X30575A

Publication X305752011 CONTINENTAL MOTORS, INC. AUG 2011

TSIO-520-C,G,H,M,P,R,T,AE,AF,CE

CONTINENTAL AIRCRAFT ENGINE

OVERHAUL

MANUAL

TECHNICAL CONTENT ACCEPTED BY THE FAA

ii TSIO-520 Sandcast Series Engine Overhaul Manual31 August 2011

Supersedure Notice

This manual revision replaces the front cover and list of effective pages for Publication Part No. X30575, datedFebruary 1987. Previous editions are obsolete upon release of this manual.

Effective Changes for this Manual0 ..............February 19871 ............ 31 August 2011

List of Effective Pages

Document Title: TSIO-520 Sandcast Series Engine Overhaul ManualPublication Number: X30575 Initial Publication Date: February 1987Page Change Page Change Page Change Page ChangeCover............................ 1 70-50-01 thru 70-50-06.0 77-20-01 thru 77-20-06 0ii.................................... 1 72-00-01 thru 72-00-16.0 78-00-01 thru 77-00-04 0iii thru xviii..................... 0 72-10-01 thru 72-10-48.0 78-10-01 thru 78-10-02 01-00-01 thru 1-00-06 .... 0 72-20-01 thru 72-20-18.0 78-20-01 thru 78-20-02 01-10-01 thru 1-10-10 .... 0 72-30-01 thru 72-30-22.0 79-00-01 thru 79-00-04 01-20-01 thru 1-20-40 .... 0 72-40-01 thru 72-40-20.0 79-10-01 thru 79-10-02 01-30-01 thru 1-30-06 .... 0 72-50-01 thru 72-50-18.0 79-20-01 thru 79-20-02 04-00-01 thru 4-00-04 .... 0 72-60-01 thru 72-60-20.0 80-00-01 thru 80-00-10 05-00-01 thru 5-00-04 .... 0 72-70-01 thru 72-70-10.0 81-00-01 thru 81-00-02 05-10-01 thru 5-10-02 .... 0 72-80-01 thru 72-80-08.0 81-10-01 thru 81-10-06 05-20-01 thru 5-20-02 .... 0 73-00-01 thru 73-00-04.0 81-20-01 thru 81-20-02 05-30-01 thru 5-30-02 .... 0 73-10-01 thru 73-10-06.070-00-01 thru 70-00-04 0 74-00-01 thru 74-00-10.070-10-01 thru 70-10-02 0 75-00-01 thru 75-00-04.070-20-01 thru 70-20-02 0 76-00-01 thru 76-00-66.070-30-01 thru 70-30-02 0 77-00-01 thru 77-00-04.070-40-01 thru 70-40-02 0 77-10-01 thru 77-10-06.0

Published and printed in the U.S.A. by Continental Motors, Inc.

Available exclusively from the publisher: P.O. Box 90, Mobile, AL 36601

Copyright 2011 Continental Motors, Inc. All rights reserved. This material may not be reprinted, republished, broadcast, or otherwisealtered without the publisher's written permission. This manual is provided without express, statutory, or implied warranties. The publisher willnot be held liable for any damages caused by or alleged to be caused by use, misuse, abuse, or misinterpretation of the contents. Content issubject to change without notice. Other products and companies mentioned herein may be trademarks of the respective owners.

WARN (Please note the following statements from FAA Advisory Circular 20-62C entitled "ELIGIBILITY, QUALITY, AND IDENTIFICATION OF APPROVED REPLACEMENT PARTS"):

3. BACKGROUND. An increasing amount of replacement parts (including standard parts), materials, appliances, and instruments are offered for sale'as being of aircraft quality when actually the quality and origin of these units are unknown. Users of such units are usually not aware of the potential hazards involved with replacement parts that are not eligible for use on certificated aircraft. Frequently such units are deceptively advertised or presented as "unused," "like new," or "remanufactured." This implies that the quality of such units is equal to an original or appropriately repaired or overhauled unit.

The performance rules for replacement of parts and materials used in the maintenance and alteration of U.S. certificated aircraft are specified in Federal Aviation Regulations (FAR) 43.13 and FAR 145.57. The responsibility for the continued airworthiness of the aircraft, which includes the replacement of parts, is the responsibility of the ownerloperator as outlined in FAR 91.163, FAR 121.363, FAR 123.45, FAR 127.131 and FAR 135.143 (a).

4, l DENTI FICATION OF THE APPROVED PARTS. Approved serviceable replacement parts are identified as follows:

a. By an FAA Form 8130-3 (Formerly FAA Form 186), Airworthiness Approval Tag. An Airworthiness - Approval Tag identifies a part or group of parts that have been approved by authorized FAA representatives.

b. By an FAATechnical Standard Order VSO) number and identification mark that indicates the pat? or appliance has been manufactured under the requirements of FAR 37.

c. By an FAA/PMA symbol, together with the manufacturer's name, trademark or symbol, part number, and the make and model of the type certificated product on which the part is eligible for installation, stamped on the part. An FAA Parts Manufacturer Approval (FWPMA) is issued under FAR 21.305. The make and model information may be on a tag attached to the part.

d. By shipping ticket, invoice, or other document which provides evidence that the part was produced by a manufacturer holding an FAA Approved Production Inspection System issued under FAR 21, Subpart F, or by a manufacturer holding an FAA Production Certificate issued under FAR 21, Subpart G.

e. By a certificate of airworthiness for export issued by a foreign government under the provisions of FAR 21, Subpart N.

I. KNOW YOUR SUPPLIER. It has come to our attention that many reproduced parts and components, particularly instruments which have been manufactured by persons other than the original manufacturer, are available for purchase and installation on U.S. certificated aircraft. Often, an original part is used as a sample to produce duplicates. The reproduced parts appear to be as good as the original part; however, there are many unknown factors to be considered that may not be readily apparent to the purchaser, i.e., heat treating, plating, inspections, tests and calibrations. All too often the faulty part is not discovered until a malfunction or an accident occurs.

2- SUMMARY, In accordance with FAR'S, certification of materials, parts, and appliances for return to service, for use on aircraft, is the responsibility of the person or agency who signs the approval. The ownerloperator, as denoted in paragraph 3 of this advisory circular, is responsible for the continued aiworthiness of the aircraft. To assure continued safety in aircraft operation, it is essential that great care be used when inspecting, testing, and determining the acceptability of all parts and materials. Particular caution should be exercised when the identity of materials, parts, and appiiances cannot be established or when their origin is in doubt.

February 1989 iii

OVERHAUL MANUAL FOR

TSIO-520 SANDCAST SERIES AIRCRAFT ENGINE

The overhauler must comply with all instructions contained in this manual in order to assure safe and reliable engine performance. Failure to comply will be deemed misuse, thereby relieving the engine manufacturer of responsibility under its warranty.

This manual contains no warranties, either expressed or implied. The information and procedures contained herein provide the overhauler with technical information and instructions applicable to proper overhaul procedures.

Prior to overhaul, the mechanic must meet requirements of Federal Aviation Regulation 65 and must follow FAR parts 43, 91, and 145, as applicable. This manual must be used in conjunction with the FAA Advisory circular 43.13-1A, Acceptable Methods, Techniques and Practices - Aircraft Inspection and Repair, as well as Teledyne Continental Motors' TSIO-520 Sandcast Series Parts Catalog X30579A.

CHAPTER

1 - Introduction

4 - Airworthiness Limitations

5 - Time Limits/Maintenance Checks

70 - Standard Practices

72 - Engine Reciprocating

73 - Engine Fuel System

74 - Ignition

75 - Air

76 - Engine Controls

77 - Engine Indicating

78 - Exhaust

79 - Oil

80 - Starting

81 - Turbines

iv February 1989 '.

INTRODUCTION

This Teledyne Continental Motors Overhaul Manual is prepared in accordance with the GAMA (General Aviation Manufacturers Association) format. The manual is divided into groups which enable a broad separation of contents (Chapters) within each group. The chapters are broken down into major systems, Engine - Reciprocating, Exhaust, Starting, etc. The System Chapters are arranged numerically. All System Chapters are assigned a number which becomes the first element of a standardized numbering system. The element '72" of the number series 72-00-00 refers to the System Chapter on "Engine Reciprocating." All information pertaining to the engine will be covered in this System Chapter.

The major System Chapters are then broken down into Sub-system Sections. These sections are identified by the second element of the standardized numbering system. The number "10" of the basic number series "72-10-00" is for the "disassembly" of the engine.

The Subsection in the third element of the standardized numbering system "72-10-12." This number is the final breakdown of the Chapter. Number "12" is for "Oil Pump Assembly," that is "disassembled" from the "Engine."

EXAMPLE:

- Chapter - - Section - - Subsection - "Engine Reciprocating" 'Disassembly" "Oil Pump Assembly"

i I I

In producing this publication, considerable effort has been put forth to provide grammatically clear and accurate information. Teledyne Continental Motors solicits the user assistance in providing information for review on changes that the user may suggest.

February 1989 V

TABLE OF CONTENTS PAGE

ii iii iv v vi vii

Current Status of Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning

Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . List of lllustrations . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 1 INTRODUCTION

SCOPE Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Reports and Inquiries . . . . . . . . . . . . . . . . . . . . . 100% Replacement Parts . . . . . . . . . . . . . . . . . . . . . . .

DEFINITIONS & ABBREVIATIONS Abbreviations/Symbols . . . . . . . . . . . . . . . . . . . . . . . Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of Engine Model Code . . . . . . . . . . . . . . . . . . Basic Design Features . . . . . . . . . . . . . . . . . . . . . . . .

TOOLS Special Tools . . . . . . . . . . .

PRODUCTS Product List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 4 AIRWORTHINESS LIMITATIONS

Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 5 TIME UMITS/MAINTENANCE CHECKS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIME UMITS/INSPECTION PROGRAM . . . . . . . . . . . . . . . . SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . Preflight Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . 100 Hour lnspection UNSCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . .

CHAPTER 70 STANDARD PRACTICES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL LOCKWIRE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . CRANKCASETHREADINGPROCEDURE . . . . . . . . . . . . . . . APPLICATION OF ADHESIVES . . . . . . . . . . . . . . . . . . . . INSTALLATION OF GASKETS . . . . . . . . . . . . . . . . . . . . . CYUNDERLEAKAGECHECK . . . . . . . . . . . . . . . . . . . . Leakage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perfoming The Check . . . . . . . . . . . . . . . . . . . . . . . . Dynamic Seal Check . . . . . . . . . . . . . . . . . . . . . . . . .

ii iii iv v vi vii

vi February 1989

SECTION PAGE

CHAPTER 72-00 ENGINE RECIPROCATING

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft

. . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rods Cams haft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . winders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Train

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . lnduction System

. . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System I Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 72-10 DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Extent of Disassembly . . . . . . . . . . . . . . . . . . . . . . . . Parts to be Discarded . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . Preliminary Cleaning Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection System (C.G.H.M.P.R. & AF) . . . . . . . . . . . . . . . Fuel Injection System (TSIO-520-AE) . . . . . . . . . . . . . . . . . Fuel Injection System (TSIO-520-CE) . . . . . . . . . . . . . . . . . Magneto and Accessory Drive . . . . . . . . . . . . . . . . . . . . Induction System (TS10520.C.G.H.M.P.R. & AF) . . . . . . . . . . . . Induction System (TSIO-520-T) . . . . . . . . . . . . . . . . . . . . Induction System (TS10-520-AE) . . . . . . . . . . . . . . . . . . . Induction System (TSIO-520-CE) . . . . . . . . . . . . . . . . . . . Oil Sump (TSIO.520-C.G. M & T) . . . . . . . . . . . . . . . . . . . Oil Sump (TS10-520.H.P.R.AE. AF & CE) . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Assembly

Starter and Starter Drive Adapter (TSIO.520.C.G.H.M.P. R & AF) . . . . . Starter and Starter Drive Adapter (TSIO.520.T. AE & CE) . . . . . . . . . Oil Pump Assembly (TSIO.520-C.G.H.M.P. R & AF) . . . . . . . . . . . Oil Pump Assembly (TSIO-520-T) . . . . . . . . . . . . . . . . . . . Oil Pump Assembly (TS10-520-AE) . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . Oil Pump Assembly (TSIO-520-CE) Cylinder and Piston Assembly (All Except TSIO-520-AE) . . . . . . . . . Cylinder and Piston Assembly (TSIO.520.AE) . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Exhaust System (TSIO.520.T) . . . . . . . . . . . . . . . . . . . . .

February 1989 vii

SECTION PACE CHAPER 72-20 CLEANING. REPAIR AND REPLACEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Shafts Pushrods. Valve Rockers and Other Small Steel Parts . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . Camshaft and Crankshaft. Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gears . . . . . . . . . . . . . . . . . Sheet Metal Parts and Intake Manifdd

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Castings . . . . . . . . . . . . . . . . . . . . . . . . . . Stud Replacement

. . . . . . . . . . . . . . . . . . . . . Helical Coil Insert Installation . . . . . . . . . . . . . . . . . . Spark Plug Hde Hdicaf Coil Inserts

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Rockers Hydraulic Valve Lifters . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rods . . . . . . . . . . . . . . . . . . . Piston Pin Bushing Replacement

Crankshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . Idler Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magneto and Accessory Drive Adapter Assembly . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . Tachometer Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . Starter Drive Adapter . . . . . . . . . . . . . . . . . . . . . . . . . Oit Pump Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition CaMes

CHAPTER 72-30 INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . Magnetic Partide Injection . . . . . . . . . . . . . . . . . . . Crankshaft Ultrasonic Inspection

. . . . . . . . . . . . . . . . . . . . Flourescent Partide Inspection . . . . . . . . . . . . . . . . . . . . . . . Dimensional Inspection

. . . . . . . . . . . . . . . . . . . . . . . . . Dimensional Limits Original Dimension . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . New Parts and Service Limits . . . . . . . . . . . . . . . . . . . . . . . . . . Protective Coating

. . . . . . . . . . . . . . . . . . . . . . . . Application of Alodine . . . . . . . . . . . . . . . . . . . . . Repair of Alodized Surfaces

. . . . . . . . . . . . . . . . . . . . . . . . . . Enamel Coatings

CHAPTER 72-40 SPECIFIED INSPECTIONS

Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . O m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft

Crankshaft and Counterweight Pins and Bushings . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gears

. . . . . . . . . . . . . . . . . . . . . . . . . . Pistons and Rings

viii February 1989

SECTION PAGE

CHAPTER 72-40 SPECIFIED INSPECTIONS (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinders

Hydraulic Valve Lifters . . . . . . . . . . . . . . . . . . . . . . . . Intake Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . Lubrication System Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System

CHAPTER 72-50 ASSEMBLY OF SUBASSEMBLIES

Gene tal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OiI Pump AssemMy (TSIO.520.C.G.H,M.P. R & AF) . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . Oil Pump Assembly (TSIO-520-T) . . . . . . . . . . . . . . . . . . Oil Pump Assembly (TS10-520-AE)

Oii Pump Assembly (TSIO-520-CE) . . . . . . . . . . . . . . . . . . Starter and Drive Assembly (TSIO.52O.C,G.H.M,P, R 8 AF) . . . . . . . . Starter and Drive Assembly (TSIO.520.T, AE & CE) . . . . . . . . . . .

. . . . . . . . . . . . . . Cylinder Assernbly (All Except TSIO-520-A) Cylinder Assembly (TSIO.520.AE). . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . Piston and Ring Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . Pushrod Housing

. . . . . . . . . . . . . . . . . . . Crankshaft and Cannecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cams haft

Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel lnjection Contrd and Air Throttle Body

CHAPTER 72-60 FINAL ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinders and P ions . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . Oil Pump CfSIO.520C.G.H.M.P. R & AF) . . . . . . . . . . . . . . . . . . . . . . . Oil Pump (TSIO-520-AE)

. . . . . . . . . . . . . . . . . . . . . Oil Pump (TSIO-520-T & CE) FuelPump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Drive Adapter . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . Magneto and Accessory Drive Adapters . . . . . . . . . . . . . . . . OilCooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . Valve Mechanism . . . . . . . . . . . . . . . . . . . . Oil Sump (TS10620.C.G. M & T)

. . . . . . . . . . . . . . . . Oil Sump (TSIO-520-H,P,R, AE,AF & CE) . . . . . . . . . . . . . . . . . . . . . . . . . . lnduction System

. . . . . . . . . . . . lnduction System (TSIO.520.C.G.H.M.P. R & AF) . . . . . . . . . . . . . . . . . . . . lnduction System (TS10-520-T)

Induction System (TSIO-520-AE) . . . . . . . . . . . . . . . . . . . Induction System (TSIO-520-CE) . . . . . . . . . . . . . . . . . . . Fud Injection System (TS10520.C.G.H.M.P.R. T & AF) . . . . . . . . . . Fuel Injection System (TS10-520-AE) . . . . . . . . . . . . . . . . . Fuel Injection System (TSlO-520-CE) * . . . . . . . . . . . . . . . . Magneto Drive Gears . . . . . . . . . . . . . . . . . . . . . . . .

February 1989 iX

SECTION CHAPTER 72-60 FINAL ASSEMBLY (Continued)

Placing Crankshaft in Timing Position . . . . . . . . . . . . . . . . . Magnetos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Lines & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System (TS10.520.T) . . . . . . . . . . . . . . . . . . . . .

CHAPTER 72-70 TESTING AFTER OVERHAUL

Test Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Club

. . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Air Scoop . . . . . . . . . . . . . . . . . . . . . . . . . Induction Air Intake

. . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls

. . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Wiring instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Breather Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . Governor Pad Cover Engine Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . Overhaul Test Run

CHAPTER 72-80 ENGINE PRESERVATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Flyable Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . Temporary Storage . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . Indefinite Storage

CHAPTER 73-00 ENGINE FUEL SYSTEM

Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set up Procedure

Turbocharged Engines . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . Special Set up Procedures . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 74 IGNITION (TCM IGNITION SYSTEM)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL Magneto l nstallation . . . . . . . . . . . . . . . . . . . . . . . . . Harness Assembly Installation . . . . . . . . . . . . . . . . . . . .

IGNITION TROUBLESHOOTING . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL Magneto installation . . . . . . . . . . . . . . . . . . . . . . . . . Harness AssemMy Installation . . . . . . . . . . . . . . . . . . . .

tGNlTION TROUBLESHOOTING . . . . . . . . . . . . . . . . . . .

X February 1989

SECTION PAGE

CHAPTER 75 AIR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL

CHAPTER 76 ENGINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL

CRUISE CONTROL BY PERFORMANCE CURVE . . . . . . . . . . . . CRUISE CONTROL BY E.G.T . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 77 ENGINE INDICATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL

OPERATING LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .

CHAPTER 78 EXHAUST

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL EXHAUST SYSTEM (TSIO-520-T) . . . . . . . . . . . . . . . . . . . EXHAUST SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . .

CHAPTER 79 OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL

APPROVED PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL SYSTEM TROUBLESHOOTING

CHAPTER 80 STARTING

. . . . . . . . . . . . . . . GENERAL Prestarting . . . . . . . . . . . . . . . Starting . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . Ground Warm-up

. . . . . . . . . . . . Pre-takeoff Check . . . . . . . . . . . . . Flooded Engine

. . . . . . . . . Cold Weather Operation . . . . . . . . . . . . . . . Preheating

. . . . . . . . . Hot Weather Operation Ground Operating At High Altitude Airports .

CHAPTER 81 TURBINES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wastegates

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controllers Turbocharger Lubrication System . . . . . . . . . . . . . . . . . . . Turbocharging System TrouMeshooting . . . . . . . . . . . . . . . .

February 1989 xi

FIGURE NO .

LIST OF ILLUSTRATIONS

TITLE

Three Quarter Right Front View of the TS10520 Sandcast Series Engine Three Quarter Left Rear View of the TS10520 Sandcast Series Engine . . . Installation Drawing TS10520 Series Sandcast . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . Strap Wrench Oil Filter Can Cutter . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Base Nut Wrench . . . . . . . . . . . . . . . . . . . . . . Cylinder Base Nut Wrench Bonanza . . . . . . . . . . . . . . . . . . Cylinder Base Nut Wrench . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . Piston Pin Removers . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Hone

Crankshaft Blade and Dampener Bushing Removers/Replacers . . . . . Holding Fixture Adapters . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . Universal Cylinder Holding Fiiure . . . . . . . . . . . . . . . . . . . . . . . . . Valve Guide Cleaner

. . . . . . . . . . . . . . . . . . . . . . . . . . . Seal Seat Cutter

. . . . . . . . . . . . . . . . . . . . . . . . . . . Spring Checker Valve Guide Removers . . . . . . . . . . . . . . . . . . . . . . . . Valve Guide Replacers . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Bushing Remover Installer Set . . . . . . . . . . . . . . . Piston Ring Compressors . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . Floating Holder Valve Spring Compressor. . . . . . . . . . . . . . . . . . . . . . . Push Rod Housing Spring Compressor . . . . . . . . . . . . . . . . Flaring Tool Push Rod Housing . . . . . . . . . . . . . . . . . . . . Valve Guide Remover . . . . . . . . . . . . . . . . . . . . . . . . Valve Seat Insert Remover/Replacer . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . Valve Seat Installer

. . . . . . . . . . . . . . . . . . . . . . . . . . Common Parts Kit . . . . . . . . . . . . . . . . . . . . . . Valve Guide to Seat Aligner

Valve Stem Hole Reamer . . . . . . . . . . . . . . . . . . . . . . . Boring Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reamers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expanding Guide Bodies . . . . . . . . . . . . . . . . . . . . . . . Valve Seat Insert Cutters . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . ~ o s a @ ~ t u d emo over Connecting Rod Reaming and Alignment Checking Fi iure . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . Adapter Kits . . . . . . . . . . . . . . . . . . Reamers. Connecting Rod Bushing

universal Connecting Rod Bushing Removers & Installer Set . . . . . . . Common Driie Handle & Pilots . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . Needle Bearing Installers Hydraulic Crankshaft Dampener Bushing Remover/Replacer Sets . . . . Counterweight Bushing Remover/lnstaller . . . . . . . . . . . . . . . All Position Engine Stand . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . Torque Band Tension Adjuster . . . . . . . . . . . . . . . . . . . . . . . Generator Drive Holders

Cylinder Heating Stand . . . . . . . . . . . . . . . . . . . . . . . . Blind Needle Bearing Puller . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . Starter Clutch Shaft Bearing Pullers Differential Pressure Gage . . . . . . . . . . . . . . . . . . . . . . Differential Pressure Cylinder Checker . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . Belt Tension Gage

PAGE NO .

xii February 1989

FIGURE NO . TITLE PAGE NO .

Hydraulic Lifter Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Tester

. . . . . . . . . . . . . . . . . . . . . . . . . Engine Timing Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulley Holder

Pulley Alignment Gauge Bar . . . . . . . . . . . . . . . . . . . . . Crankcase Drill Flxture for Starter Clutch Adapter . . . . . . . . . . . . Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Pulley Puller . . . . . . . . . . . . . . . . . . . . . . . . Bearing and Bushing Drill Flxture . . . . . . . . . . . . . . . . . . . Spark Plug Insert Replacer . . . . . . . . . . . . . . . . . . . . . . Thru Bolt Bore Step Cutters . . . . . . . . . . . . . . . . . . . . . Spark Plug Insert Tap . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug Insert Remover . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . Slide Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug Tap

. . . . . . . . . . . . . . . . . . . . . . ~osan@~ock h in^ installer Stud Drivers 505 Series . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . Scavenge Pump Drill Fixture Drill Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Splitter Set . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . Propeller Shaft Oil Seal Installer

. . . . . . . . . . . . . . . . . . . . Oil Pressure Relief Spot Facers Runout Block Set . . . . . . . . . . . . . . . . . . . . . . . . . . Polishing Tools for Crankshaft Bearings 8087 Series . . . . . . . . . . . Injector Nozzle Remover and Installer . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . Crankcase Thru-Bdt Removers Hex Drive for Hex Tube Nuts . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . Rotobroach Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pullers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pullers

Pullers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pullers

. . . . . . . . . . . . . . . . . . . . . . . . . Outside Micrometers Dial Bore Gages . . . . . . . . . . . . . . . . . . . . . . . . . . . Blade Micrometers . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . Screw Thread Micrometers 126, 226 Depth Micrometers . . . . . . . . . . . . . . . . . . . . . . . . . Reamers. Rocker Shaft Support Boss . . . . . . . . . . . . . . . . . Reamers. Rocker Arm & Shaft Bushing . . . . . . . . . . . . . . . . Reamers. Valve Guide Boss . . . . . . . . . . . . . . . . . . . . . Engine Appiication Chart for Valve Guide Stem Hde Reamers . . . . . . Square Shank Reamers . . . . . . . . . . . . . . . . . . . . . . . Valve Guide Stem Hde Plug Gauges . . . . . . . . . . . . . . . . . Dial Thickness Gauge . . . . . . . . . . . . . . . . . . . . . . . . Precision Vernier Calipers . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . Inside Measuring Instruments . . . . . . . . . . . . . . . . . . Alternator. Voitage Regulator Tester

Alternator. Regulator. Battery Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multiple Vdtage & Circuit Tester

. . . . . . . . . . . . . . . . . . . . . . . . Magneto Timing Light Timing Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . Cold Cyiinder Tester . . . . . . . . . . . . . . . . . . . . . . . . . . Hi-Voltage Tester

February 1989 xiii

Avantext, Inc.


Master Orifice Tool . . . . . . . . . . . . . . . . . . . . . . . . . Alcor Portable Digital EGT Unit . . . . . . . . . . . . . . . . . . . . Alcor Portable Digital CHT Unit . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . Lockwire Procedure Permatex and Threading Procedure . . . . . . . . . . . . . . . . . . Master Orifice Assembly Tod . . . . . . . . . . . . . . . . . . . . . Cylinder Slatic Seal & Dynamic Seal . . . . . . . . . . . . . . . . . . Differential Pressure Tester . . . . . . . . . . . . . . . . . . . . . . Dynamic Seal Check . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Numbering . . . . . . . . . . . . . . . . . . . . . . . . . Gear Train Diagram

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized Magneto Installation . . . . . . . . . . . . . . . . . . . Exploded View of Ignition System . . . . . . . . . . . . . . . . . . . Fuel Injection System TSIO.520.C.G.H.M.P.R. T & AF . . . . . . . . . . Fuel Injection System TSIO-520-AE . . . . . . . . . . . . . . . . . . Fuel Injection System TSIO-520-CE . . . . . . . . . . . . . . . . . . Magneto & Accessory Drives . . . . . . . . . . . . . . . . . . . . . Induction System TSlO.520.C.G.H.M.P. R & AF . . . . . . . . . . . . . Induction System TSIO.520.T . . . . . . . . . . . . . . . . . . . . . Induction System L/TS10-520-AE . . . . . . . . . . . . . . . . . . . Induction System TSIO-520-CE . . . . . . . . . . . . . . . . . . . . Oil Sump TSI0.52O.C.G. M & T . . . . . . . . . . . . . . . . . . . . Oil Sump TSIO.520.H.P.R.AE. AF & CE . . . . . . . . . . . . . . . . . Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter and Starter Drive Adapter TSIO.520.C.G.H.M.P. R & AF . . . . . .

. . . . . . . . . . . . . . . . . Starter Adapter TSIO.520.T. AE & CE Oil Pump Assembly TSIO.520.C.G.H.M.P. R & AF . . . . . . . . . . . . Oil Pump Assembly TSIO.520.T. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . Oil Pump Assembly LPSIO-520-AE Oil Pump Assembly TSIO-520-CE . . . . . . . . . . . . . . . . . . . Cylinder and Piston Assembly (All Except L/fSIO.520.AE) . . . . . . . . Cylinder and Piston Assembly LflSIO-520-AE . . . . . . . . . . . . . Crankcase Assembly . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Assembly (TSIO.520.T) . . . . . . . . . . . . . . . . . . . . Crankcase Stud Setting Heights . . . . . . . . . . . . . . . . . . . . Installing Typical Helical Insert . . . . . . . . . . . . . . . . . . . . Installing Spark Plug Hde Helical Insert . . . . . . . . . . . . . . . . Expanding Spark Plug Hole Helical Insert . . . . . . . . . . . . . . . Removing Spark Plug Hole Helical Insert . . . . . . . . . . . . . . . . Valve. Rocker Bushing Dimensions . . . . . . . . . . . . . . . . . . Cylinder Assembly Dimensions (Inclined Valve) . . . . . . . . . . . . . Cylinder Assembly Dimensions (Straight Valve) . . . . . . . . . . . . . Hydraulic Lifter . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . Connecting Rod and Bushing Dimensions Ignition Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . Crankshaft Ultrasonic Inspection Procedure Counterweight Bushing Diameter Check . . . . . * . . . . . . . . . . Inspection Ring Side Clearance . . . . . . . . . . . . . . . . . . . . Measuring Ring Gap in Cylinder . . . . . . . . . . . . . . . . . . . . Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

X ~ V February 1989


Reverse Spark Plug Procedure . . . . . . . . . . . . . . . . . . . . Slipjoint Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-Segment Y" Band Clamp . . . . . . . . . . . . . . . . . . . . Valve Spring Installation . . . . . . . . . . . . . . . . . . . . . . . Fuel manifold Valve Fitting Locations for TSIO.520.CE . . . . . . . . . . Fuel Manifold Valve Fi ing Locations for TSIO.520.C.G.H.M.P. R.T.AE&AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Control Valve Fitting Locations . . . . . . . . . . . . . . . . . . Fuel Pump Fitting Locations for TSIO-520-T . . . . . . . . . . . . . . Fuel Pump Fitting Locations for TSIO.520.AE . . . . . . . . . . . . . . Fuel Pump Fi ing Locations for TS10.520.C.G.H.M.P.R.A. F & CE . . . . . Air Throttle & Metering Assembly Fitting Location for TSIO-520-AE . . . . Left Crankcase and Shafts Assembled on Stand. . . . . . . . . . . . . Alignment of Timing Marks . . . . . . . . . . . . . . . . . . . . . . Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . Left Side of Complete Crankcase on Stand . . . . . . . . . . . . . . . Installing No . 6 Cylinder . . . . . . . . . . . . . . . . . . . . . . . Tightening Cylinder Base Nut . . . . . . . . . . . . . . . . . . . . . Cylinder Flange Torque Sequence for Single Cylinder Installation . . . . . Oil Pump. Fud Pump and Starter Adapter Installed . . . . . . . . . . . Installing Pushrod Housing . . . . . . . . . . . . . . . . . . . . . . Bottom View with Valve Mechanism and Oil Sump Suction Tube . . . . . Position of Magneto Couplings . . . . . . . . . . . . . . . . . . . . Ignition Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . Exhaust Flange Dimensions . . . . . . . . . . . . . . . . . . . . . Fuel System Schematic . . . . . . . . . . . . . . . . . . . . . . . Coating lnsulationg Sleeve . . . . . . . . . . . . . . . . . . . . . . installation of Elbow Clamp . . . . . . . . . . . . . . . . . . . . . . Basic Turbocharger System . . . . . . . . . . . . . . . . . . . . . Basic Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . Fied Orifice Wastegate . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Wastegate . . . . . . . . . . . . . . . . . . . . . . . . . Absolute Pressure Contrdler . . . . . . . . . . . . . . . . . . . . . Absolute Pressure Contrdler and Rate of Change Controller Combined . . Rate of Change Contrdler . . . . . . . . . . . . . . . . . . . . . . Ratio Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Absolute Pressure Controller . . . . . . . . . . . . . . . . . Throttle Connection . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger lubrication System . . . . . . . . . . . . . . . . . . .

February 1989 XV

LlST OF CHARTS

FIGURE NO . n m PAGE NO .

Engine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 1-10-09 Special Tools Procurement Sources . . . . . . . . . . . . . . . . . . 1-20-02 Identification Code for Tods . . . . . . . . . . . . . . . . . . . . . 1-20-03 Special T d Index . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20-04

thru 07 Application Chart Sealants/lubdcants . . . . . . . . . . . . . . . . . 130-01

thru 05 winder Leakage Check . . . . . . . . . . . . . . . . . . . . . . . 70-50-06 Standard and Oversize Stud Identification . . . . . . . . . . . . . . . 72-20-06 Crankcase Stud Setting Heights . . . . . . . . . . . . . . . . . . . . 72-20-07 Miscellaneous Stud Setting Heights . . . . . . . . . . . . . . . . . . 72-20-08 Magnetic Particle Inspection . . . . . . . . . . . . . . . . . . . . . 72-30-04 Table of Limits Chart (1) . . . . . . . . . . . . . . . . . . . . . . . 72-30-09 Table of limits Chart (2) . . . . . . . . . . . . . . . . . . . . . . . 7230-1 0.

11. 12 . . . . . . . . . . . . . . . . . . . . . . Table of limits Chart (3) .72.30.13.14. 15 . . . . . . . . . . . . . . . . . . . . . . . Table of Limits Chart (4) 72-30-1 6.17 . . . . . . . . . . . . . . . . . . . . . . . Table of Limits Chart (5) 7240.18. 19

. . . . . . . . . . . . . . . . . . . . . Critical New Part Dimensions 7230.20. 21 Inspection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 72-40-1 1

thru 19 General Use . Tightening Torques . . . . . . . . . . . . . . . . . . . 72-50-03 Table of Tightening Torques . . . . . . . . . . . . . . . . . . . . . 72-50-04 Pipe Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-50-05 Hydraulic l ine Fittings . . . . . . . . . . . . . . . . . . . . . . . . 72-50-05 Fuel Manifdd Valve Fitting Locations for TSIO.520.CE . . . . . . . . . . 72-50-1 1 Fuel Manifdd Valve Fi ing Locations for TSI0.520.C.G.H.M.P.R. T AE&AF 72-50-1 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Contrd Valve Fi ing Locations . . . . . . . . . . . . . . . . . . 72-50-1 3 Fuel Pump Fitting locations for TSIO-520-1 . . . . . . . . . . . . . . 72-50-1 4 Fuel Pump F i ing Locations for TSIO.520dE . . . . . . . . . . . . . . 72-50-1 5 Fuel Pump Fitting Locations for TS10.520.C.G.H.M.P.R. AF & CE . . . . . 72-50-1 7 Crankcase Assembly Procedure . . . . . . . . . . . . . . . . . . . 72-60-05 Magneto-to-Engine Timing . . . . . . . . . . . . . . . . . . . . . . 72-60-1 6 Standard Acceptance Test . . . . . . . . . . . . . . . . . . . . . . 72-70-06 Oil Consumption Determination . . . . . . . . . . . . . . . . . . . . 72-70-07

. . . . . . . . . . . . . . . . . . . . . . . . Test Operating Limits 72.70438. 09 Fud System Pressure and Flow Value Charts . . . . . . . . . . . . . . 73-1 0-03 Fuel Injection System Troubleshooting Chart . . . . . . . . . . . . . . 73-1 0-04 Coupling Nut Torque Values . . . . . . . . . . . . . . . . . . . . . 74-00-05 Ignition Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 7400-06 Coupling Nut Torque Values (Slick) . . . . . . . . . . . . . . . . . . 74-00-09 Ignition Troubleshooting (Slick) . . . . . . . . . . . . . . . . . . . . 7400-1 0 Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . . 76-00-05

thru 65 Opemting Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7 - l ~ i

thru 06 Engine Trouble Shooting 77-20-01 . . . . . . . . . . . . . . . . . . . . . . .

thru 06

xvi February 1989


78-20-00 Exhaust System Troubleshooting . . . . . . . . . . . . . . . . . . . 78-20-01 79-1 0-00 Approved Oil Products . . . . . . . . . . . . . . . . . . . . . . . . 79-10-01 79-20-00 Lubrication System Troubleshooting . . . . . . . . . . . . . . . . . . 79-20-01 81 -50-00 Turbocharging System Troubleshooting . . . . . . . . . . . . . . . . 81 -20-01 81 -50-00 Maximum Allowable Manifold Pressure vs . Altitude . . . . . . . . . . . 81 -20-02

February 1989 xvii

INTENTIONALLY

LEFT

BLANK

xviii February 1989

CHAPTER 1 INTRODUCTION

1-00-00 SCOPE 1-00-01 Related Publications 1-00-02 Service Bulletins 1-00-03 Service Reports And Inquiries 1-00-04 100% Replacement Parts

1-10-00 DEFINITIONS & ABBREVIATIONS 1-1 0-01 Abbreviations/Symbofs 1-1 0-02 Definitions 1-10-03 Description of Engine Model Code 1-10-04 Basic Design Feature

1-20-00 TOOLS 1-20-01 Special Tools

1-30-00 PRODUCTS 1-30-01 Product List

February 1989 1-00-01

l NTENTl ON ALLY

LEFT

BLANK

1-00-02 February 1989

1-00-00 SCOPE

Recommendations, cautions and warnings regarding overhaul of this engine are not intended to impose undue restrictions, they are inserted to obtain maximum petformance from the engine in accordance with safety and efficiency. Abuse, misuse, or neglect of any piece of equipment can cause eventual failure. For an aircraft engine, it is obvious that a failure may have disastrous consequences. Failure to observe the instructions contained in this manual constitutes unauthorized operation in areas unexplored during development of the engine, or in areas which experience has proved to be undesirable or detrimental.

NOTES, Cautions and Warnings are included throughout this manual. Application is as follows:

NOTE . . . Special interest information which may facilitate the operation of equipment.

GlUTION . . . Infomzation issued to emphasize certain instructions or to prevent possible damage to engine or accessories.

WARNING . . . Information which, if disregarded, may result in severe damage to or destruction of the engine or endangerment to personnel.

1-00-01 RELATED PUBLICATIONS

A. Engine Manuals:

1. Maintenance and Overhaul Manual for TSIO-520 Sandcast Series Aircraft Engine, Form X30575A.

2. Illustrated Parts Catalog for TSIO-520 Sandcast Series Aircraft Engine, Form X30579A.

3. Teledyne Continental Motors Aircraft Engine Service Bulletins.

4. Fuel Injection Manual. Form X30593A. 5. Starter Service instructions Form X30592,

The above publications can be ordered through your Teledyne Continental Motors Distributor or ordered directly, if prepaid, from:

Teledyne Continental Motors Aircraft Products P. 0. Box 90 Mobile, AL 36601

Attn: Publications Department

February 1989 1-00-03

B. Accessory Manuals:

1. Magnetos Service Manual Teledyne Continental Motors Aircraft Products Divsion P.O. Box 90 Mobile, AL 36601 Attn: Publications Department

Service Manual Slick Electro Inc. 530 Blackhawk Park Avenue Rockford, Illinois 61 100

2. Alternator Alternator Service Instructions Form X30531-2 Teledyne Continental Motors Aircraft Products Divsion P.O. Box 90 Mobile, AL 36601 Attn: Publications Department

3. Starter Teledyne Continental Motors Aircraft Products Division P.O. Box 90 Mobile, A 1 36601 Attn: Publications Department

1-00-02 BULLETINS. Bulletins that are issued to Distributors and subscribers from Teledyne Con- tinental Motors are divided into three separate groups: (1) Customer Infonation Bulletins; (2) Service Bulletins and (3) Mandatory Service Bulletins.

(I) Customer information Bulletins are published to help provide the latest information on TCM marketing procedures, policies and product information.

(2) Service Bulletins provide current information related to service, maintenance and technical support of the product.

(3) Mandatory Service Bulletins are issued with required compliance information that may affect safety of flight.

These bulletins are also available to owners, operations or maintenance personnel on an annual subscription basis.

1-00-03 SERVICE REPORTS AND INQUIRIES. If for any reason you have an inquiry or require technical assistance beyond the scope of your service facility, contact your local TCM distributor or TCM field representative. Requests for copies of Teledyne Continental Aircraft Engine Service publications should be made through your distributor or Teledyne Continental Motors, Aircraft Products Division, P.O. Box 90, Mobile, AL 36603, Attn: Publications Dept.

1-00-04 February 1989

1-00-04 100% REPLACEMENT PARTS.

It is recommended that the following parts be replaced 100 percent during the major overhaul of any Teledyne Continental Motors' aircraft engine regardless of conditions.

Hydraulic Lifters

Rubber Hoses Oil Seals Gaskets and Packings Circlips, Lock Plates & Retaining Rings Piston Rings Valve Keepers Bearings- Main and Rod Rubber Drive Bushings Exhaust Valves Piston Pins Rotocoils Needle Bearings Woodruff Keys Rocker Arm & Conn. Rod Busings All Nuts - Self-locking Cotter Pins Pistons Springs - Oil Pressure Thrust Washers Generator Belts Spring - Starter Clutch Harnesses Oil Suction Screens with Small Openings Spark Plugs Washers - locking Washers - Plain Exhaust Clamps, Turbo to Tailpipe Counteweight Bushings Intake Guide Seals

All 10-346,lO-360, LTSIO/ TS10-360,0-470,10470

TS10-470, GIO-470,IO-520 GTSIO-520, LTSIO/TSIO-520

and 6-285 Models

All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All TSlO Models All Models All Models

Special Note:

If for any reason lifters are removed for inspection before the overhaul period has been reached, they must be placed back in the same location from which they were removed.

CRANKCASES ALL MODELS

Re-assembly with configuration as per Service Bulletin M77-14 Rev. 1 and M83-10 Rev. 1 at the time major overhaul is recommended.

February 1989 1-00-05

INTENTIONALLY

LEFT

BLANK

1-00-06 February 1989

1-10-00 DEFINITIONS AND ABBREVIATIONS

TERM A.B.C. ADMP Approx. A.T.C. Bar. B.B.C. B.H.P. BSFC B.T.C. FAA C.A.R. C.G. c.f.m. C.H.T. ccw cw 0 OF EGT Fig. Front ft . F.T. FT-LBS G.P.M. gms Hex H20 Hg- hr. I.D. IN-LBS in. (") Left Side

Lbs. Lockwire 1 o o u Man. Max. Min. 30' N.P.T. N.C. N.F. NRP OAT O.D. 02. Press.

EXPLANATION After Bottom Center Absolute Dry Manifold Pressure Approximately After Top Center Barometric Before Bottom Center Brake Horsepower Brake Specific Fuel Consumption Before Top Center Federal Aviation Administration Civil Air Regulations Center of Gravity Cubic Feet Per Minute Cylinder Head Temperature Counterclockwise Rotation Clockwise Rotation Degrees of Angle Degrees Fahrenheit Exhaust Gas Temperature Figure (Illustration) Propeller End of Engine Foot or Feet Full Throttle Foot Pounds Torque Gallons Per Minute Grams Hexagon Water Mercury Hour Inside Diameter Inch Pounds Torque Inches Side on which No's 2,4 and 6 cylinders are located. (Rear to Front) Pounds Stainless steel wire used to safety connections, etc. 100 Octane Low Lead Fuel Manifold Manometer Maximum Minimum Thirty minutes of angle (60' equal one degree) National Pipe Thread (Tapered) National Course (Thread) National Fine (Thread) Normal Rated Power Outside Air Temperature Outside Diameter Ounce Pressure

February 1989 1-10-01

p.s.i. PSlA PSlG PPH Rear Rec. Right Side

R.P.M. Std. TBO T.D.C. T.I.T. Torque

Pounds Per Square lnch Pounds Per Square Inch Absolute Pounds Per Square lnch Gauge Pounds Per Hour Accessory End of Engine Recommended Side on which No's 1, 3 and 5 cylinders are located. (Rear to Front) Revolutions Per Minute Standard Time Between Overhaul Top Dead Center Turbine Inlet Temperature Force x lever arm (1 25 ft.-lbs. torque = 125 Ibs. Force applied one ft. from bolt center or 62-1 /2 Ibs. applied 2 ft. from center), etc.

1-1 0-02 DEFINITIONS

ADMP Absolute dry manifold pressure, is used in establishing a baseline standard of engine performance. Manifold pressure is the absolute pressure in the intake manifold; measured in inches of mercury.

Ambient A term used to denote a condition of surrounding atmosphere at a particular time. For example; Ambient Temperature or Ambient Pressure.

BHP Brake Horsepower. The power actually delivered to the engine propeller shaft. It is called brake horsepower because it was formerly measured by applying a brake to the power shaft of an engine. The required effort to brake the engine could be converted to horsepower -hence: "brake horsepower".

BSFC Brake Specific Fuel Consumption. Fuel consumption stated in pounds per hour per brake horsepower. For example, an engine developing 300 horsepower while burning 150 pounds of fuel per hour, has a BSFC of .5.

Fuel Consum~tion in PPH Brake Horsepower

Cavitation

Cold Soaking

Corrosion

Critical Altitude

Density Altitude

Formation of partial vacuums in a flowing liquid as a result of the separation of its parts.

Prolonged exposure of an object to cold temperatures so that its temperature throughout approaches that of ambient.

Deterioration of a metal surface usually caused by oxidation of the metal.

The maximum altitude at which a component can operate at 100% capacity. For example, an engine with a critical altitude of 16,000 feet cannot produce 100% of its rated rnainfold pressure above 16,000 feet.

Altitude as determined by pressure altitude and existing ambient temperature. In Standard Atmosphere (IAS) density and pressure altitudes are equal. For a given pressure altitude, the higher the temperature, the higher the density altitude.

1-1 0-02 February 1989

Dynamic Condition

E.G.T.

Exhaust Back Pressure

Four Cycle

Fuel Injection

Gallery

Galling or Scuffing

Humidity

Hydrostatic Lock

Impulse Coupling

Lean Limit Mixture

I Major Overhaul

Manifold Pressure

Mixture

A term referring to properties of a body in motion.

Exhaust Gas Temperature. Measurement of this gas temperature is sometimes used as an aid to fuel management.

Opposition to the flow of exhaust gas, primarily caused by the size and shape of the exhaust system. Atmospheric pressure also affects back pressure.

Short for "Four Stroke Cycle." It refers to the four strokes of the piston in completing a cycle of engine operation (Intake, Compression, Power and Exhaust). A process of metering fuel into an engine by means other than a carburetor.

A passageway in the engine or subcomponent. Generaily one through which oil is flowed.

Excessive friction between two metal surfaces resulting in particles of the softer metal being torn away and literally welded to the harder metal.

Moisture in the atmosphere. Relative humidity, expressed in percent, is the amount of moisture (water vapor) in the air compared with the maximum amount of moisture the air could contain at a given temperature.

Inability or restriction of piston rotation at TDC due to fluid accumulation in excess of combustion chamber displacement.

A mechanical device used in some magnetos to retard the ignition timing and provide higher voltage at cranking speeds for staring.

The leanest mixture approved for any given power condition. It is not necessarily the leanest mixture at which the engine will continue to operate.

Per FAA AC43-11 consists of the complete disassembly of an engine, inspected, repaired as necessary, reassembled, tested, and approved for return to service within the fas and limits specified by the manufacturer's overhaul data. This could be to new fits or limits or serviceable limits. The determination as to what Ws and limits are used during an engine overhaul should be clearly understood by the engine owner at the time the engine is presented for overhaul. The owner should also be aware of any parts that are replaced, regardless of condition, as a result of manufacturer's overhaul data, service bulletin, or an aitw- orthiness directive.

Pressure as measured in the intake manifold down-stream of the air throttle. Usually measured in inches of mercury.

Mixture ratio. The proportion of fuel to air used for combustion.

February 1989 1-1 0-03

Naturally Aspirated (Engine)

Octane Number

Oil Temperature Control Valve

Overboost Valves

Overhead Valves

Performance Rating

Permold

Pressure Altitude

Propeller Load Curve

Propeller Pitch

PSlA

Ram

Rated Power

Retarded Breaker

Rich Limit

Rocker Arm

A term used to describe an engine which obtains induction air by drawing it directly from the atmosphere into the cylinder. A non- supercharged engine.

A rating which describes relative anti-knock (detonation) characteristics of fuel. Fuels with greater detonation resistance than 100 octane are given performance ratings.

A thermostatic valve used to divert oil through or around the oil cooler, as necessary, to maintain oil temperature within desired limits (ref. vernatherm valve). A pressure relief valve, set slightly in excess of maximum deck pressure, to prevent damaging overboost in the event of a system malfunction.

An engine configuration in which the valves are located in the cylinder head itself.

A rating system used to describe the ability of fuel to withstand heat and pressure of combustion as compared with 100 octane fuel. For example, an engine with high compression and high temperature needs a higher Performance Rated fuel than a low compression engine. A rating of 100/130 denotes performance characteristics of lean (100) and rich (1 30) mixtures respectively. A term used to describe a process by which a crankcase is made. An engine with a perrnold crankcase has a front, right-hand mounted, gear driven alternator.

Altitude, usually expressed in feet, (using absolute static pressure as a reference) equivalent to altitude above the standard sea level reference plan (29.92" Hg. Standard). A plot of horsepower, versus RPM, depicting the power absorption characteristics of a f i pitch propeller.

The angle between the mean chord of the propeller and the plane of rotation.

The absolute thermodynamic pressure measured by the number of pounds - force exerted on an area of one square inch.

Increased air pressure due to forward speed.

The maximum horsepower at which an engine is approved for operation.

A device used in magnetos to delay ignition during cranking. It is used to facilitate starting.

The richest fuellair ratio permitted for a given power condition. It is not necessarily the richest condition at which the engine will run.

A mechanical device used to transfer motion from the pushrod to the valve.

1-1 0-04 February 1989

Run Out

Sandcast

Scavenge Pump

Sonic Venturi

Standard Day

Static Condition

Sump

T.D.C.

Thermal Efficiency

T.1.T

Torque

Turbocharger

Turbo Supercharged (engine)

Vapor Lock

Variable Pressure Controller

Eccentricity or wobble of a rotating part.

A term used to described a process by which a crankcase is made. An engine with a sandcast crankcase has belt driven alternator mounted on the left rear accessory case and a front, right-hand mounted oil cooler.

A pump (especially an oil pump) to prevent accumulation of liquid in some particular area.

A restriction, especially in cabin pressurization systems, to limit the flow of air through a duct.

By general acceptance, a condition of the atmosphere wherein specific amounts of temperature, pressure, humidity, etc. exist.

A term referring to properties of a body at rest.

The lowest part of a system. The main oil sump on a wet sump engine contains the oil supply.

Top Dead Center. The position in which the piston has reached the top of its travel. A line drawn between the crankshaft rotational p i s , through the connecting rod end axis and the piston pin center would be- straight line. Ignition and valve timing are stated in terms of degrees before or after TDC.

Regarding engines, the percent of total heat generated which is converted into useful power.

Turbine Inlet Temperature. The measurement of E.G.T. at the turbocharger turbine inlet.

Twisting moment, or leverage, stated in pounds - foot (or pounds- inch). A device used to supply increased amounts of air to an engine induction system. In operation, a turbine is driven by engine exhaust gas. In turn, the turbine directly drives a compressor which pumps air into the engine intake.

A term used to describe an engine which obtains induction air by drawing it directly from the atmosphere into the Turbocharger Com- pression Inlet, compressing the air and routing it to the pressurized induction system.

A condition in which the proper flow of a liquid through a system is disturbed by the formation of vapor. Any liquid will turn to vapor if heated sufficiently. The amount of heat required for vaporization will depend on the pressure exerted on the liquid.

A device used to control the speed, and thus the output of the turbocharger. It does so by operating the wastegate which diverts, more or less, exhaust gas over the turbine.

February 1989 1-10-05

Vernatherm Valve

Viscosity

Volatility

Volumetric Efficiency

Wastegate Valve

A thermostatic valve used to divert oil through or around the oil cooler, as necessary, to maintain oil temperature within desired limits.

The characteristic of a liquid to resist flowing. Regarding oil, high viscosity refers to thicker or "heavier" oil while low viscosity oil is thinner. Relative viscosity is indicated by the specified "weight" of the oil such as 30 "weight" or 50 "weight". Some oils are specified as multiple-viscosity such as 10W30. In such cases, this oil is more stable and resists the tendency to thin when heated or thicken when it becomes cold.

The tendency of a liquid to vaporize.

The ability of an engine to fill its cylinders with air compared to their capacity for air under static conditions. A "naturally aspiratedu engine will always have a volumetric efficiency of slightly less than 100%, whereas superchargers permit volumetric efficiencies in excess of 100%.

A unit, used on turbocharged engines, to divert exhaust gas through or around the turbine, as necessary to maintain turbine speed. As more air is demanded by the engine, due to throttle operation, the compressor must work harder. In order to maintain compressor and turbine speeds, more exhaust must be flowed through the turbine. The wastegate valve closes and causes gas, which would go directly overboard, to pass through the turbine. The wastegate is usually operated by an actuator which gets necessary signals from the turbocharger controller.

DEFINITION OF TERMS

Front, rear, left and right, as used in this manual, refer to the engine as viewed by the mechanic in a normal position, facing the accessory end. Accessory end being the rear and propeller flange being the front of the engine. Cylinders are numbered starting from the rear, with odd numbers on the right and even numbers on the left.

1-10-03 DESCRIPTION OF ENGINE MODEL CODE

DETalLED ENGINE DESCRIPTION

Example: TS,I 0 - 5 i 0 c , E ~

Prefii Specification Number

TS- Turbosupercharged Refer to specification Manual X30508A for information.

I- Fuel Injection I S u f f M 0- Horizontally Opposed

Cylinder Configuration

Displacement

The CE Letter Identifies The Model of Engine

520 Cubic Inch Cylinder Volume Displacement

1-1 0-06 February 1989

1-10-04 BASIC ~ESIGN FEATURE

The TS10-520 Series engines are air cooled, having six horizontally opposed overhead inclined valve or straight valve cylinders. The cylinder displacement of 520 cubic inches is achieved with a 5.25 inch bore and a 4.00 inch stroke. The TSIO-520 engines are turbosupercharged and have a 7.5 to 1 compression ratio. The TSIO-520 series is fuel injected with an updraft runner induction system. The crankshaft is equipped with pendulum type counterweight dampers that suppress torsional vibrations.

The TSIO-520 engines have a doweled six bolt hole configuration propeller flange. A mounting pad is provided to utilize a hydraulic controlled governor for the constant speed propeller.

The TSIO-520 series engines are of a wet sump design with a positive displacement oil pump installed on the lower rear portion of the crankcase. The desired oil pressure is maintained by a pressure relief valve located in the oil pump housing. Engine cranking is accomplished by a geared right angle drive starter adapter and a direct current starter motor.

The oil cooler is installed on the right front side of the crankcase forward of the No. 5 cylinder. The engine is equipped with two gear driven magnetos. The exhaust system may or may not be supplied with the engine by the engine manufacturer depending on the particular engine model.

February 1989 1-1 0-07 J

THREE-QUARTER RIGHT FRONT VIEW OF THE TSIO-520 SANDCAST SERIES ENGINE.

THREE-QUARTER LEFT REAR VIEW OF THE TSIO-520 SANDCAST SERIES ENGINE.

1-1 0-08 February 1989

INSTALLATION DRAWING TSIO-520-SERIES SANDCAST.

February 1989 1-10-09

MODEL

TS 10-520 C

G H

M

P

R

T

AF

L/T AE

CE

H

-

-

-

-

-

-

-

-

7.64

-

G

-

-

-

-

-

-

-

-

8.15

-

I

-

-

-

-

-

-

-

-

14.00

-

A

40.91

40.91 40.91

40.91

40.91

40.91

38.20

40.91

41 .OO

41 .OO

DIMENSIONS E

8.20

8.20 8.20

8.20

8.20

8.20

8.20

8.20

-

8.20

B

33.56

33.56 33.56

33.56

33.56

33.56

33.56

33.56

33.29

34.00

F

17.10

17.10 17.10

17.10

17.10

17.10

17.10

17.10

-

17.10

C

20.04

20.04 23.54

20.04

20.04

20.04

28.67

26.60

21.12

25.00

D

7.62

7.62 7.62

7.62

7.62

7.62

7.62

7.62

-

7.62

INTENTIONALLY

LEFT

BLANK

1-10-10 February 1989 t

1-20-00 The mechanic should be equipped with a complete set of common tods to indude the minimum of:

1. Wrenches - 1 14" thru 1 " 2. Common and Philister Head Screwdrivers 3. Pliers - Common Diagonal Cutters, Needle Nose, Duck Bill, Vise Grip, Snap Ring. 4. Ratchets 1 /4", 3/8', 1/2" Drive 5. Sockets - 1/4" Drive 5/32" thru 1/2" - 318" Drive 318" thru 1" - 1/2" Drive 7/16"

thru 1-1 14" 6. Sockets (Deepwell) - 1/2" Drive 7/16" thru 1" 7. Feeler Gages 8. Leather Mallet 9. Torque Wrenches* (Calibrated) - 0-500 In. Lbs. - 0-1 00 Ft. Lbs.

10. Micrometers* (Calibrated) * Must be currently calibrated, and the calibration must be traceable to the National Bureau of Standards.

1-204 1 SPECIAL TOOLS

Specific tods illustrated or similar tods marketed by other manufacturers are necessary for setvice and maintenance of the aircraft engine. Tod llustrations shown on the following pages are used with the permission of the respective manufacturers.

Illustrations in this section show only the general appearance of tods and do not correspond to the actual size or shape. Details of special tods, fixtures, equipment and consumable materials appropriate to overhaul procedures are listed in the various chapters and subsystems of this manual; the following information is primarily for procurement purposes.

The following special tools are for All the Teledyne Continental Engines for the purpose of convenience. To determine which tods are needed for your particular engine, refer to "Special Tool Index".

SPECIAL TOOLS PROCUREMENT SOURCES

COMPANY GENERAL PRODUCT

SUMMARY

ALCOR Box 3251 6 101 30 Jones Maltsberger Rd. San Antonio, TX 78284 51 2/349-3771

lnstruments for Light Powered Aircraft Special Tools

BORROUGHS TOOL AND EQUIP. CORP. 2429 N. Burdick St. Kalamazoo, MI 49007-1 897 61 6/345-5163 or 345-2700

Precision lnstruments Measuring lnstruments Precision Tools Special Tools

CHAMPION SPARK PLUG, CO. Box 91 0,900 Upton Ave. Toledo, OH 43661 41 9/535-2461

Spark Plugs, Ignitors Oil Filters Special Tools

EASTERN ELECTRONICS, INC. 180 Roberts St. East Hartford, CT 061 08 203/528-9821

Fuel Pressure Test Equipment Measuring lnstruments Precision Tools Piston Position Indicators Printed and Standard Circuits

- -- -

FEDERAL TOOL SUPPLY CO., INC. 10631 Capital Precision Inspection Oak Park, Michigan 48237 Instruments 800/521-1508 T O U FREE Special Tools or 31 3/543-9300

OTC TOOLS & EQUIPMENT Division of Owatonna Tool Company Owatonna, Minnesota 55060 507/451-53 1 0

Precision Tools Special Tools Hydraulic Accessories

McMASTER-CARR SUPPLY CO. P.O. Box 4355 Chicago, Illinois 60680 31 2/833-0300

Precision Tools Special Tools

SNAP ON TOOLS 261 1 Commerce Blvd. Birmingham, Alabama 35210 205/956-1722

Precision Tools Special Tools

Kell-Strom Tool Company, Inc. 214 Church St. Wethersfield, CT 061 09

Ignition Test Equipment

1-20-02 February 1989

- NOTICE - All tools referenced under Sub-section 1-20-01 Special Tools, are for reference only, not for the purpose of promoting or suggesting tools to be purchased from the indicated sources.

IDENTIFICATION CODE FOR TOOLS

CODE SUPPLIER

(ALR) (BTC) (CSPC) (EEI) (FTSC) (OTC) (MCSC) (SOT)

ALCOR, INC. BORROUGHS TOOL AND EQUIPMENT CORP. CHAMPION SPARK PLUG, CO. EASTERN ELECTRONICS, INC. FEDERAL TOOL SUPPLY CO., INC. OTC TOOLS 81 EQUIPMENT CO. McMASTER-CARR SUPPLY CO. SNAP ON TOOLS

(KTC) = KELL-STROM TOOL COMPANY INC. CODE -- -

Numbers referenced in the left-hand bottom comer of each picture correspond to the @ numbers located in the Special Tool Index.

WARNING . . . Whenever using test equipment, keep equipment and personnel clear of prop area.

February 1989 1-20-03

SPECIAL TOOLS

Item & Nomenclature Application Vendor

Strap Wrench Strap Wrench Strap Wrench Oil Filter Can Cutter Cylinder Base Nut Wrenches Cylinder Base Nut Wrenches Piston Pin Removers Cylinder Hone Holding Fixture Adapters Crankshaft Blade and Damper Bushing Remover/ Replacer Crankshaft Blade and Damper Bushing Remover/ Replacer Crankshaft Blade and Damper Bushing Remover/ Replacer Crankshaft Blade and Damper Bushing Remover/ Replacer Crankshaft Blade and Damper Bushing Remover/ Replacer Holding Fixture Adapters Holding Fixture Valve Guide Cleaner Seal Seat Cutter Spring Checker Valve Guide Remover Valve Guide Remover Valve Guide Replacer Valve Guide Replacer Valve Guide Replacer Rocker Arm Bushing Remover/lnstaller Ring Compressor Ring Compressor Ring Compressor Ring Compressor Ring Compressor Ring Compressor Ring Compressor Ring Compressor Floating Holder Valve Spring Compressor Push Rod Spring Compressor Flaring Tool Push Rod Hsg. Valve Guide Remover Valve Seat Insert R&R

Oil Filter Removal 3" to 3 3/8" Oil Filter Removal 3 112" to 3 718" Oil Filter Removal 4 1 /8" to 4 7/16" Oil Filter Sludge lnspection Cylinder Removal Cylinder Removal Piston Removal Cyfinder Reconditioning Cylinder Hold Down Crankshaft Recondintioning

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Crankshaft Reconditioning BTC




Cylinder Hold Down Cylinder Hold Down Cylinder Reconditioning Cylinder Reconditioning Spring lnspection Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Recondiioning Cylinder Reconditioning Rocker Arm Reconditioning

Engine Assembly Engine Assembly Engine Assembly Engine Assembly Engine Assembly Engine Assembly Engine Assembly Engine Assembly Cylinder Reconditioning Cylinder Assembly/Disassembly Push Rod Housing Installation/Removal Push Rod Housing Reconditioning Cylinder Reconditioning Cylinder Reconditioning

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1-20-04 February 1989

Item & Nomenclature Part Number

4910 4956 81 16 81 1 6-24 thru 29 81 16-1 R thru 15R 81 16-1 B thru 15B 81 16-1 thru 16 4909

4954

4985

5224

5225

81 35

81 36

81 38

2769A13 8111A 8042C 874-40,41 5008,8071 8098

81 22A 81 39,40,41 23-1 8053 8077A&B 8077C 81 04 7726 4973 81 56 8093C 8093D 5210 725 1

BT-33-73F

lnstaller Valve Seat lnsert lnstaller Valve Seat lnsert Common Parts K i Valve Stem Hole Reamers

Reamers

Boring Bars

Expanding Guide Bodies

Valve Seat (Straight Side) lnsert Cutters Valve Seat (Straight Side) lnsert Cutters Valve Seat (Straight Side) lnsert Cutters Valve Seat (Straight Side) lnsert Cutters Valve Seat (Straight Side) lnsert Cutters Valve Seat (Step Side) lnsert Cutters Valve Seat (Step Side) lnsert Cutters Valve Seat (Step Side) lnsert Cutters ~ o s a n ~ Stud Remover Connecting Rod Fiiure Adapter Kit Reamers Conrod Bushing Reamers Conrod Bushing Remover/lnstaller Set Connecting Rod Bushing Common Drive Handle Pilots Needle Bearing lnstaller Needle Bearing lnstaller Bushing R/R Set Bushing R/R Counterweight Engine Stand Tork Band Tension Adjuster Generator Drive Holders Cylinder Heating Stand Bearing Puller Bearing Puller Differential Pressure Gauge Diierential Pressure Cylinder Checker Belt Tension Gauge

Application Vendor

Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning

Cylinder Reconditioning











Stud Remover Connecting Rod Inspection Connecting Rod Inspection Connecting Rod Reconditioning Connecting Rod Reconditioning Connecting Rod Reconditioning

Cylinder Reconditioning Cylinder Reconditioning Needle Bearing Replacement Needle Bearing Replacement Crankshaft Reconditioning Crankshaft Reconditioning Engine Assembly/Disassembly Generator/Alternator Belt Tensioning Generator/Alternator Disassembly Cylinder Reconditioning Bearing Removal Starter Clutch Shaft Bearing Removal Starter Clutch Shaft Setting Differential Fuel Pressure Checking Cylinder Compression

Alternator/Generator Belt Adjustment

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February 1989 1-20-05

Item & Nomenclature Application Vendor Part Number

Hydraulic Valve L ier Tester GEN/ALT Tester Timing Disc Pulley Holder Alignment Gage Bar

Crankcase Drill Fixture Vacuum Pump Pulley Puller Drill Fixture Spark Plug lnsert Replacer Step Cutter Thru-Bolt Step Cutter Thru-Bolt Spark Plug lnsert Tap Spark Plug lnsert Remover Slide Hammer Spark Plug Tap ~ o s a n ~ Lock Ring Installer Stud Drivers Scavenge Pump Drill Fixture Drill Fixture Crankcase Spitter Propeller Shaft Oil Seal lnstaller Oil Pressure Relief Spot Facer Oil Pressure Relief Spot Facer Runout Block Set Polishing Tools for Crank- shaft Bearings lnjector Nozzle Remover and Installer Crankcase thru Bolt Removers Hex Drive Rotabroach Cutters Puller Puller Puller Puller Puller Puller Puller Outside Micrometers Dial Bore Gages Blade Micrometers Screw Thread Micrometers Screw Thread Micrometers Depth Micrometers

Hydraulic Lifter Testing

Checking GEN/ALT Output Setting Engine Timing Sheave Removal Checking Comp & Driver Sheave Alignment Crankcase Modification Vacuum Testing GEN/ALT Sheave Removal Journal Bearing Modification Cylinder Reconditioning Crankcase Modification Crankcase Modification Cylinder Reconditioning Cylinder Reconditioning Multi Use Cylinder Reconditioning Stud Installation Stud lnstallation Crankcase Modification Crankcase Squirt Nozzle Replaceme Crankcase Separation Installation of seal over Propflange

Removal of surface Material around holes Removal of surface Material around holes Crankshaft lnspection Crankshaft Reconditioning

Injector Removal & Replacement Engine Disassembly Loosening Tubing "B* Nuts Hole Cutting Removal of Press Fit Parts Removal of Press Fit Parts Removal of Press Fit Parts Removal of Press Fi Parts Removal of Press Fii Parts Removal of Press Fit Parts Removal of Press Fit Parts Dimensional lnspection Dimensional lnspection Dimensional lnspection Dimensional lnspection Dimensional lnspection Dimensional lnspection

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1-20-06 February 7 989

Item & Nomenclature Part Number

4903-1 thru -5 4905

51 29-1 thru -5 51 30

7232

491 4-1 HS thru 5HS 4943-1 HS thru 5HS 2847-2Cp 491 3-1 CP 3606-CP 2847-1 Cp 2847-2HP 491 3-1 HP 3606-HP 28471 HP 2684 2686 2689 2693 41 04 2848-1 2848-2 361 5 7308 52.030-006 600R-30 647

El 00

Model 29 11-9110-1 Model E25 Model El0 Model E5 646953 85328

85329

Reamers Rocker Shaft Support Boss Reamers Rocker Arm & Shaft Bushing Reamers (Straight Valve Cylinder) Reamer Rocker Shaft Bushing Reamer Rocker Arm Bushing Reamers Valve Guide Boss

Reamers Valve Guide Boss

Reamer (Carbide Tipped) Reamer (Carbide Tipped) Reamer (Carbide Tipped) Reamer (Carbide Tipped) Reamer (High Speed Steel) Reamer (High Speed Steel) Reamer (High Speed Steel) Reamer (High Speed Steel) Reamer (Square Shank) Reamer (Square Shank) Reamer (Square Shank) Reamer (Square Shank) Reamer (Square Shank) Plug Gage Plug Gage Plug Gage Dial Thickness Gage Precision Vernier Calipers Inside Measuring Instrument Alternator Analyzer Voltage Regulator Tester Alternator/Regulator/ Battery Tester Voltage & Circuit Tester Magneto Timing Light Timing Indicator Cold Cylinder Tester Hi-Voltage Tester Master Orifice Tool Alcor Portable Digital EGT Unit Alcor Portable Digital CHT Unit

Application Vendor


Rocker Arm Reconditioning



Rocker Arm Reconditioning



Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Valve Guide lnspection Valve Guide lnspection Valve Guide lnspection Dimensional lnspection Dimensional lnspection Dimensional lnspection Charging System Test

Charging System Test

Electrical System Test Set Engine Timing Set Engine Timing Cylinder Firing Improperly Test Ignition Cable Continuity Cylinder Compression Test Engine Test

Engine Test

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February 1989 1-20-07

Strap Wrench

Oil Filter Can Cutt

0 a. Insert threaded adader in female threads of

filter, or screw roiating bushing on male threads of filter.

For removal of oil filter, spring steel band surrounds and tightens as the handle is pulled. b. Slightly tighten cutter blade against filter Vinyl gripped handle swivels to clear obstruc- and rotate 360~. Repeat operation until tions. mounting plate section separates.

GA333 for 3" to 3-3/8" Dia. Filters c. L i i mounting plate to expose complete GA340 for 3-1 /2" to 3-7/8" Dia. Filters filter media for inspection. YA 341 for 4-1 / 8 to 4-7/16" Dia. Filters

Oil Filter Sludge lnspection lnspection of engine sludge trapped in spin-on oil filters has been a recommended practice for many years. Licensed aircraft mechanics recog- nize the value of visual inspection to aid in determining if internal engine wear or malfunction has occurred, and to inspect for metal or other contaminates within the engine oil system.

Use of the Champion CT-470 Oil Filter Can Cutter eases the opening of spin-on filters without introclucing foreign material into the filter.

Following is the recommended procedure for inspection of full flow oil filters:

3) Using a clean plastic bucket containing approximately 1 pt. clean varsol, swish filter element around in the varsol to loosen entrapped metal or other contaminant.

4) Using a clean magnet, work it around in the varsol solution. Ferrous metal particles in the solution should adhere to the magnet for inspection.

1) Remove filter from the engine and place on 5) After all ferrous metal particles have been a drain tray. Allow oil to drain through a retrieved by the magnet, pour remaining clean cloth to determine if foreign material varsol through another clean shop rag, and drains from the filter. in a bright light, any non-ferrous metals

should be detectable. 2) Using the Champion CT-470 Can Cutter,

open the filter as follows; (See photos):

Cylinder Base Nut Wrenches 3882 Series The 3882 Series Wrenches feature 112" square drive and 12-point hex sockets. The wall thickness between the hex and wrench O.D. is closely controlled for maximum strength. Approx. 16" long overall.

3882 9/16" hex 3882-3 518" hex 3882-1 7/16" hex 3882-4 314" hex

,3882-2 1 /2 " hex

3882A 9 / 16"hex 3882-3A 5/8" hex

Cylinder Base Nut Wrench Special modified 3882-type wrench, this special wrench is perfect for those occasional situations when the 3882 wrench won't fit. It's a slightly different configuration, as shown.

(3882-style shown in ,.-, ,-. phantom, to scale)

8079 911 6" hex

Cylinder Base Nut Wrench For 470 and 520 Series

The special configuration of these wrenches permits access to the cylinder base nut areas as shown. Approx. 17" long.

6'" "" 518" hex

Piston Pin Removers Piston

Size 8121 Series Design allows piston pin removal without removing adjoining cylinder. Sizes to fit Continental engines.

Body Assy. Piston Size

8121A 4-7/16" 81218 5" 8121 K (Kit) 8121C 5-118" 8121D 5-114"

Cylinder Hone Expandable racks adjust to cylinder size with universal joint action. Optional set for use on TCM cylinders.

Crankshaft Blade and Dampener Bushing Rernovers/Replacers

Back-up plates and forcing screws are rugged, heat-treated alloy steel. Be sure to keep forcing screws greased.

496% - for 518" I.D. Bushing 36U4 - for 314" I.D. Bushing 3607 - for 15/32" I.D. Bushing 3607-1 - for GTSIO-520 8060 - for .604 I.D. Bushings

1-20-1 0 February 1989

Holding Fixture Adapters Wih these adapters, you may bolt the cyiinder onto the 5221 B Fixture in order to do:

Cylinder Honing Valve Seat Insert Work (insert removal, seat cutting, insert installation).

5221-13A Adapter for Continetat 0 and 10-470 and 520 Series

Note: The originai #5221 f i u r e s require 4 additional tapped holes in rocker plate to accept the above adapters- a blueprint showing hole sizes and locations is included with adapters.

Universal Cylinder Holding Fixture 5221 8 This is a heavyduty, precision fixture manufactured to extremely close tolerances. Suitable for use on vertical mills or drill presses, it allows quick indexing of required angles for valve work.

FEATURES:

* For all Continental Engines

* F iu re indexes in all present positions required to machine valve guides.

* Locks in at these angles:

* Adapter rings are included to cover all Continental engines.

5221-1 OLA For wide deck 5221-1 1 LA For narrow deck

5221 -1 7A Cylinder Holdown Clamp Assembly (one req'd. fits all adapters). Order separately.

February 1989 1-20-1 1

Valve Guide Cleaner 122 Expandable type fits all Continental engines.

Seal Seat Cutter 8066 Per Continental Bulletin M76-24R.1

Modifies valve guide to comply with M76-24R.1 carbide-tipped cutter blades compensate for wear.

Spring Checker 7521 A Per Continental Bulletin M74-16

Check valve spring quickly and easily. Hy- draulically actuated extremely accurate readout (0-160 pounds). Includes step gauges for all required dimensions. 7521 Checker is less step gauges.

Max. spring dimensions: Ht.-2-1/2", O.D.2".

(Heat-Shrink Type)

Valve Guide Removers (Cold Force Removal Type) Tough heat-treated steel. 361 1 - .375" 1.D. Guide 2874 - .436/.438" 1.D. Guide

Valve Guide Replacers Alloy steel, heat-treated for maximum toughness.

4912 - .344" I.D. Guide 3619 - .375' I.D. Guide 2842 - .436/.438 I.D. Guide

Rocker Arm Bushing Remover/lnstafler Set 81 1 8 Driver and Pilot Ram Replaces Adapter Assy. Dia. Dia. Tool

8118 Set includes one each 81 18G, 81 18H, 81 18J. 81 18K and 8098-10 Base.

Driver and Adapter Assemblies also available individually. The 8098-10 Base must be used with 81 186, 81 1 H, 81 18J and 81 18K Driver and Adapter Assemblies.

Makes rocker arm bushing removal/installation fast and easy. All components of 81 18 set are also available individually.

Piston Ring Compressors Flexible Band Ty

X30575A

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