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~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.
AVCO LYCOMING SERVICE TOOLS
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
AVCO LYCOMING SERVICE TOOLS
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
AVCO LYCOMING SERVICE TOOLS
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
AVCO LYCOMING SERVICE TOOLS
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
AVCO LYCOMING SERVICE TOOLS
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
AVCO LYCOMING SERVICE TOOLS
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
2.2970/2.2975 bearing bores
17 64530-11 Sleeve, Tapered, Connecting Rod Parallelism and squareness gage. Detail of 64530. Used on
2.4305/2.4310 bearing bores
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,
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. ToolNo. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. ToolNo. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
222 ST-14 Reamer, Hollow Dowel Holes in Reduction Gear .010 ols All GO and GSO-480 engines with
flange propeller shaft
223 ST-15 Reamer, Hollow Dowel Holes in Reduction Gear .020 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
AVCO LYCOMING SERVICE TOOLS
Ref. ToolNo. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
252 ST-51-1 Cutter, Valve Seat (Intake) (.010 ols) All cylinder heads with 2.281 valve seat hole
253 ST-51-2 Cutter, Valve Seat (Intake) (.020 ols)- All cylinder heads with 2.281 valve seat hole
254 ST-51-3 Cutter, Valve Seat (Intake) (.030 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
257 ST-52-3 Cutter, Valve Seat (Exhaust) (.030 ols)- All cylinder heads with 1.734 valve seat hole
258 ST-53-1 Cutter, Valve Seat (Intake) (.010 ols) All cylinder heads with 2.074 valve seat hole
259 ST-53-2 Cutter, Valve Seat (Intake) (.020 ols) All cylinder heads with 2.074 valve seat hole
260 ST-53-3 Cutter, Valve Seat (Intake) (.030 ols) All cylinder heads with 2.074 valve seat hole
261 ST-54-1 Cutter, Valve Seat (Exhaust) (.010 ols)- All cylinder heads with 1.927 valve seat hole
262 ST-54-2 Cutter, Valve Seat (Exhaust) (.020 ols) All cylinder heads with 1.927 valve seat hole
263 ST-54-3 Cutter, Valve Seat (Exhaust) (.030 ols)- All cylinder heads with 1.927 valve seat hole
264 ST-55-1 Cutter, Valve Seat (Intake) (.010 ols) All cylinder heads with 2.160 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
268 ST-56-2 Cutter, Valve Seat (Intake) (.020 ols) All cylinder heads with 1.919 valve seat hole
269 ST-56-3 Cutter, Valve Seat (Intake) (.030 ols)- All cylinder heads with 1.919 valve seat hole
270 ST-57-1 Cutter, Valve Seat (Intake) (.010 ols)- All cylinder heads with 2.0885 valve seat hole
271 ST-57-2 Cutter, Valve Seat (Intake) (.020 ols)- All cylinder heads with 2.0885 valve seat hole
272 ST-57-3 Cutter, Valve Seat (Intake) (.030 ols) All cylinder heads with 2.0885 valve seat hole
273 ST-58-1 Cutter, Valve Seat (Exhaust) (.010 o/s)- All cylinder heads with 1.995 valve seat hole
274 ST-58-2 Cutter, Valve Seat (Exhaust) (.020 ols)- 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
AVCO LYCOMING SERVICE TOOLS
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
284 ST-66-4 Pilot, Valve Seat Cutter (.040 o/s)- All cylinder heads with .5913 valve guide hole
285 ST-66-5 Pilot, Valve Seat Cutter (.005 ols)- All cylinder heads with .5913 valve guide hole
286 ST-67 Pilot, Valve Seat Cutter (Standard)- All cylinder heads with .6613 valve guide hole
287 ST-67-1 Pilot, Valve Seat Cutter (.010 ols)- All cylinder heads with .6613 valve guide hole
288 ST-67-2 Pilot, Valve Seat Cutter (.020 ols)- All cylinder heads with .6613 valve guide hole
289 ST-67-3 Pilot, Valve Seat Cutter (.030 ols)- 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
293 ST-68-1 Pilot, Valve Seat Cutter (.010 ols)- All cylinder heads with .6247 valve guide hole
294 ST-68-2 Pilot, Valve Seat Cutter (.020 ols)- All cylinder heads with .6247 valve guide hole
295 ST-68-3 Pilot, Valve Seat Cutter (.030 ols)- All cylinder heads with .6247 valve guide hole
296 ST-68-4 Pilot, Valve Seat Cutter (.040 ols)- All cylinder heads with .6247 valve guide hole
297 ST-68-5 Pilot, Valve Seat Cutter (.005 ols)- 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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
443 ST-257-2 Pilot, Valve Seat Cutter (.020 o/s)- All cylinder heads with .6933 valve guide hole
444 ST-257-3 Pilot, Valve Seat Cutter (.030 ols) All cylinder heads with .6933 valve guide hole
445 ST-257-4 Pilot, Valve Seat Cutter (.040 ols) 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
447 ST-258-1 Reamer, Valve Guide OD (Exhaust) (.010 ols)- All valve guides with .69331.6943 valve guidehole in cylinder head
448 ST-258-2 Reamer, Valve Guide OD (Exhaust) (.020 o/s)- All valve guides with .69331.6943 valve guidehole in cylinder head
449 ST-258-3 Reamer, Valve Guide OD (Exhaust) (.030 ols)- All valve guides with .69331.6943 valve guidehole in cylinder head
450 ST-258-4 Reamer, Valve Guide OD (Exhaust) (.040 ols)- 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
456 ST-259-4 Gage, Plug, Valve Guide OD (Exhaust) (.040 ols)- All valve guides with .69331.6943 valve guidehole in cylinder head
457 ST-259-5 Gage, Plug, Valve Guide OD (Exhaust) (.005 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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
Ref. Tool No. Nomenclature and Description
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
AVCO LYCOMING SERVICE TOOLS
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 head570 ST-429-3 Gage, Plug Valve Guide OD (Intake and Exhaust) (.030 ols) All valve guides with .59131.5923
valve guide hole in cylinder head571 ST-429-4 Gage, Plug Valve Guide OD (Intake and Exhaust) (.040 ols) All valve guides with .59131.5923
valve guide hole in cylinder head572 ST-429-5 Gage, Plug Valve Guide OD (Intake and Exhaust) (.005 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
AVCO LYCOMING SERVICE TOOLS
Ref. ToolNo. Nomenclature and Description
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
580 ST-431-2 Gage, Plug Valve Guide OD (Exhaust) (.020 ols)- 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
583 ST-431-5 Gage, Plug Valve Guide OD (Exhaust) (.005 ols)- All valve guides with .66131.6623 valve guidehole in cylinder head
584 ST-432-1 Reamer, Valve Guide OD (Exhaust) (.010 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
586 ST-432-3 Reamer, Valve Guide OD (Exhaust) (.030 ols)- All valve guides with .66131.6623 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
Tool No. Name of Publication No.
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-30 Wrench S.I. 1069
ST-40 Fixture S.I. 1073
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-51 Cutter S.I. 1092
ST-52 Cutter S.I. 1092
ST-53 Cutter S.I. 1092
ST-54 Cutter S.I. 1092
ST-55 Cutter S.I. 1092
ST-56 Cutter S.I. 1092
ST-57 Cutter S.I. 1092
ST-58 Cutter S.I. 1092
ST-62 Driver S.I. 1092
ST-63 Adapter S.I. 1092
ST-64 Drift S.I. 1092
ST-65 Drift S.I. 1092
ST-66 Pilot S.I. 1092
ST-67 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-83 Wrench S.I. 1029
ST-84 Wrench S.I. 1029
ST-91 Cage S.I. 1143
ST-92 Driver S.I. 1143
38
SERVICE PUBLICATION CROSS REFERENCE INDEX (CONT.)
See Latest Revision
Tool No. Name of Publication No.
ST-93 Fixture S.I. 1143
ST-94 Gage S.I. 1143
ST-95 Weight S.I. 1143
ST-96 Arbor S.I. 1143
ST-105 Fixture S.I. 1073
ST-107 Wrench S.I. 1098
ST-112 Pilot S.I. 1117
ST-113-1 Reamer S.I. 1425
ST-113-2 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-144 Fixture S.I. 1112
ST-145 Cutter S.I. 1112
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-150 Reamer S.I. 1114
ST-155 Gage S.I. 1425
ST-156 Stop Collar S.I. 1112, S.I. 1123
ST-157 Drift S.I. 1112
ST-158 Puller ("V" Pulley) S.I. 1283
ST-168 Driver S.I. 1145
ST-169 Fixture S.I. 1145
ST-170 Drift S.I. 1145
ST-171 Tool S.I. 1145
ST-172 Puller Set S.L. L195
ST-179 Fixture S.I. 1136
ST-180 Reamer S.I. 1136
ST-181 Reamer S.I. 1136
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-210 Reamer S.I. 1142
ST-211 Reamer S.I. 1142
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-227 Fixture S.I. 1168
ST-228 Counterbore S.I. 1168
ST-229 Pilot S.I. 1168
ST-230 Drive S.I. 1168
39
SERVICE PUBLICATION CROSS REFERENCE INDEX (CONT.)
See Latest RevisionTool No. Name of Publication No.
ST-231 Reamer S.I. 1168
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-246 Reamer S.I. 1172
ST-248 Countersink S.I. 1172ST-249 Drift S.I. 1172
ST-250 Fixture S.I. 1092
ST-252 Fixture S.I. 1112
ST-253 Driver S.I. 1168
ST-254 Reamer S.I. 1209
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-267 Reamer S.I. 1200
ST-269 Cutter S.I. 1112
ST-270 Plate S.I. 1112, S.I. 1123ST-271 Puller S.I. 1123, S.I. 1290ST-273 Countersink S.I. 1168
ST-274 Counterbore S.I. 1168
ST-275 Driver S.I. 1168
ST-276 Drift S.I. 1168ST-277 Fixture S.I. 1168
ST-280 Fixture S.I. 1142
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-299-3 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
SERVICE PUBLICATION CROSS REFERENCE INDEX (CONT.)
See Latest RevisionTool No. Name of Publication No.
ST-319 Fixture S.I. 1211
ST-322 Wrench S.I. 1029
ST-323 Counterbore S.I. 1123
ST-324 Pilot S.I. 1123
ST-325 Stop Collar S.I. 1123
ST-327 Plate S.I. 1123
ST-328-2 Reamer S.I. 1123
ST-329 Fixture S.I. 1292
ST-329-1 Fixture S.I. 1292
ST-329-2 Stand S.I. 1292
ST-331 Gage S.I. 1123
ST-332 Driver 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-357 Fixture S.I. 1297
ST-360 Reamers S.I. 1225, S.B. 326
ST-361 Shroud Tube Tool S.I. 1297
ST-362 Reamer S.I. 1297
ST-363 Cutter S.I. 1297ST-364 Fixture S.I. 1297ST-365 Flaring Tool S.I. 1297
ST-366-5 Reamer S.I. 1290
ST-366-1 Reamer S.I. 1290
ST-367 Wrench S.I. 1029
ST-372 Drill Jig S.I. 1292
ST-376 Holder S.I. 1297
ST-377 Fixture S.I. 1312
ST-378 Driver S.I. 1312
ST-379 Drill S.I. 1312
ST-380 Reamer S.I. 1312
ST-383 Oil Seal Tool S.I. 1303, S.I. 1324
ST-387 Fixture S.I. 1011
ST-388 Reamer, Guide and Stop S.I. 1316
ST-389 Separator Tool S.I. 1123
ST-394 Wrench S.I. 1029
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-436 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)
64511 Gage, Plug Valve Guide OD (Replaced by ST-429-2)
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)
64522 Wrench, Cylinder Base Nut (Replaced by ST-394)
64523 Wrench, Cylinder Base Nut (Replaced by ST-367)
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)
64572 Wrench, Cylinder Base Nut (Replaced by ST-394)
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)
64639 Gage, Plug Valve Guide OD (Replaced by ST-429-3)
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)
64678-4 Reamer, Valve Guide OD (Replaced by ST-430-2)
64678-5 Reamer, Valve Guide OD (Replaced by ST-430-3)
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)
64893 Counterbore Valve Seat Removal (Intake) (See latest revision of S.I. 1092)
64694 Counterbore Valve Seat Removal (Intake) (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.)
Tool No. Description
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
OBSOLETE SERVICE TOOLS (CONT.)
Tool No. Description
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
OBSOLETE SERVICE TOOLS (CONT.)
Tool No. Description
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)
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
Cause Solution Procedure for Solution
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
Cause Solution Procedure for Solution
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
Cause Solution Procedure for Solution
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
Cause Solution Procedure for Solution
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
Cause Solution Procedure for Solution
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
Cause Solution Procedure for Solution
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
Cause Solution Procedure for Solution
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
Cause Solution Procedure for Solution
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
Cause Solution Procedure for Solution
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
Cause Solution Procedure for Solution
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
Cause Solution Procedure for Solution
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)
Cause Solution Procedure for Solution
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
Cause Solution Procedure for Solution
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
Cause Solution Procedure for Solution
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.
34J/
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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