (.030 ols) All valve guides with .66131.6623 valve guidehole in cylinder head

582 ST-431-4 Gage, Plug Valve Guide OD (Exhaust) (.040 ols) All valve guides with .66131.6623 valve guidehole in cylinder head



585 ST-432-2 Reamer, Valve Guide OD (Exhaust) (.020 ols)- All valve guides with .6613/.6623 valve guidehole in cylinder head


587 ST-432-4 Reamer, Valve Guide OD (Exhaust) (.040 o/s)- All valve guides with.66131.6623 valve guidehole in cylinder head

588 ST-432-5 Reamer, Valve Guide OD (Exhaust) (.005 ols)- All valve guides with .6613/.6623 valve guidehole in cylinder head

589 ST-435 Reamer, Accessory Housing Oil Transfer Dowel 1GSO-540 engines590 ST-436 Reamer, Accessory Housing Oil Transfer Dowel IGSO-540 engines591 ST-439 Countersink, (800) Oil Relief Valve Seat Repair 76 series engines with 1/2 inch oil supply port

(Use with ST-245 bushing)592 ST-440 Tool, Hydraulic Plunger Removal TIG, TIGO-541 series

593 ST-443 Seal Puller and Installation Tool Remove and install STD 2217 seal in vacuum pump adapter594 ST-455 *Adapter, Test Club All 0-235 engines with AS-127 Type 1 prop flange and bushings for 3/8

inch prop attaching bolts

595 ST-456 *Club, Test 0-235 with AS-127 Type 1 prop flange (See 64801 for 0-235 with AS-127 Type 2

prop flange)596 ST-460 Mount, Engine Maintenance All 6 cylinder direct drive engines without turbocharging. Use

with 64759 at right top crankcase mounting pad597 ST-461 Mount, Engine Maintenance All 6 cylinder direct drive Engines without turbocharging. Use

with 64759 at left top crankcase mounting pad598 ST-474 Tool Hydraulic Plunger Removal. 76 Series and TIG-541 Series

AS-127 Type 1 prop flanges can be identified by measuring from one prop attaching bushingacross the center of the crankshaft to the opposite bushing. The center to center measurement

is 4-3/8 inches.

~5h

578 THRU 583 584 THRU 588 589 590591

3G3j,--Q

~h/,r’I542

593

594

595

597 598

36

SERVICE PUBLICATION CROSS REFERENCE INDEX

See Latest Revision

Tool No. Name of Publication No.

1225-B Wrench S.I. 1144

40714 Wrench S.B. 290, S.I. 1144

64501 Fixture S.I. 1246, S.I. 1366

64514 Gage S.I. 1425

64530 Gage S.B. 244

64535 Drift S.B. 244

64536 Drift S.B. 244

64547 Drift S.I. 1167

64572 Wrench S.I. 1029

64580 Burnisher S.B. 244

64593 Expanding Tool S.I. 1043

64594 Inserting Tool S.I. 1043

64596-1 Tap S.I. 1043

64597 Fixture S.B. 244

64607 Block S.B. 184, S.I. 1144

64648 Driver S.I. 1167

64681 Drift S.I. 1098

64684 Reamer S.I. 1425

64698 Puller S.B. 290

64700 Wrench S.I. 1029

64701 Wrench S.I. 1029

64719 Wrench S.B. 290

64737 Adapter S.B. 292

64765 Test Stand S.I. 1144

64767 Gage S.B. 244

64770 Drift S.I. 1098

64772 Puller S.I. 1044, S.I. 1145

64796 Drift S.I. 1246

64810 Gage S.I. 1366

64827 Drill S.B. 216

64828 Reamer S.B. 216

64829 Reamer S.B. 216

64856 Drill Jig S.B. 239

64861 Crimping Tool S.I. 1119

64862 Spotfacer S.B.225

64868 Counterbore S.B. 252

64872 Puller S.I. 1142

64874 Reamer S.I. 1142

64875 Reamer S.I. 1142

64876 Reamer S.I. 1142

64878 Fixture S.I. 1143

64891-1-2 Reamer S.B. 257, S.I. 1117

64892-1-2-3 Gage S.I. 1012

64894 Test Drive Assembly S.I. 1144

64899 Adapter S.I. 1011

64900 Reamer S.I. 1425

64901 Gage S.I. 1425

64902 Reamer S.B. 273

64903 Reamer S.B. 273

64904 Counterbore S.B. 273

37

SERVICE PUBLICATION CROSS REFERENCE INDEX (CONT.)

See Latest Revision


64905 Collar S.B. 273

64906 Plug S.B. 273

64907 Tap S.B. 273

64908 Universal S.B. 273

64910 Spinning Tool S.I. 1167

64923 Installation Drift S.I. 1136

64925 Reamer S.I. 1028

64927 Gage S.I. 1028, S.I. 1136, S.I. 1425

64939 Drill S.I. 1028

64942 Wrench S.I. 1029

64943 Wrench S.I. 1029

64915 Gage S.B. 302, S.B. 303, S.I. 1071, S.I. 1138, S.I.

1323, S.B. 371

64974 Shroud Tube Tool S.I. 1347

64975 Gasket S.I. 1144

ST-8 Fixture S.I. 1064

ST-10 Drill S.I. 1064

ST-11 Stop Collar S.I. 1064

ST-23 Gage S.B. 314, S.B. 315

ST-25 Compressor S.I. 1425

ST-26 Plug Gage S.I. 1246

ST-27 Reamer S.I. 1246

ST-29 Wrench S.I. 1069



ST-44 Drift S.B. 292

ST-49 Puller S.I. 1092, S.I. 1136, S.I. 1246

ST-50 Cutter S.I. 1092









ST-62 Driver S.I. 1092

ST-63 Adapter S.I. 1092

ST-64 Drift S.I. 1092


ST-66 Pilot S.I. 1092


ST-71 Gage S.B. ~93, S.I. 1088, S.B. 388

ST-71-8 Gage Adapter S.B. 388

ST-73 Gage S.I. 1143

ST-78 Plierwrench S.B. 302, S.I. 1296



ST-91 Cage S.I. 1143


38


See Latest Revision



ST-94 Gage S.I. 1143

ST-95 Weight S.I. 1143

ST-96 Arbor S.I. 1143




ST-113-1 Reamer S.I. 1425


ST-115 Tool S.B. 253, S.I. 1098, S.I. 1111, S.I. 1342

ST-122 Plate S.I. 1112, S.I. 1123

ST-123 Plate S.I. 1112, S.I. 1123

ST-124 Drill S.I. 1112, S.I. 1123

ST-125 Reamer S.I. 1112, S.I. 1123

ST-126 Gage S.I. 1112, S.I. 1123

ST-131 Gage S.L. L160, S.I. 1129

ST-143-1 Reamer S.I. 1342, S.I. 1425

ST-143-2 Reamer S.I. 1342, S.I. 1425



ST-146 Holder S.I. 1112

ST-147 Ball S.I. 1114

ST-148 Spacer S.I. 1114, S.I. 1236

ST-149 Fixture S.I. 1114, S.I. 1236


ST-155 Gage S.I. 1425

ST-156 Stop Collar S.I. 1112, S.I. 1123


ST-158 Puller ("V" Pulley) S.I. 1283




ST-171 Tool S.I. 1145

ST-172 Puller Set S.L. L195




ST-184 Repair Kit S.I. 1122, S. L. L162

ST-190-2 Socket S.B. 387, S.I. 1231

ST-198 Crimping Tool S.I. 1153

ST-199 Counterbore S.I. 1136



ST-212 Blocks S.I. 1142

ST-222 Plate S.I. 1112, S.I. 1029, S.I. ~1123, S.I. 1290

ST-226 Gage S.I. 1168




ST-230 Drive S.I. 1168

39


See Latest RevisionTool No. Name of Publication No.


ST-232 Fixture S.I. 1092ST-236 Arbor S.I. 1184

ST-237 Arbor S.I. 1184ST-243 Drill Bushing S.I. 1172ST-244 Reamer S.I. 1172

ST-245 Drill Bushing S.I. 1172


ST-248 Countersink S.I. 1172ST-249 Drift S.I. 1172





ST-255 Reamer S.I. 1209ST-256 Fixture S.I. 1209ST-264-B Probe S.I, 1187

ST-264-C Probe S.I. 1187

ST-265 Extension S.I. 1187

ST-266 Compressor S.I. 1192, S.I. 1425



ST-270 Plate S.I. 1112, S.I. 1123ST-271 Puller S.I. 1123, S.I. 1290ST-273 Countersink S.I. 1168



ST-276 Drift S.I. 1168ST-277 Fixture S.I. 1168


ST-289 Swaging Tool S.I. 1355

ST-291 Driver S.I. 1225, S.B. 326ST-299-1 Reamer S.I. 1236ST-299-2 Reamer S.I. 1236


ST-300-1 Sizing Ball S.I. 1236ST-300-2 Sizing Ball S.I. 1236

ST-300-3 Sizing Ball S.I. 1236ST-302 Drift S.I. 1256, S.I. 1430

ST-303 Drift S.I. 1256ST-304 Drift S.I. 1256ST-305 Driver S.I. 1225ST-309-1 Reamer S.I. 1116, S.I. 1425ST-309-2 Reamer S.I. 1116, S.I. 1425ST-310 Gage S.B. 388

ST-314 Gage S.I. 1116, S.I. 1425ST-315 Reamer S.I. 1116, S.I. 1425ST-316 Driver S.I. 1290ST-317 Driver S.I. 1290ST-318 Gage S.I. 1211

40


See Latest RevisionTool No. Name of Publication No.





ST-325 Stop Collar S.I. 1123

ST-327 Plate S.I. 1123



ST-329-1 Fixture S.I. 1292

ST-329-2 Stand S.I. 1292

ST-331 Gage S.I. 1123


ST-338 Reamer S.I. 1116, S.I. 1425ST-340 Former S.I. 1172

ST-354 Reamer and Stop S.I. 1297ST-356 Puller S.I. 1297


ST-360 Reamers S.I. 1225, S.B. 326

ST-361 Shroud Tube Tool S.I. 1297


ST-363 Cutter S.I. 1297ST-364 Fixture S.I. 1297ST-365 Flaring Tool S.I. 1297




ST-372 Drill Jig S.I. 1292

ST-376 Holder S.I. 1297



ST-379 Drill S.I. 1312


ST-383 Oil Seal Tool S.I. 1303, S.I. 1324


ST-388 Reamer, Guide and Stop S.I. 1316

ST-389 Separator Tool S.I. 1123


ST-395 Tester S.I. 1308

ST-418 Tool S.L. L196

ST-419 Compressor, Valve Spring S.B. 435

ST-427 Reamer S.I. 1366ST-435 Reamer S.I. 1394


ST-439 Countersink S.I. 1172

ST-474 Hydraulic Tool S.I. 1352, S.B. 424, S.B. 435

41

OBSOLETE SERVICE TOOLS

Tool No. Description

218-B Socket, Spark Plug Wrench (Replaced by ST-288)

1121-B Wrench Cylinder Base Nut (Replaced by ST-367)

1130-B Compressor Valve Spring (Replaced by ST-25)

1228-B Wrench Thrust Bearing Locknut (Replaced by 40714)

61550 Wrench, Cylinder Base Nut (Replaced by ST-367)

61551 Wrench, Cylinder Base Nut (Replaced by ST-394, ST-375)

61552 Extension Cylinder Base Nut Wrench (No Replacement)61678 Bar Wrench (No Replacement)64507 Gage, Plug Valve Guide OD (Repiaced by ST-429-5)

64509 Gage, Plug Valve Guide OD (Replaced by ST-429-1)


64516-1 Pilot Valve Seat Removal (See latest revision of S.I. 1092)

64517 Holder Remove Valve Seat Counterbore (See latest revision of S.I. 1092)

64518 Counterbore Remove Exhaust Valve Seat (See latest revision of S.I. 1092)

64519 Counterbore Remove Valve Seat (Exhaust) (See latest revision of S.I. 1092)

64520 Fixture Remove and Replace Valve Seat (Replaced by ST-250)

64521 Drift, Replace Exhaust Valve Seat (Replaced by ST-65)



64525 Drift Replace Intake Valve Seat (Replaced by ST-65)

64527 Drift Piston Pin (Replaced by 64843)

64547 Drift, Crankshaft Oil Tube (Replaced by 64548)

64565 Drift, Main Bearing Oil Tubes (No Replacement)64571 Gage, Plug Valve Guide OD (Replaced by ST-429)


64579 Drift, Main Bearing Oil Tubes (No Replacement)64581 Plate Engine Mounting (No Replacement)64582 Pointer Ignition Timing (No Replacement)64583 Gage, Flat Plug Rejection Valve Guide ID (Replaced by ST-81)

64597-1 Fixture Remove, Replace, Burnish Connecting Rod Bushing ~Replaced by 64597)

64598 Drift Replace Generator Mounting Bushing (No Replacement)65600 Gage, Plug Generator Mounting Bushing Finished ID (No Replacement)64609 Shroud No Replacement64635 Compressor Valve Spring (Replaced by ST-25)


64642 Drift Valve Seat Replacement (Exhaust and Intake) (Replaced by ST-64)

64645 Puller Valve Guide (Replaced by ST-49)

64670 Puller Generator Drive Shaft Gear (No Replacement)64678-2 Reamer, Valve Guide OD (Replaced by ST-430-5)

64678-3 Reamer, Valve Guide OD (Replaced by ST-430-1)



64688 Wrench, Pinion Cage Locknut (No Replacement)64690 Driver Relief Valve Sleeve (Replaced by ST-215)

64691 Counterbore Valve Seat Removal (Intake) (See latest revision of S.I. 1092)

64692 Counterbore Valve Seat Removal (Exhaust) (See latest revision of S.I. 1092)



64695 Drift Valve Seat Replacement (Replaced by ST-64)

64696 Fixture Valve Seat Replacement (Angle Heads) (Replaced by ST-232)

64699 Drift, Piston Pin Puller (Replaced by 64843)

64702 Wrench, Pinion Cage Nut (No Replacement)64703 Wrench, Engine Rotor (Replaced by 64764)

64708 Holder Accessory Drive Shaft (Replaced by ST-173, ST-174)

42

OBSOLETE SERVICE TOOLS (CONT.)


64717 Wrench Cylinder Base Nut (Replaced by 64942)64718 Wrench Cylinder Base Nut (Replaced by 64943)64722 Wrench, Pinion Cage Nut (No Replacement)64724 Gage Flat Plug Rejection Valve Guide ID (Replaced by ST-81)64725 Gage, Plug Valve Guide ID (No Replacement)64726 Reamer, Valve Guide ID (No Replacement)64727 Drift, Piston Pin Removal (Replaced by 64843)64753 Tool Vertical Lifting (Replaced by ST-48)64755 Drift, Crankshaft Rear Oil Tube (Replaced by ST-44)64760 Skid, A-Frame Overhaul (Replaced by ST-278)64761 Wrench, Magneto Bushing (No Replacement)64762 Stand (Engine), A-Frame Overhaul (Replaced by ST-162)64786 Handle, Cutter Valve Seat Recess (Replaced by ST-62, ST-63)64787-1,-2,-3 Cutter Valve Seat Recess (Exhaust) (See latest revision of S.I. 1092)64788-1,-2,-3 Pilot Valve Seat Recess Cutter (Exhaust and Intake) (See latest revision of S.I.

1092)64789-1,-2,-3 Cutter Valve Seat Recess (Intake) (See latest revision of S.I. 1092)64790-1,-2,-3 Cutter Valve Seat Recess (Intake) (See latest revision of S.I. 1092)64791-1,-2,-3 Cutter Valve Seat Recess (Exhaust) (See latest revision of S.I. 1092)64792-1,-2,-3 Cutter Valve Seat (See latest revision of S.I. 1092)64793-1,-2,-3 Cutter Valve Seat Recess (Intake) (See latest revision of S.I. 1092)64794-1,-2,-3 Cutter Valve Seat Recess (Intake) (See latest revision of S.I. 1092)64795-1,-2,-3 Cutter Valve Seat Recess (Exhaust) (See latest revision of S.I. 1092)64800 Club Test (Use 64801 or ST-456)64804 Club Test (No Replacement)64805 Club Test (No Replacement)64806 Club Test (Four-Blade) (Replaced by 64773)64808 Jig Drill, Rocker Shaft Bushing Dowel Hole (No Replacement)64809 Jig Dowel, Installing, Rocker Shaft Bushing (No Replacement)64817 Drift, Dowel Installation, Rocker Shaft Bushing (No Replacement)64818 Cutter Rocker Shaft Bushing Dowel (No Replacement)64832 Reamer 0.005 ols Inner Rocker Shaft Bushing Hole in Cylinder Head (Replaced by

64338)64833 Reamer 0.010 o/s Inner Rocker Shaft Bushing Hole in Cylinder Head (Replaced by

64839

64837 Plate Engine Mounting (No Replacement)64842 Plate Engine Mounting (No Replacement)64869 Tool Install and Remove Propeller Flange Bushing (Replaced by ST-115)64873 Fixture Ream Crankshaft Counterweight Holes (Replaced by ST-280)64873-10 Plug, Crankshaft Counterweight (Replaced by ST-280-10)64873-11 Plug, Crankshaft Counterweight (Replaced by ST-280-ii)64879 Spacer Adjustable Install Bushings in Counterweights (Replaced by ST-93)64880 Counterbore Exhaust Valve Seat Removal (See latest revision of S.I. 1092)64881 Counterbore Intake Valve Seat Removal (See latest revision of S.I. 1092)64882-1,-2,-3 Cutter Intake Valve Seat Recess (See latest revision of S.I. 1092)64883-1,-2,-3 Cutter Valve Seat Recess (Exhaust) (See latest revision of S.I. 1092)64894-18 Gasket, Test Drive (Use 74822 Gasket)64896 Drift, Installation, Expansion Plug (Replaced by 64681)64897-1 Reamer No Replacement64897-2 Reamer No Replacement64911 Gage Check Cam Lobe Wear (No Replacement)64912,-1 Cutter Copperlytic Exhaust Valve Seats (No Replacement)64913,-1 Cutter Copperlytic Intake Valve Seats (No Replacement)64920 Gage, Flat Plug Rejection Exhaust Valve Guide I.D. (See Table of Limits)

43



64921 Drift Valve Seat Replacement (Intake) (Replaced by ST-64)64922-1,-2,-3 Cutter Intake Valve Seat (See latest revision of S.I. 1092)64924 Reamer, Valve Guide OD (Replaced by ST-432)64924-1 Reamer, Valve Guide OD (Replaced by ST-432-5)64924-2 Reamer, Valve Guide OD (Replaced by ST-432-1)64924-3 Reamer, Valve Guide OD (Replaced by ST-432-2)64924-4 Reamer, Valve Guide OD (Replaced by ST-432-3)64926 Gage, Flat Plug Rejection Exhaust Valve Guide I.D. (See Table of Limits)64928 Gage, Plug Valve Guide OD (Replaced by ST-431-5)64929 Gage, Plug Valve Guide OD (Replaced by ST-431-1)64930 Gage, Plug Valve Guide OD (Replaced by ST-431-2)64931 Gage, Plug Valve Guide OD (Replaced by ST-431-3)64935 Hub and Cone Assembly, (Replaced by ST-415)64937 Wrench No. 30 Spline (Replaced by ST-38)64938 Club Test (Replaced by 64783)64940 Gage, Plug Valve Guide OD (Replaced by ST-431)64969 Gage Dry Tappet Clearance (Replaced by ST-279)64978 Reamer, Rocker Shaft Bushing Hole (Replaced by ST-427)64985 Bolt Propeller (See 64801 or ST-456)64986 Flange, Propeller (See 64801 or ST-456)65521 Handle, Offset Spark Plug Wrench (Replaced by ST-345)65522 Wrench Cylinder Base Nut (Replaced by ST-375)65523 Wrench Cylinder Base Nut (Replaced by ST-374)65526 Socket Universal Joint (No Replacement)65528 Gage, Valve Clearance Dry Tappet (Replaced by ST-23)ST-41 Fixture Spotface, Mill Contour of Stretch Bolt in Connecting Rod Cap (No

Replacement)ST-42 Drill Special Flat Bottom Core, Mill Contour in Connecting Rod Cap for Stretch

Bolt (No Replacement)ST-59 Pilot Valve Seat Cutter (No Replacement)ST-60 Pilot Valve Seat Cutter (No Replacement)ST-61 Pilot Valve Seat Cutter (No Replacement)ST-74 Gage Ring (No Replacement)ST-85 Fixture Drill Jig (No Replacement)ST-90 Reamer Valve Guide OD (No Replacement)ST-97 Gage Counterweight Hole Location (No Replacement)ST-98 Weight Counterweight Master (No Replacement)ST-106 Drift Crankshaft Oil Plug (No Replacement)ST-110 Fixture Ream and back spotface reduction gear housing (No Replacement)ST-116 Puller Remove Sludge Tubes from Crankshaft (Replaced by 64784)ST-117 Gage, Flat Plug Rejection Exhaust Valve Guide I.D. (See Table of Limits)ST-118 Gage, Flat Plug Rejection Intake Valve Guide I.D. (Replaced by ST-81)ST-119 Gage, Flat Plug Rejection Exhaust Valve Guide I.D. (See Table of Limits)ST-120 Gage, Flat Plug Rejection Exhaust Valve Guide I.D. (See Table of Limits)ST-121 Gage, Flat Plug Rejection Exhaust Valve Guide I.D. (See Table of Limits)ST-127-1 Fixture, Test Density Controller Calibration (Replaced by ST-282, ST-282-38)ST-130 Drill, Piloted Counterbore Crankcase for Oil Seal Retainer (No Replacement)ST-132 Meter Fuel Flow (No Replacement)ST-151 Reamer Hand Valve Guide ID (Short) (Exhaust) (Replaced by ST-338)ST-157 Driver Dowel Crankcase (Replaced by ST-332)ST-175 Reamer, Crankcase Vent Hole (No Replacement)ST-176 Fixture, Reaming Valve Guide Hole in Cylinder Head (No Replacement)ST-178 Reamer (Piloted) Rework Valve Guide Hole in Cylinder Head (No Replacement)ST-181 Reamer, Valve Guide I.D. Exhaust (Replaced by ST-181-1 and ST-181-2)

44



ST-182 Wrench Cylinder Base Nut 3/8" (End Spline) (No Replacement)ST-183 Wrench Cylinder Base Nut 1/2" (End Spline) (No Replacement)ST-185 Bushing Plate, (4 Cylinder) Crankcase Body Fit Stud (No ReplacementST-186 Bushing Plate, (6 Cylinder) Crankcase Body Fit Stud (No Replacement)ST-187 Drill Jig, (4 Cylinder) Crankcase Bushing Pin (No Replacement)ST-188 Drill Jig, (6 Cylinder) Crankcase Bushing Pin (No Replacement)ST-189 Counterbore, Crankcase Bushing "O" Ring (No Replacement)ST-190 Wrench Injector Nozzle (Replaced by ST-190-2)ST-190-1 Wrench Injector Nozzle (Replaced by ST-190-2)ST-192 Gage, Flat Plug Rejection Exhaust Valve Guide I.D. (See Table of Limits)ST-193 Fixture, Test (Adjustable) Absolute Pressure Controller (Replaced by ST-282,

ST-282-38)ST-194 Fixture, Test Absolute Pressure Controller (Replaced by ST-282, ST-282´•38)ST-200 Rings, Engine Mounting (Replaced by 64759)ST-202 Shroud, Cooling (Replaced by 64612 and ST-352)ST-204 Reamer, Valve Guide ID (Exhaust) (No Replacement)ST-205 Gage, Plug, Valve Guide ID (Exhaust) (No Replacement)ST-206 Reamer, Valve Guide ID (Exhaust) (No Replacement)ST-207 Gage, Flat Plug Rejection (Exhaust) (No Replacement)ST-208 Gage, Flat Plug Rejection (Exhaust) (No Replacement)ST-209 Gage, Plug, Valve Guide ID (Exhaust) (No Replacement)ST-214 Wrench Cylinder Base Nut (No Replacement)ST-218 Bearingizer Internal Thru 2.4210/2.4205 Dia. (No Replacement)ST-219 Bearingizer Internal Thru 2.2875/2.2870 Dia. (No Replacement)ST-238 Skid, Engine A-Frame Overhaul (Replaced by ST-278)ST-258 Reamer, Valve Guide O.D. (No Replacement)ST-282 Test Stand (See Latest Revision of S.L. 184)ST-282-37 Kit Vacuum System (See Latest Revision of S.L. 184)ST-282-38 Test Stand (See Latest Revision of S.L. 184)ST-290 Driver, Bearing Dowel (Replaced by ST-291)ST-308 Reamer, Hand Short Valve Guide (Replaced by ST-338)ST-311 Driver, Intake Pipe Pin (No Replacement)ST-328-1 Reamer, Crankcase Thru-Stud Dowel (No Replacement)ST-330 Gage, Plug and Depth, Crankcase Thru-Stud Dowel (No Replacement)ST-331 Gage, Plug and Depth, Crankcase Thru-Stud Dowel (No Replacement)ST-335 Counterbore No ReplacementST-336 Counterbore No ReplacementST-337 Fixture No ReplacementST-387 Wrench, Cyl. Base Nut (Replaced by ST-374)ST-373 Fixture No ReplacementST-391 Bushing Pilot, (Reamer) Oil Cooler Bypass Valve Housing (No Replacement)ST-392 Driver, Seat Thermostatic Control Valve (No Replacement)ST-393 Bushing Pilot, (Reamer) Oil Cooler Bypass Valve Housing (No Replacement)ST-394 Wrench, Cyl. Base Nut (Replaced by ST-375)ST-395 Tester, Magneto Pressurization (No Replacement)ST-414 Extractor, Hydraulic Lifter Plunger (Replaced by 91‘-4743ST-430 Reamer, Valve Guide O.D. (No Replacement)81‘-432 Reamer, Valve Guide O.D. (No Replacement)

RECIPROCATING ENGINE

TROUBLE

Sn00TIlllL;

G~UIDE

~NILLIAIMSPORT 1975PENNA. SSP-475

HECEIVED BY

INDEX

Page No.

1. HARD STARTING 1 5

2. ROUGH IDLE 6 9

3. ENGINE WON’T IDLE UNLESS BOOST PUMP ON 10

4. ENGINE WON’T IDLE UNLESS BOOST PUMP OFF 11

5. POOR IDLE CUT-OFF 12 13

6. HIGH FUEL FLOW 14 15

7. LOW FUEL FLOW 16

8. ENGINE WILL NOT TURN STATIC RPM 17 18

9. ENGINE SURGES 19 20

10. FAILURE OF ENGINE TO DEVELOP RATED POWER 21 25

11. LOSS OF POWER GOING TO ALTITUDE 26 28

12. CANNOT REACH SPECIFIED CRITICAL ALTITUDE 29 33

13. LOW OIL PRESSURE 34 36

14. HIGH OIL CONSUMPTION 37 39

15. HIGH CYLINDER HEAD TEMPERATURE 40 41

16. SPLIT IN M.P. (TWIN ENGINE) 42 43

17. HIGH OIL TEMPERATURE 44

18. HIGH M.P. AT IDLE 45

19. HIGH OIL PRESSURE 46 47

INTRODUCTION

TROUBLE-SHOOTING

i. Trouble-shooting is the step-by-step procedure used to determinethe cause for a given problem and then selecting the best and quickestway to solve that problem. The use of turbochargers and automaticcontrollers has somewhat complicated the trouble-shooting procedures.A good rule to follow when trouble-shooting is to always start by dis-

cussing the problem with the pilot and the facility management peopleto assist you in narrowing the problem to as few possibilities as

possible. In the case of twin engine aircraft, let’s make sure youare working on the correct engine. After a thorough discussion and

verbal analysis of the problem, you are ready to go to work. If youare an experienced mechanic, you may be able to automatically eliminate

some of the probable causes. If you are new on the job, you will have

to go through all of the possibilities available to you. The importantthing to remember is always start with the simple and inexpensive thingsfirst and work toward the more complicated, time consuming, and expensivethings later.

2. After the mechanic has received all possible information from

the pilot and management people, a quick observation of the external

condition of the engine may give him an indication of the problem.Some areas to look are the intake and exhaust pipes for leaks, the

ignition harness, breather, and the engine compartment for excessive

oil stains, gas stains or exhaust stains. More information may be

gained rather quickly by doing a compression check to locate any low

compression cylinders. Do a boroscope inspection to determine the

condition of the combustion chamber. Some information that may be

obtained is: the presence of excessive carbon deposits indicates

high oil consumption; the lack of carbon deposits may indicate

continuous lean engine operation or detonation; scratched or scored

cylinder walls may indicate broken rings. More information may be

compiled by removing the spark plugs and observing their condition.

Note: Keep track of which plugs came out of which cylinders. Another

good trouble-shooting tool is the use of spectrometric oil analysis.To be effective the engine must be in the analysis program from an

extended period of time to develop a useful history of periodicsamples o´•f oil that were analyzed. The program must be carried out

by experienced and reputable people in the oil analysis field.

3. The following list of problems, causes, and solutions was

selected because we believe it represents the more common and re-

curring problems encountered by mechanics when doing trouble-shooting.It should be noted that the list is general in nature, and does applyto both normally aspirated and turbocharged engines. The sequence in

which the lists are arranged is not necessarily the exact step-by-stepprocedure -to use, but should be used as a guide to determine all of the

possible causes and solutions to a problem and then decide on his own

the exact procedure, always keeping in mind to do the simple and in-

expensive things first, then prr,ceed with the more complicated and

expensive things later.

1-

HARD STARTING

Cause Solution Procedure for Solution

i. Technique i. Refer to operator’s i. Solution is self-explanatory.

manual recommended start-

ing procedures.

2. Flooded 2. Clear engine 2. Crank engine with throttle

full open and mixture in idle

cu~toff.

3. Throttle valve 3. Set for approximately 3. Solution is self-explanatory.

open too far. 800 RPM.

4. Insufficient prime 4. Increase same. 4. Note: Make sure primer is

(may be accompanied by not leaking.

backfire).

5. Mag impulse coupl- 5. Remove and check for 5. Remove mag and check that

ing not operating binding, or broken im- spring is not broken and fly-

properly. pulse spring, weights move freely. Check

torque on coupling retaining nut.

If unable to locate problem,

remove coupling and check accord-

ing to S.I. 1096 and SI 1189.

6. Defective spark plugs 6. Inspect and replace 6. Remove plugs, inspect, clean,

or ignition wire, or repair as necessary. and/or replace as necessary.

Visually inspect ignition harness

for breaks and cracks. Test

leads by removing distributor

block from mag and using a Bendix

high tension lead tester No.

11-8888 or 11 8888-1 or equiva-

lent type equipment.

2

HARD STARTING (con’t)

7. Low voltage at 7. Check with voltmeter and 7. Measure voltage between

vibrator input, replace battery, if necessary, vibrator terminal marked "in"

(Be sure battery terminals are and ground terminal while

clean and tight, also check operating starter. Must be at

leads for condition.) least 8 volts on 12 volt sy-

stem, or 13 volts on 24 volt

system.

8. Inoperative or 8. Check and replace 8. If voltage is o.k, listen

defective vibrator. vibrator, if necessary, for interrupted buzzing of vi-

brator during starting. If no

buzzing is heard, either vi-

brator is defective or the

circuit from the "output"

terminal on the vibrator to

the retard contact assembly

is open. Check both switch

and retard circuit. Also

check for good electrical

ground.

9. Retard contact assy. 9. Check all connections at 9. Retard points may not be

in magneto not operating switch and vibrator. Adjust closing due to improper ad-

electrically. Engine may retard points. See appropriate justment or may not have a

kick back during cranking. Bendix Manual for procedures. good electrical connection in

circuit. Check for good con-

tact of switch and retard leads

at magneto and vibrator.

Check condition of wire.

3

10. Vibrator Magneto 10. Check and replace, if 10. Disconnect Starter and all

combination not putting necessary. Spark Plug Leads. Turn engine in

out electrically. right direction until retard points

open on ~1 cylinder firing posi-

tion. Hold ~1 plug lead approxi-

mately 3/16" from ground, energize

vibrator by turning switch to

start. Plug lead should throw a

shower of sparks to ground. If

spark is weak or missing, replace

vibrator. Also check mag for

correct internal timing. Proper

duration of shower of sparks may

be checked by holding switch in

start position, and hand turning

prop until sparks stop. Degrees

of prop rotation may be measured

or estimated to determine if re-

tard points are adjusted properly.

Note: All checks must be made with

starter and plug leads disconnected.

11. Magneto improperly 11. Check mag timing as 11. Disconnect starter. Turn

timed to engine. per engine manufacturer’s engine in proper rotation to ~1

instructions. cyl. firing position. Attach

timing light to primary leads

(marked switch) of mag and ground

lead to engine. Rotate engine

until advance points break,

-4-

indicated by timing lights going

out or coming on, depending dn

type of light used. Observe that

when points break, timing marks on

engine are aligned. Engine timing

marks are located on engine as

follows:

Direct Drive Line on starter

ring gear to dot on starter hsg.

TIGO Degree markings on crank-

shaft to split of case observed

at top front of Engine.

Geared Supercharged Pointer

mounted to accy. hsg. to lined

bevel tooth on camshaft gear

observed on right side of engine

in accy. housing

12. Magneto internal 12. Adjust magneto Remove mag from engine and turn

timing not adjusted internal timing, or mag to ~1 firing position, attach

properly or ’’E" gap replace points if timing light, turn mag in proper

drifting because of either follower or rotation. Observe that when lights

point or follower wear. points are worn. go out, built-in pointers in the

magneto are aligned in the

observation window provided. (See

Bendix Maintenance Instruction

Manual for your particular mag.)

13. Impulse coupling 13. Repair or replace 13. Remove magneto from engine,

on mag, inoperative. impulse coupling, turn in proper direction by hand

and observe that flyweights in

impulse coupling contact stop pins.

If this condition does not exist,

flyweight axles are worn excess-

ively and impulse coupling must

be replaced. If flyweights are

in good condition, rotate mag

several times to snap impulse

and determine that impulse spring

is not broken. Check torque on

impulse coupling nut to be sure

it is not binding due to an over

torque condition.

For complete information on mag-

neto impulse couplings, get a

copy of the booklet, "I ~M YOUR

IMPULSE COUPLING", fL-1019 from

Bendix at Sidney, N.Y.

6RBUGH IDLE


i. Mix to rich or lean i. Adjust idle mixture i. Lean engine if mixture is

(If mixture is lean, too rich. Engine will smooth

poor acceleration may out and pick up RPM as it is

be noticed). leaned. If mixture is too

lean, condition will become

more aggravated as engine is

leaned. Adjust for proper

mixture by turning scalloped

wheel at side of injector to

either rich or lean condition,

as indicated by arrow and

letter "R" located on injector

linkage. Note: After mixture

is set, re-adjust idle speed

to desired RPM, if necessary.

2. Plugged nozzles 2. Cle an nozzles, inspect 2. Wash in acetone or MEK,

(Usually accompanied by with magnifying glass before blow out with compressed air.

indicated high fuel flow). cleaning if contamination is Note: Flow-check nozzles in con-

found, remo~e same. No need tainers of equal size to lo-

to check further. Note: May cate plugged or partially

locate problem by feeling for plugged nozzles. (S.I. 1275)

cold cylinder.

3. Induction air leak 3. Check previously mentioned 3. Solution is self-explan-

at one of the following locations and tighten or re- atory.

locations: place as necessary.

a) Hoses and hose clamps.b) Cracked int, pipes.c) Bad gaskets.d) Loose flange bolts

e) Loose plugs in int. portof cylinders.

f) Fuel drain valve not

seating properly.

4. Cracked engine moun~s 4. Replace same 4. Solution is self-explanatory,

or defective mount bush-

ings.

5. Mount bushings im- 5. Install as per manu- 5. Solution is self-explanatory.

properly installed. facturer’s instructions.

6. Internal injector leak 6. Replace injector. 6. Check by disconnecting

(Usually unable to adjust induction system at injector

injector at idle) or won’t inlet to observe impact tubes,

hold adjustment, then put throttle in full for-

ward position and mixture in

full rich position, cap fuel

line to flow divider, turn

on boost pump, and if fuel is

observed coming out of impact

tubes, then injector has internal

leak and must be replaced.

7. Fuel vaporizing in lines 7. I(eep ground operation 7. Solution is self-explanatory,

and distributor, (encountered to a minimum and operate

only at high ambient temper- with cowl flaps in full

atures and.prolonged opera- open positions. (If

tion at low or idle RPM). necessary, operate with

booster pump on.)

8. Nozzle screen and 8. Replace nozzle. 8. Remove nozzles from cylinder

shroud deformed to ex- so that they may be adequately

tent it blocks or inspected.

partially blocks air

bleed hole.

9. Sticking valve in 9. Disassemble and clean. 9. Remove divider from engine.

fuel flow divider. Disassemble and flush out dirt.

Also divider valve may be hand

lapped in seat to remove any

burrs that may be present. Note:

Never interchange fuel flow divid-

er parts and do not damage dia-

phragm.

10. Uneven cylinder 10. Differential check 10. Differential compression

compression. cylinders to determine if check is accomplished by rotating

further disassembly and cylinder to be checked to T.D.C.

repairs are necessary. on compression stroke and intro-

ducing 80 psi air´•into cylinder

and observing how much is re-

tained. Step-by-step procedures

and equipment requirements will

be found in S.I. 1191.

11. Improper fuel 11. Adjust as necessary. 11. Minimum and maximum limits

pressure. are found in engine and airframe

manufacturer’s operates’s manual.

12. Faulty ignition 12. Check mag drop and 12. Set engine to produce 50-65%

system. condition of plugs and power with prop at min. angle.

leads. Check both mags for excessive

dropoff. Note: Smooth dropoff

that exceeds limits may indicate

a lean or ridh injector or car-

buretor. Leads must be checked

by removing distributor block

from mag and using a Bendix high

-9-

tension lead tester, ~11-8888 or

11-8888-1 or equivalent, type

equipment to determine lead con-

dition. A visual check is also

helpful. Note: The difference

in drop between mags is just as

important as the total mag drop

(not more than 50 RPM difference

between mags).

Fuel Pressure 13. Adjust to at least 13. Note: If unable to adjust

too low. minimum pressure as found pressure, replace pump.

in Operator’s Manual.

10

ENGINE WON’T IDLE UNLESS BOOST PUMP ON


i. Idle mixture ex- i. Richen idle mixture i. Turn scalloped wheel at side

tremely lean. at injector, of injector toward rich condition.

Note: Arrow on linkage indicates

rich and lean. Idle speed will

no doubt have to be adjusted.

2. Engine fuel pump 2. Replace fuel pump, or 2. Solution is self-explanatory.

failed, or pressure adjust pressure as necess-

too low at idle speed, ary.

"x3. Fuel pump by-passing 3. Replace fuel pump. 3. Solution is self-explanatory.

fuel internally. (Note:

AN type pump).

11

ENGINE WON’T IDLE UNLESS BOOST PUMP XS OFF


i. Idle mixture i. Lean idle mixture i. Turn scalloped wheel at side

extremely rich. at injector. of injector toward lean condi-

tion. Note: Arrow on linkage

indicates rich and lean. Idle

speed will no doubt have to be

adjusted. Condition indicated

by excessive black smoke.

2. Engine pump fuel 2. Adjust fuel pressure 2. Solution is self-

pressure set too high. at pump if AN type. Re- explanatory,

place fuel pump if dia-

phragm type.

-12-

POOR IDLE CUT-OFF


i. Improper rigging of i. Adjust same, i. Solution is self-explanatory.

mixture control linkage.

2. Mixture control 2. Disassemble and re- 2. Remove mixture control

valve scored or not move scratches and burrs. assembly from injector lap idle

seating properly, or Replace "0" ring, if cut-off jet and valve assembly

"O" ring on mixture jet necessary, on a good lap plate using a

broken or deformed, mild abrasive until all scores

and burrs are removed. Clean

thoroughly and re-assemble.

Also observe the condition of the

"O" ring on mixture control jet.

Note: Check for leak by dis-

connecting fuel line at entrance

to flow divider. Keep throttle

and mix off and boost pump on.

There should be no fuel flow.

3. Vapor in lines. 3. Avoid prolonged ground 3. Solution is self-explanatory.

operation at low RPM and

idle. Keep nacelle as

cool as possible. Note:

Use boost pump, if necessary.

4. Dirt in air bleed 4. Remove and clean. 4. Wash in acetone or MEK and

hole of nozzle. blow out with compressed air.

5. Fuel jets in nozzle 5. Replace nozzles. 5. Nozzles may be tested by

Lmproperly located. fabricating test rig as explained

in S.I. 1275. Note: No visual

check of jets is possible.

13

6. Valve in flow divider 6. Remove and clean. 6. Remove flow divider from

sticking. engine and disassemble. Flush

out any dirt that may be present.

Flow divider valve may be hand

lapped in seat to remove any burrs.

Clean thoroughly and reassemble.

Note: Never interchange flow

divider parts.

7. Loose fuel line at 7. Tighten all fuel 7. Check main fuel line at flow

flow divider or nozzle. connections. divider and fuel injector. Also

Note: Engine may be rich all fuel lines at divider and

at idle. nozzles. Make sure nozzles are

tight in cylinders and not cross-

threaded.

3. Mixture valve stuck, 8. Disassemble carburetor 8. Solution is self-explanatory,

(corroded) to valve seat. to enable cleaning land

(carbureted engines) lapping, if necessary) the

mixture valve and seat.

-14-

HIGH mTEL FLOW


i. Plugged nozzles. i. Clean or replace same. i. Plow-check nozzles in con-

Ins pect with magnifying tainers of equal size to locate

lens first. plugged nozzles. If plugged,

wash in acetone and blow out

with compressed air.

2. Air leak or restric- 2. Locate and repair. 2. Pressure check to 9 Ibs.

tion in deck pressure and observe gage for drop in

gage line (airframe). pressure.

3. Injector rich. 3. Replace same. Check 3. Run engine at a given power

mags for excessive smooth setting full rich. Observe

drop in RPM. Recalibrate fuel flow and compare to fuel

and/or overhaul injector at flow requirements for that

an approved facility, power setting as found in

operator’s manual.

4. Faulty gage. 4. Replace same. 4. Prove by installing master

gage and running engine to

compare gages.

5. I.D. of fuel lines 5. Replace lines. 5. Lines must be between .085

too small. -.090 I.D. Check with gage and

be sure not to mark inside of

fuel lines. Make sure all

nozzles are the same I.D. in

all cylinders (except 10-540

in Aero Cormnander).

15

6. Incorrect nozzle 6. Replace nozzles. 6. Flow-check nozzles in

flow.containers of equal size to

locate problem nozzles. Flow

rate of nozzles may be deter-

mined by following procedures

set forthin S.I. 1275.

"7. Cracked or broken .k7. Replace defective line. *7. While pressurizing system

fuel injector nozzle with boost pump, give it a

line. Note: Separation good visual inspection for

may be at silver solder signs of fuel dye.

connection.

Jr8. Deck pressure gage 6;8. Remove any obstructions. Jc8. Disconnect line from gage

line plugged (turbo- and engine. Use compressed

charged), air to blow through lines to

remove any dirt that may be

present.

-16-Low FUEL now


i. Dirty fuel filter i. Clean same, i. Remove and clean in acetone

screen.or MEK. Blow out with com-

pressed air.

2. Injector lean. 2. Replace same or recali- 2. Run engine at a given

brate or overhaul at approved power setting full rich. Ob-

facility. serve fuel flaw and compare

to fuel flow requirements for

that power setting as found in

Operator’s Manual. An in-

crease in cyl. head temp, EGT

or oil temp, may be an indica-

tion of a lean injector.

3. Faulty gage 3. Replace same. 3. Prove by installing master

gage and running engine to

compare gages.

4. Flow divider does 4. Disassemble, check for 4. NOTE: NEVER INTERCHANGE

not open all the way dirt, and drag on dia- FLOW DIVIDER PARTS. THEY ARE

(problem may not occur phragm stem. Also parts FLOWED AS AN ASSEMBLY.

at all times). may be lapped together to

insure free operation.

~5. Fuel line to fuel 5. Repair or replace line. 5. To detect broken or loose

flow gage broken, loose line check for fuel dye stains.

or plugged. To check plugged line, dis-

connect at gage and injector

and blow out with compressed

air.

*6. Low fuel pressure. 6. Increase fuel pump pressure 6. Solution is self-explana-

to limits in Operator’s Manual tory.

and also check for leaks.

17

ENGINE WILL NOT TURN STATIC RPM

Cause solution Procedure for Solution

i. Restriction in in- i. Inspect and remove i. Solution is self-explanatory.

duction air system, in- restriction.

correct airbox, or air-

box improperly installed.

2. Injector rich or lean. 2. Replace same or recali- 2. Run engine at a known power

brate or overhaul at approved setting, full rich. Observe

facility. fuel flaw and compare to fuel

requirements as found in Opera-

tor’s Manual. Lean injector,

if too rich engine will pick

up RPM and run smooth. If

injector is too lean, engine

will become more aggravated.

3. Prop out of adjust- 3. Adjust same. 3. Solution is self-explana-

ment (low pitch). tory.

4. Governor linkage 4. Adjust for full travel. 4. Solution is self-explana-

not adjusted properly, tory.

5. Crankshaft to cam- 5. Remove accessory housing 5. This condition may be

shaft timing off. and time correctly, checked by first disconnecting

starter. Remove top spark plugs

and rocker box cover on ~2 cyl-

inder. Turn engine to T.D.C. on

compression stroke on ~1 cyl-

inder, observe that when piston

in ~1 cylinder goes over T.D.C.

on compression, the intake valve

in ~2 cylinder is just starting

to open and the

18

exhaust is just closing. If this

condition does not exist, the

crank to cam timing is off.

~6. Exhaust muffler 6. Remove muffler for 6. Note: If baffles are broken

internal baffles broken thorough inspection and and are free to move around in

and blocking exhaust replace same, if necessary. muffler, engine may turn static

outlet. and develop power sometimes and

other times it may not due to the

restricted flow of exhaust gases.

Strike muffler with rubber mallet

or soft object and listen for

rattle in muffler.

,’(7. Excessively dirty 7. Replace at regular 7. Note: Sometimes new filters

air filter. intervals. Time between may have an excessive air drop

filter changes will de- through them. If this condition

pend on operating con- is suspected, remove filter and

ditions of individual run engine to F.T. without filter

aircraft. installed to observe whether the

engine performs better. (This

test should be performed in a

dust-free area and on a hard

surface).

-19-

ENGINE SUR~ES


i. Injector nozzles dirty. i, Remove and clean. i. Clean by flushing in

acetone or MEK and blow out

with compressed air.

2. Faulty governor. 2. Replace governor. 2, Solution is self-

explanatory.

3. Air in oil lines or 3. Bleed system. 3. Engine will usually bleed

wastegate actuator, air out of actuator and

turbocharged control system by running.

If this does not work, loosen

lines and bleed system.

4. Breather plugged. 4. Remove any obstruct- 4. Solution is self-

ions from breather, explanatory,

5. Injector nozzle 5. Repair leak 5. Check all hose connections,

pressure reference "0" rings, tubing, and hoses

system leaking (turbo- for breaks or loose connections.

charged).

Jr 6. Incorrect prop 6. Replace Gov. 6. NOTE: Check Part No. of

governor Gov. to be sure someone did not

put wrong Gov. on engine.

-20-

J( 7. Defective oil pump. 7. Repair or replace oil 7. Erratic oil pressure may

pump. be traced to the fact that

pump may be sucking air. On

TIO and TIGO-541 engines

inspect "O" rings on inlet

and outlet of pump, also high

press oil relief at pump may

be defective. NOTE: To remove

oil pump from 541 engines, the

sump must be dropped.

Jr 8. Prop blades sticking 8. Remove and overhaul 8. Check for prop blade

in hub intermittently. prop. movement and sticking. Check

stops and angle on blades

when against flat pitch stops.

21-FAILURE OF ENGINE TO DEVELOP RATED POWER


i. Leaks in induction i. Tighten all plugs and i. Solution is self-explanatory,

system and exhaust system. clamps and replace any Note: This condition is more

(Turbocharged engines) defective parts, noticeable at alt.

2. Improper fuel flow. 2. Check screen and gage, 2. Remove screens and flush out

and replace injector, if dirt. Disconnect gage and in-

necessary stall master to determine accuracy

of aircraft instrument.

3. Restriction in air in- 3. Check and clean or 3. Note: Always make sure air

let or manifold. repair as necessary. filters are kept clean and there

are no breaks in ducting to allow

foreign material or heated air

from nacelle to enter induction

system.

4. Improper fuel. 4. Drain tanks and refill 4. Note: Never use a lower than

with recommended octane recommended grade of fuel. Consult

fuel. S.I. 1070.

5. Controllers out of 5. Adjust same. 5. Variable absolute controller

adjustment, is adjusted by turning adjustment

(Turbocharged) screw at cam end of controller

counter-clockwise to increase

boost, and clockwise to decrease

boost. Controllers are set to

obtain a specific MP and no

compensation for density and temp

is necessary. Required MP settings

will be found in Operator’s Manual.

Adjust for full throttle setting

only.

22

Density controllers do compensate

for temperature and pressure and

require special equipment to

adjust. S.I. 1187 sets forth

procedures and required equip-

ment for adjusting density con-

trollers in the field.

Differential pressure controllers

are set to maintain 6" differen-

tial between deck and MP, special

equipment is required for adjust-

ing. Note: This is not normally

adjustable in the field.

6. Damaged turbo im- 6. Visually inspect for 6. Note: If turbo wheel is

peller, binding or damage and check for free damaged or tips of blades are

tight turbo wheels, rotation of turbo. Dis- missing, turbo must be replaced

(Turbocharged) assemble and clean, if because this condition will

necessary, cause turbo to become unbalanced

and severely wear the bearings

causing complete turbo failure.

7. Throttle lever not 7. Check and adjust, as 7. Solution is self-explanatory.

properly adjusted. necessary.

8. Excessive dirt build- 8. Inspect and clean. 8. Solution is self-explanatory.

up in compressor housing Note: Excessive dirt buildup on

or on compressor wheel, compressor wheel may create an

(Turbocharged) out-of-balance condition and

accelerate bearing wear.

-23-

9. Kinked or restricted 9. Remove and inspect 9. Solution is self-explanatory.

oil lines from engine to or replace, as necessary.

actuator, and actuator

~o controller.

10. Wastegate out of 10. Adjust same to correct 10. ~The wastegate is adjusted

adjustment. open and closed limits. to full closed position first,

(Turbocharged) then full open. To adjust full

closed, cap off outlet of actuator

and apply 50 to 60 Ibs. oil

pressure to inlet. When oil

pressure closes wastegate,

measure clearance between butter-

fly and housing. If adjustment

is improper, disconnect linkage

and lengthen or shorten as re-

quired. After full closed adjust-

ment is correct, set full open

by disconnecting oil supply and

allowing spring in actuator to

open wastegate. Again, measure

clearance between butterfly and

housing. If adjustment is impro-

per, loosen jam nut at end of cyl-

inder and turn adj. rod in or out

as required to obtain proper full

open setting, then retighten jam

nut.

11. Inlet orifice in 11. Remove inlet line at 11. Note: If orifice is plugged

~ctuator plugged, actuator a~d clean orifice. tight, it may be necessary to re-

(Turbocharged) move cylinder from actuator to

enable thoroughly cleaning orifice.

-24-

12. Wastegate stuck 12. Remove actuator and 12. Wastegate butterfly may be

open. loosen wastegate butterfly. freed by removing from engine,

(Turbocharged) and using a wrench on the butter-

fly shaft. Rotate back and forth

until all corrosion is removed

and butterfly moves freely. This

operation may be aided by using a

corrosion penetrant to help

loosen butterfly. One penetrant

used by some people in the field

is mouse milk, manufactured by

Worldwide Aircraft Filter Corp.,

1685 Abram Ct., San Leandro, CA

94577. This penetrant could be

used at each 25-hour inspection

as a preventative measure. A

little at each end of the shaft

may help keep shaft from binding.

13. Piston seal in 13. Disassemble, clean 13. Note: Any time wastegate

wastegate actuator cylinder, and replace seal, actuator is disassembled or parts

leaking. Noted by or replace wastegate actua- are replaced, the full open and

excess oil coming tor assy. full closed positions of the

out of drain, butterfly should be checked and

(Turbocharged) reset, if necessary. (Reset

according to item marked Jr of this

section)

14. Oil pressure too 14. Adjust oil pressure 14. Check to make sure that the

ow to close wastegate. to at least minimum low proper oil pressure relief spring

(Turbocharged) limit in manual. is in engine and that it is not

broken, or that relief valve ball

25does not have any dirt under it

causing the low oil pressure.

15. Injector and con- 15. Adjust as per S.I. 15. Procedures set forth in

troller linkage not ad- 1211 to get full travel S.I. 1211 include the use of

justed properly. on both controller and two special tools, ST 318 and

(541 series engine) injector. ST 319, to position the cross

shaft and establish the clearance

settings at full throttle and

idle when making linkage adjust-

ments. Thesestep-by-step proce-

dures should be followed to

insure accurate linkage adjust-

ment.

s16. Broken Baffles 16. Remove from engine 16. PJote: If section of baffle

in muffler. and replace muffler sy- is loose in muffler, engine may

(Normally aspirated stem. operate satisfactory at times and

engines)may be low on power at other times

This indicates baffle is moving

around in muffler, blocking ex.

gases sometimes and out of the

way at other times allowing an

unrestricted flow of exhaust.

J´•17. Poor combustion 17. Do a diff. comp. check 17. Do a top overhaul to correct

and borescope inspection to this problem.

locate excessively leaking

valves, valve guides or rings

and to locate any broken rings.

Butterfly in waste- 18. Replace wastegate. 18. Solution is self-explanatory.

gate warped.

26

LOSS OF POWER GOING TO ALTITUDE

Ca~ Solution Procedure for Solution

i. Leak in turbo system i. Check all clamps and i. Observe that all clamps

bolts on induction and are tight on turbo induction

exhaust system, and exhaust system. Inspect

Note: Make sure alternate all gaskets and "0" rings on

air door closes completely, intake pipes to be sure they

and suck-open door is pro- are in place and properly

perly adjusted and gasket seated. Check for cracks on

is not damaged. both intake and exhaust system.

Green stain on induction system

indicates induction leak,

White stains on exhaust system

indicates an exhaust leak.

Make sure that all nuts on

exhaust stacks are tight and

that no exhaust gaskets are

burned out.

2. Density controller 2. Replace controller. 2. To check density controller,

does not follow curve disconnect differential con-

to altitude,~roller from system and block

oil lines. Fly aircraft to

altitude and observe that

you get a steady rise in

manifold pressure not to

exceed airframe manufacturer’s

limits, If no rise is in-

dicated, density controller must

27

be replaced. Note: Exercise

extreme caution as there will

be severely staggered throttles

at part throttle conditions.

3. Oil line to actuator 3. Remove line. Clean or 3. Solution is self-

inlet kinked or blocked. replace and elimidate explanatory.

kinked condition.

4. Actuator piston seal 4. Disassemble, clean 4. Note: Any time wastegate

failed and leaking cylinder, and replace actuator is disassembled you

excessively. seal must check the full closed

and full open positions of

the wastegate. If adjust-

ment is necessary, always

adjust full closed first then

full open. (Never plug the

wastegate actuator drain as

it may cause a hydraulic lock).

5. Differential con- 5. Replace differential 5. Apply 80 psi oil to inlet

troller poppet valve controller. port of differential con-

leaking. troller, only minute drainage

should be observed at drain

port. If excessive, oil is

28

observed at drain port,

this indicates controller

valve is leaking oil at all

times and must be replaced.

J´•6. Poor combustion. 6. Do a diff. comp. check 6. Do a top overhaul to

and borescope inspection to correct this problem.

locate excessively leaking

valves, valve guides or

rings and to locate any

broken rings.

~7. Binding turbo. 7. Overhaul or replace 7. Solution is self-

turbo. explanatory.

Jr8. Lean injector. 8. Replace injector or re- 8. Solution is self-

calibrate or overhaul at explanatory.

approved facility.

-29-CWNNOT REACH SPECIFIED CRITICAL ALTITUDE


i. Dirty induction air i. Beplacesame i. Note: Also check for any

filter.type of blockage in induction

system.

2. Damaged compressor 2. Replace or overhaul 2. Visually inspect to see if

or turbine wheel.turbo. Note: Determine the turbine or compressor

(Turbocharged)reason for damage and wheels are damaged or tips of

eliminate. blades are missing. If this

has happened, turbo replacement

is necessary because this dam-

age causes a severe out-c~-

balance condition which will

rapidly wear out the turbo

bearings.

3. Wastegate does not 3. ildjust for full travel. 3. When setting closed and

go to full closed posi- If butterfly is sticking, open positions, always set full

tion (turbocharged). work free and apply corro- closed position first, then

sion penetrant. If actuator full open. The procedure for

seal is leaking, disassemble, checking full closed position

clean cylinder and replace is to cap off actuator dis-

seal, charge, apply 60-65 Ibs. oil

pressure to inlet. When waste-

gate closes, measure clearance

between butterfly and hsg. If

adjustment is necessary, dis-

connect linkage and lengthen or

shorten as required. To check

full open, release oil pressure

and allow wastegate to open full

and measure clearance between

-30-CANNOT REACH SPECIFIED CRITICAL ALTITUDE

butterfly and housing. If ad-

justment is necessary, loosen

jam nut at top of cylinder and

turn adjustment in or out as

required. Re-tighten jam nut.

If butterfly is sticking, looser

by manually moving back and

forth until free, then lubri-

cate with a corrosion pene-

trant mouse milk, manufactured

and sold bl Worldwide Aircraft

Filter Corporation, 1685 Abram

Ct., San Leandro, CA. May

also be used as a preventative

by applying to butterfly shaft

at 25 hr, inspections. If

actuator cylinder is leaking,

disassemble, clean cylinder and

replace seal. If any parts are

replaced, check open and closed

limits as described above.

4. Bad bearings in turbo. 4. Replace or overhaul turbo. 4. Check radial and axial bear-

Note: Spin turbine by hand to ing limits, as per AiResearch

check for free rotation. Turbo Manual.

5. Suck-open door on 5. Adjust magnet so door 5. Observe that no physical

compression discharge closes properly. Replace damage has occurred to door and

housing not fully closed gasket. no foreign material is lodged

or door gasket damaged between door and gaskets.

(TIO-540 engines).

-31-6. Faulty controller. 6. Repair or replace. 6. Absolute Va~iable. If engine loses

power, consider leaking poppet valve or

oil leaking into induction system be-

cause of broken boot bellows. Remove

controller and check for oil in in-

duction housing. In either case, con-

troller will have to be replaced.

Density Controller. Check as per solu-

tion ~2 under "Loss of Power Going to

Altitude’’.

Differential Controller. Apply 80 psi

oil to inlet port. Observe that only

minute draining occurs at drain port.

7. Improperly adjusted 7. Adjust same, 7. Absolute Variable. The variable

controllers, absolute pressure controller is only

sensitive to pressure settings so no

special equipment is necessary for ad-

justment. To increase manifold pressure

turn adjusting screw at cam end of con-

troller counter-clockwise, To decrease

MP, turn adjusting screw clockwise.

~These adjustments to be made for full

throttle power settings only. MP

settings will be foundin Operator’s

Manual.

Density Controller is sensitive to

temperature and pressure and does

require special equipment to set.

Procedures for setting density con-

trollers are set forth in S.I. 1187.

32 3

Differential Controller If

differential controller is leaking

critical altitude would not be

reached. Check by applying 80 psi

oil to inlet port and observing

that only minute oil is seen at

drain port. If excess oil is

seen at drain port, controller is

leaking at all times and must be

replaced.

8. Insufficient oil 8. Adjust oil pressure 8. Check to be sure the proper

pressure to close to specifications found spring is in the oil pressure

was tegate. in Operator’s Manual. relief valve and is not broken or

Check for kinks or re- that no foreign material is under

strictions in actuator the relief ball. Eliminate re-

supply line, strictions in actuator supply

line and route line to eliminate

any kinks.

9. Damagetocom- 9. Replace turbocharger. g. Irisually inspect turbo wheels

presser or turbine wheel. for damage such as bent or broken

blades, rub marks on compressor

or turbo housing. If parts of

blades are missing, check for

excessive bearing wear caused by

severe out of balance condition

when turbo turns at high speed.

-33-

10. Leaks in exhaust 10. Repair or replace as 10. Tighten all clamps and

system. required. bolts on turbo system. Check

gaskets for good condition

and proper seating. Also

inspect for any cracks (may

be located by the presence

of white stains on exhaust

system). Make sure all nuts

on exhaust stack flanges are

tight and no gaskets are

burned out.

*11. Poor combustion. 11. Do a diff. comp. 11. Do a top overhaul to

check and borescope correct this problem.

inspection to locate

excessively leaking

valves, valve guides

or rings and to locate

any broken rings.

-34-

~ROBLEM LOW OIL PRESSURE


i. Insufficient oil. i. Fill oil sump or tank i. Note: Make sure you are using

to proper level. the correct grade and weight of

oil.

2. Pressure relief out 2. Adjust oil pressure 2. On external adjustable type

of adjustment. to proper limits. increase oil pressure by turning

adjusting screw clockwise, and

to decrease turn counter-clockwise

On types with solid tower standard

flat washers are used to con-

trol oil pressure. Add washers

to increase oil pressure and re-

move washers to decrease oil

pressure. On short tower, a maxi-

mum of three washers may be used

on a tall tower, a maximum of

nine washers may be used.

3. Dirt or metal chips 3. Remove, disassemble, Solution is self-explanatory.

under oil pressure re- and clean.

lief valve.

4. Damaged oil pressure 4. Replace or repair. 4. On engines with the removable

relief seat, seat, seat may be pulled out and

another pressed into place. On

engines that have seat machined

in the case, repairs must be made

by repairing existing seat with

special Tools ST-2.43, ST-248 anti

S-340 that make up the reseating

tool assy. (Ref. S.I. 1172)

35

5. High oil temperature. 5. Check all areas that 5. Inspect the following areas

involve lube system and for trouble: (a) Proper oil level

lube oil cooling system. (b) Proper grade and weight of oil

(c) Thermostatic by-pass valve

working properly and seating

squarely. (d) Plugged or partially

plugged oil cooler lines or oil

cooler. (e) Excessive blowby.

(f) Air duct to cooler blocked

or cooler partially covered. (g)

Defective temperature gage.

6. Restriction at inlet 6. Remove and clean oil 6. Solution is self-explanatory,

side of oil pump. suction screen and oil

passage to inlet side of

oil pump, if necessary.

7. Excessive internal 7. Check the following 7. Solution is self-explanatory.

spill-off of oil. areas for excessive oil

flow and repair or re-

place.

(a) Loose or missing plugs

in oil galley.

(b) Piston cooling squirts

blocked open. Note: Low oil

pressure usually occurs at

low or idle RPM.

(c) Excessive bearing clearance.

(d) Cracked crankcase in area

of oil galley.

3i8. Relocating the oil 8. Use only the o.p. takeoff 8. Solution is self-explanatory.

pressure takeoff point on point approved by the engine

the engine, manufacturer.

~9. Oil pressure relief 9. Remove and replace seat. 9. Solution is self-explanatory.

seat in crankcase cocked,

(could be cage type or

flat type).

37

PROBLEM HIGH OIL CONSUMPTION


i. Improper grade of oil, i. Consult Operator’s i. Note: Consult S.I. 1014 for

Manual for type and weight information on approved lubricating

of oil, oils for Lycoming engines.

2. Failure of new rings 2. Use correct grade of 2. On new and remanufactured en-

to seat properly. oil and proper operating gines, use mineral oil until con-

procedures. sumption stabilizes (usually from

50 to 100 hrs.) then if desired,

change to A.D. oil. On the 541

series of engines, A.D. oil must

be used from the beginning.

Note: Consult S.I. 1014 for re-

commended lubricating oils. For

best ring seating, always use

full throttle for takeoff wher-

ever the application applies (the

only exception is the geared

supercharged engines where takeoff

power is limited by a specific

manifold pressure). Also use a

high cruise power setting for

break-in "75%"

3. Failed or failing 3. Replace same. 3. Disassemble engine for in-

bearings, spection and replacement of bear-

ings. Prior to disassembly, ex-

cessive bearing wear may be deter-

mined by the presence of metal in

oil suction screen or oil filter.

-38-

4. Worn piston rings and/or 4. Remove cylinders and de- 4. Prior to disassembly, the

cyl. barrels. glaze barrels, replace with condition of the rings may be

new piston rings, determined by doing a differen-

tial compression check. This

is accomplished by rotating the

cylinder to be checked to T.D.C.

on compression stroke. After

insuring that the prop will

not turn, introduce 80 psi air

in cylinder and observe how

much is retained. Air leaking

by rings can be detected by

listening at breather entrance

for a hissing sound in crank-

case indicating air escaping

around rings. For equipment

required and procedures, con-

sult S.I. 1191.

5. Worn valve guides. 5. Replacesame. 5. Remove cylinders from en-

gine and take out valves.

Measure guides and if worn

beyond tolerances allowed in

the table of limits, the guides

will have to be replaced. Use

procedures set forth in~appli-

cable overhaul manual.

6. Excessive oil leaks. 6. Inspect external of en- 6. Solution is self-explanatory.

gine for leaks and repair

same.

39

,t7. Oil being siphoned 7. Insure that oil filler 7. Solution is self-explanatorg

from engine in flight. cap is on tight and oil

access door closes pro-

perly. Also be sure that

the breather hose is cut

properly and located so

there is no chance of

siphoning oil from engine.

48. Expander in oil 8. When using oil control 8. Solution is self-explanatory

control ring improperly ring with corrugated type

installed or lost its expander, make sure ends of

tension. expander are butted together

not overlapDed When using

oil control ring with spiral

wound type expander, ring

design is such that improper

assy. is not likely.

40

Jn´•~ HIGH CYLINDER TEMPERATURE

cause Solution Procedure for Solution

i. Spark plugs of im- i. Use only approved spark i. Note: Consult S.I. 1042 for

proper heat rating in- plugs for your engine. approved spark plugs.

stalled in engine.

2. Cooling baffles miss- 2. Insure that all baffles 2. Note: Never attempt to modi-

ing broken or improperly are installed properly and fy, relocate or eliminate any

installed. not broken. cooling baffles.

3. Partially plugged fuel 3. Clean in M.E.K. or ace- 3. Solution is self-explanatory

nozzles. tone and blow-out with com-

pressed air.

4. Fuel lines of improper 4. Fuel line I.D. should be 4. Note: Primer lines have

I.D. being used. .085-.090. same threaded connections as

fuel lines but are of much

smaller I.D.

Note: The only exception to this

rule is the IO-540-E1B5 used in

the Aero Commander 500S. This

engine uses primer lines for

fuel lines and they are .060

I.D.

5. Engine improperly 5. Check mag to engine 5. Note: Even though mag syn-

timed, timing and insure that en- chronization is correct, if en-

gine is timed to the correct gine is timed at 250 ETC when it

no. of degrees B.T.C. should be 200 ETC, engine will

run hotter.

-4´•1-

6. Engine being oper- 6. Check operator’s manual 6. Note: If this condition is

sted excessively lean. for minimum fuel flows for suspected, check combustion

various power settings and chamber for carbon deposits.

never go below them. If there are none, this is

sufficient reason to be

suspicious of a continuous

lean engine operation.

7. Mix control impro- 7. Rig for complete Note: Even though mix control

perly rigged. travel. lever at pilot seat appears to

have full travel, be sure to

check at carb. or injector to

insure that mix lever is go-

ing against the F.R. (full

rich) and I.C.O. (idle cut-off)

stops.

-42-

INM.P. (Twin Engine)


i. ProDeller blade angle i. Adjust props for correct i. Solution is self-explanatory

not adjusted properly, blade angle when against flat

pitch stops.

2. Controllers out of 2. Adjust to proper limits. 2. Variable abs. press. con-

adjustment. troller is adjusted to a spcci-

(Turbocharged) fic M.P. as found in Operator’s

Manual with no compensation for

temp.

Density controllers are ad-

justed as per S.I. 1187. Where

procedures and equipment re-

quirements are set forth on

density controlled engines,

some split in MP. may have to

be acdepted because of varia-

tions in turbo efficiency.

Note: Both controllers are

adjusted for full throttle

setting condition only.

3. Excessively dirty air 3. Replace with new filer. 3. Note: Problem may be more

filter. noticeable when aircraft is

flown to altitude because of

the decrease in air density.

4. Alternate air door 4. Replace door or adjust 4. Note: Although door may

leaking for complete closing, appear to close completely on

the ground, it may be opening

-43-

slightly in flight due to vibra-

tion or air currents. To deter-

mine if this is happening, tape

alternate air door shut and fly

aircraft to altitude and observe

manifold pressure.

5. Incorrect hydraulic 5. Replace hydraulic 5. Note: On turbocharged en-

lifters or hydraulic lifters. gines M.P.’s will, no doubt, come

lifters bleeding down back together when M.P. gets

too rapidly, above 30" on turbocharged engines.

6. Restriction in air- 6. Inspect and remove 6. Solution is self-explanatory,

frame or engine induction restriction.

system.

7. Leaks in airframe 7. Inspect and repair 7. Solution is self-explanatory.

or engine induction leaks.

system.

-44-

OIL TEMPERATURE

Cause Solution Procedure for.Solution

i. Insufficient oil i. Check oil at regular i. Solution is self-explanatory,

supply. intervals and maintain

proper level.

2. Insufficient cooling 2. Check air inlet and 2. Solution is self-explanatory,

air, outlet to cooler and re-

place or repair parts and

ducting as required.

3. Improper grade of oil. 3. Use only grade and 3. Note: Consult S.I. 1014 for

weight of oil specified proper grades and weight of oils

for engine. used in Lycoming engines.

4. Oil cooler or lines 4. Remove cooler and 4. Solution is self-explanatory,

plugged or partially lines and flush out.

plugged.

5. Thermostatic by-pass 5. Replace thermostatic 5. Note: If valve is not seating

valve not operating pro- by-pass valve. properly, the filter base may

perly or seating squarely. have to be replaced also.

6. Excessive blow-by. 6. (Do a top overhaul) This 6. Note: To locate exactly

condition usually caused by where the blow-by is originating

worn or stuck rings. from, do a differential comp.

check as described in S.I.1191.

7. Defective temp. gage. 7. Replace same. 7. Solution is self-explanatory.

45

**HIGH MANIFOLD PRESSURE AT IDLE


i. Improperly adjusted fuel i. Adjust idle mixture i. Note: Speed may have to be

injector or carburetor. to get a 25 to 50 RPM adjusted also.

rise when moving mix.

control from F.R. to

I.C.O.

2. Incorrect hydraulic 2. Replace with correct 2. Solution is self-explanatory.

lifters installed. part no, lifters.

3. Hydraulic lifters 3. Replace with new hy- 3. Note: Any time hydraulic

bleeding down too rapidly. draulic lifters. lifters are removed from an en-

gine for cleaning and inspection,

be sure to keep the cylinder and

plunger together as an assy. If

they become separated, do not

just arbitrarily assemble any

body and plunger together be-

cause you may change the leak-

down rate. On twin engine in-

stallations, a split in M.P.

will no doubt be noticed during

acceleration.

4. Air leak in in- 4. Check ind. system and 4. Note: Engine will, no doubt,

duction system. repair leak, be rough at idle also.

-46-

OIL PRESSURE


i, Oil pressure i. Adjust to within min. i. On external adj. type oil

improperly adjusted. and max. range as found pressure relief adjustment,

in Operator’s Manual. turn adjustment counter-clock-

wise to decrease oil pressure.

On engines using the pressure

relief that is not externally

adjustable, remove the pressure

relief valve from the engine

and take out washers from

behind spring.

2. Improper weight 2. Use the suggested 2. ~onsult S.I. 1014 for

of oil, weight of oil for the lubricating oil recommendations.

ambient temp. in which

the engine is being

operated.

3. Oil passage from 3. Remove blockage from 3. Remove pressure relief

pressure relief valve oil passage. from engine and run a soft

to sump plugged. copper wire down through oil

passage to sump; if blockage is

found, remove same. Note: If

blockage persists, sump may

have to be removed to clear

passage.

4. Incorrect pressure 4. Replace with correct 4. Solution is self-

relief spring being pressure relief spring. explanatory.

used.

-47-

Relocating the oil 5. Use only the O.P. take- 5. Note: If the oil pressure

pressure takeoff point on off point on engine approved takeoff point on the engine is

the engine. by manufacturer. moved closer to oil pump dis-

charge, a rise in oil pressure

will be noted.

6. Oil temp. too cold. 6. Allow oil temp. to in- 6. Solution is self-explana-

crease before increasing tory.

throttle.

TEST EqUIPMENT

Q80088000~Q

a

baob66b

YCOMING DIVISION

SSP 1169 VVILL~AMSPORT, PA. 17701

34J/

3, 1: 5

0’

42 43~ ~O 080036 a o

39

I" 12

19 is38

3 B B ´•d B B

it’--" Sa

Ile~ttl--

1614

25-18

B

26--11~ -26--21

aa 22

24

27

Engine Test Stand Instrument Panel consists of:

1. Line Fuel Pressure Gage 0 to +30 Psig. 19. Thermocouple Selector Switches Iron Constantan2. Engine Fuel Pressure Gage "Differential" Cylinder Head Temperature

0 to +60 Psig. Venturi Air Temperature3. Oil Supply Pressure Gage 0 to +30 Psig. Compressor Output Air Temperature4. Oil Filter Pressure Gage 0 to +30 Psig. (Deck Temperature)5. Oil Scavenge Pressure Gage "Compound" Ambient Air Temperature

30 to +30 Psiff. Air from and Air to Sonic Cooler Temperature6. Engine Oil Pressure Gage 0 to +100 Psig. Induction Air Temperature7. Governor Oil Pressure Gage 0 to +100 Psig. Fuel Temperature8. Torque Meter 0 to +250 Psig. Circulating Oil Temperature9. Diversion Pressure Gage 0 to +60 Psig. 20. Engine Throttle

10. Waste Gate Pressure Gage 0 to +60 Psig. 21. Mixture Control

11. Electrical Control Panel, includes: 22. Air ThrottlePilot Lights 23. Toggle ValvesMaster Switch 24. Sonic Air Cooling SystemOil Supply Pump Switch 25. Steam Control Pressure GagesOil Scavenge Pump Switch 26. Steam Pressure Shut-Off ValveFuel Valve Switch 27. Fuel ManifoldFuel Pump Switch 28. Main Air Shut-Off ValveWater Valve Switch 29. Manometer +5 to +62" Abs. HGStarter Voltage Selector Switch 30. Manometer +5 to +62" Abs. HG

Starter Vibrator Selector Switch 31. Manometer +5 to +62" Abs. HGTest Stand Elapsed Time Indicator 32. Manometer 0 to +90" H2O

Ignition Switch 33. Manometer 0 to +90" 112012. Safety Glass Window 34. Manometer 0 to +60" HG

13. Oil Weight Scale 0 to +50 Lbs. 35. Manometer +5 to -25" HG

14. Oil Tank 36. Manometer +5 to -25" H2O15. Oil Tank Shut-Off Valve 37. Potentiometer 0 to +600’F.16. Cylinder Head Temperature Gage 0 to +600;F. 38. Dial Temperature Gage 50 to +300~ F.

Iron Constantan 39. Dial Temperature Gage 50 to +300" F.17. Exhaust Temperature Gage 0 to +2000" F. 40. Differential Pressure Gage 0 to +60 Psig.

Chromel Alumel 41. Clock18. Chrono Tachometer 42. Flowmeter 90 to +500 PPH

43. Flowmeter 25 to +130 PPH

44. Flowmeter 3 to +21 PPH

TEST STAND BASIC DRY SUMP SYSTEM

SCAV PUMPAIR AFTER

SEPARATOR COOLER

TEMP. 1OIL WEIGH VALVE CHECK VALVE

OIL

SCALE II AIR

SEPARATOR

FILTER 1 SUPPLYt BY-PASSVALVE

SCALE TANK PRESSURE I I I PRESSURE OIL

COOLER SCAV. PR.10 GAL.

OR VAC.

OIL RESEVOIR

SHUT OFFVALVE

HEATER I I FILTER r IENG~NE1

PUMP

OIL IN TEMP OIL OUT TEMP

TEST STAND BASIC WET SUMP OIL SYSTEM

OILSCALE

SCAV PUMPCIRCULATING TEMP

SCALE TANK I I I Ij OIL IN OIL OUT

to GAL. I I I TEMP TEMP

OIL RESEVOIR

tBY PASS VALVE

SHUT-OFF

fVALVE

HEATER I I I I FILTER ENGINE

PUMP

Fl LTER SUPPLY SCAV.PRESSURE PRESSURE VAC.

SCHEMATIC DIAGRAM OF GASOLINE SUPPLY FOR TEST CELL VAPOR VENT LINE RETURN

SHUT OFF VALVE

PUMP

HAND VALVES-2 AND 3

PRESSURE GbUGE

7~ ENGINEPRESS. REGULATOR

5-MICRON FILTER eB15tELEC.OPERATED VALVE

HAND VALVE ~n IEn I~n I 6IHIGH FLOAtGA

FUEL SUPPLY

HAND VALVES- 4 AND 5I llOW FLOAT~ IA HAND VALVES 6 AND 6A

HAND VALVE

FLOW METERS

HAND VALVES-IAND 6

FUEL MANIFOLD OPERATION

TO RUN ON LINE PRESSURE-CLOSE VALVES l,lA,3,4,5,6 AND 6A-OPEN VALVE 2

TO RUN ON LOWER FLOAT BOWL-CLOSE VALVES 2,3,4,6 AND 6A-OPEN VALVES I,IA AND 5

TO RUN ON BOOSTER PUMP-CLOSE VALVES 2,5,6 AND 6A-OPEN VALVES I, IA,3 AND 4

TO RUN ON HIGH FLOAT BOWL-CLOSE I,IA,2,3 AND 4 OPEN 6, 6A AND 5

FUEL SYSTEMS REQUIRING VAPOR VENT MUST BE RUN ON HIGH FLOAT

ELECTRIC CONTROLLEDSOLENOID VALVE AUTO. HEAT

HAND VALVE STEAM VALVE EXCHANGERTO OIL SUPPLY PUMP

STEAM SUPPLY

AUTO.TEMP REGULATOR

AIR PRESS.REGULATOR

PRESS. GAUGE

I/4"VALVE

AIR SUPPLY

SCHEMATIC DIAGRAM OF SYSTEM FOR HEATING OIL IN TEST CELL

COOLING SHROUD

MOUNTING STAND

AIRAIR THROTTLE VALVE FLOW

~P1BLOWER------\

PIEZORAETER RINGTRANSITION ASSY,

AIR

~ATMOSPHERICPRESS. INLET THERMOCOUPLE

FOUR BLADETEST CLUB

WATER COOLING COIL LAIR MEASURING VENTURIHEATING COIL BELT GUARDFILTERS ~-2 HP MOTOR INSIDE

BEARING PEDESTAL

AIR INDUCTION AND COOLING SYSTEMS

‘I‘

~1114~ 11 i B, r14

2 7

~-12

75

71

68

/I4

t

494~ 111 1 48

27 ,5Q,

33

NOTE-ALL DIMENSIONS APPROXIMATE

6)

Lycoming Tg St Ste

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