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october 2000 - Red Sky Ventures

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1. 1 3 1 2 1 3 1 3 Definitioniof TEMS 1 3 1 4 Manual 1 3 1 5 Related Publications 2 1 4 1 6 Service Documents n Dp 1 5 1 7 Service Reports and 1 5 1 8 Engine Design Features 1 7 MAY 1998 1 1 1 2 INTENTIONALLY LEFT BLANK 1 3 INTRODUCTION This overhaul manual and the publications listed in section 1 5 Related Publications contain the information necessary to overhaul an aircraft engine when it reaches it s manufacturer s specified time between overhaul TBO For a list of chapters contained in this manual refer to the Chapter Index on page x For a list of subject matter figures and tables contained in each chapter see the first page of each chapter The pages figures and tables contained in this publication are numbered consecutively This manual covers the 10 550 and engines SCOPE This publication contains the information necessary to disassemble clean inspect repair and replace reassemble adjust and test the above model engines DEFINITION OF TERMS In this manual front rear left and right refer to the engine as viewed
2. 17 14 17 6 Crankshaft Hanger Blade Bushing Replacement 17 16 17 7 Counterweight Inspection Repair and Installation 17 18 17 8 Control Plug Installation 17 19 17 9 Control Plug Leak Test 17 20 17 1410 Crankshaft Leak ott eet p estt 17 21 17 11 Helix Pattern 17 22 17 12 Old Style Camshaft Plug Installation 17 23 17 13 Connecting Rod Position 17 28 17 14 Seal Installation 17 28 OCTOBER 2000 17 1 17 1 CAMSHAFT AND CRANKSHAFT DISASSEMBLY CAMSHAFT 1 See Figure 17 1A Camshaft Assembly Old Style Remove the governor drive gear 7 and woodruff key 6 Cut and remove lockwire from bolts 5 Remove four bolts 5 and camshaft gear 4 Remove rear 1 4 18 brass plug Using a 30 inch long section of 3 8 diameter round bar stock and a non marring hammer carefully drive front camshaft plug out The camshaft must now be magnetic particle inspected in accordance with section 6 9 During magneflux inspection pay particular attention to front plug and keyway area Camshafts with evidence of cracks must be discarded WARNING Failure to replace camshaft plugs at reassembly will result in loss of
3. 9 18 9 6A Fuel Nozzle 0 550 9 19 9 6B Fuel Nozzle 10 550 N P 9 19 9 7 Fuel Pump Drive Coupling Fits amp Limits 9 21 9 8 General Lever Bushing Replacement 9 22 9 9 General Sealant Application 9 23 OCTOBER 2000 9 1 9 1A FUEL INJECTION SYSTEM REMOVAL AND DISASSEMBLY See Figure 9 1 1 Mark each fuel injection line 19 through 24 with its cylinder number to facilitate installation WARNING Fuel injection lines must not be bent or deformed Discard and replace bent chafed or deformed fuel injection lines 2 Fuel injection line removal a Disconnect fuel lines 19 through 24 from fuel nozzles 25 b Disconnect other end of fuel lines from fuel manifold valve assembly 18 and remove fuel lines from engine 3 Fuel Nozzle Removal a Remove fuel nozzles 25 from each cylinder 4 Remove fuel hoses 35 36 from fuel control unit and fuel pump Remove fuel hose 35 from fuel control unit and manifold valve Discard fuel hoses 35 36 5 Remove the throttle and fuel control unit in accordance with the airframe STC holders instructions Place the throttle and fuel control unit in a clean protected area until it is to be ov
4. 14 13 Oil Sump and Suction Tube Remowval 14 14 Lubrication System Component Cleaning 14 15 Lubrication System 14 16 Lubrication System Component Repair amp Replacement 14 21 Lubrication System 2 14 23 PAGE Oil Pump Assembly FOR 10 550 A A2B A3B 10 550 B B1F B2F B3F B4F B5F B6F B9B B11B B14B B15B B16B B19B B21B B23B B29B B30B B32B B35B B37B 10 550 C C1F C2F CAU C3F C6F C8B C11B C12B C13B C15B C18B C19B C25B C26B C27B C28B 29 C30B een o tutte Sete eed oe ieee 14 3 Oil Pump Assembly For 10 550 4 A5B AGB A7B 10 550 B5F B12F B13F B17B B18B 20 B22B B24B B25B 26 B27B B28B B31B B34B B36B 10 550 C16B C17B C21B C22B 10 550 G1B G2B G4B 10550 N N1B 10 550 10 550 14 5 Oil Pump Assembly For 10 550 5 G6B 10550 NB Cep oda ida Mcd eere ee e 14 7 Oil Cooler Assembly For 10 550 10 550 10 550 G G1B G2B GAB 14 8 Oil Cooler Assembly For 10 550 14 9 Oil Cooler Assembly For 10 550 G5B G6B 10 550 10 550 P 10 550 14 10 Oil Sump I0 5505 14 11 Oil Sump 10 550 B
5. WWW SSS MOSH WWW RS lt N NEW BUSHINGS MUST NOT PROTRUDE BEYOND SHAFT BOSS FIGURE 10 3 THROTTLE BODY FITS AND LIMITS 10 550 amp 10 10 MAY 1998 10 5 10 6 INDUCTION SYSTEM REPAIR AND REPLACEMENT Any induction system component worn beyond new parts limits or failing to meet the inspection criteria in section 10 4 must be replaced unless repair is possible with the following instructions 1 Throttle assemblies may be re bushed providing the throttle body bushing bore is not damaged during bushing removal Remove the throttle body bushings using the correct size tool and an arbor press Inspect the bushing bore The bushing bore maximum diameter must not exceed 0 4385 when old bushing is removed After new bushing is installed its inside diameter must be 3745 min to 3760 max 2 The throttle lever bushings as used must be replaced during engine overhaul Place the lever bushing over a ring that will allow the bushing to pass through Using the correct size drift and an arbor press remove the old bushing Inspect the lever bushing bore for a diameter of 249 251 Discard levers that exceed the specified dimension Using the correct size drift and an arbor press install the new bushing in accordance with the specifications in Figure 10 4 The lever and bushing must have a press fit of 007T to 013T CHAMFERED SIDE MUST HAVE A PRESS FIT OF 007T TO
6. 6 5 5 Cotter Pin Procedure tet e 5 5 Application 5 6 Installation Of 5 6 PAGE General Lockwire 5 3 General Lockwire 2 44 5 4 Tab Washer Installation 5 5 General Cotter Pin Installation 5 6 5 1 GENERAL To facilitate and insure proper reinstallation tag or mark all parts and hardware as they are removed or disassembled Tag any unserviceable parts or units for investigation and possible repair Take extreme care to prevent lockwire nuts washers dirt etc from entering the engine on or off the aircraft Make use of protective caps plugs and covers to insure openings are unexposed CAUTION Dust caps used to protect open lines must be installed OVER the tube ends and NOT IN the tube ends Flow through the lines will be blocked if lines are inadvertently installed with the dust caps in the tube ends If anything is dropped into the engine work must be stopped immediately and the item removed Insure all parts are thoroughly clean and lubricated as specified before assembling All lockwire and cotter pins must fit snugly in holes drilled in sp
7. 15 8 15 6 Cylinder Assembly Repair and Replacement 15 24 15 7 Cylinder and Piston Sub Assembly 15 43 FIGURE PAGE 15 1A Cylinder and Piston Assembly for IO 550 A B amp C 15 3 15 1A1 Connecting Rod 15 3 15 1B Cylinder and Piston Assembly for 550 15 5 15 2 Cylinder INSpection oett ton e inta deett ens 15 10 15 3 Cylinder Stud Setting Heights 15 11 15 4A Cylinder Fits and Limits for IO 550 A B amp C 15 16 15 4A1 Cylinder Dimensions for IO 550 A B amp 15 17 15 4B Cylinder Fits and Limits for IO 550 G N P R 15 21 15 4B1 Cylinder Dimensions for IO 550 G N PR 15 22 15 5 Intake Valve Seat 15 29 15 5B Exhaust Valve Seat 15 29 15 6A Removing Spark Plug Hole Helical Insert 15 32 15 6B Installing Spark Plug Hole Helical Insert 15 32 15 6C Expanding Spark Plug Hole Helical Insert 15 32 15 6D Rocker Shaft Retention Improvement 15 34 15 6E Cylinder Identification 15 34 15 7A Old Style Rocker Arm Bushing Replacement 15 35 15 7B Style
8. J NOTE ITEMS 1 THROUGH 6 FOR 10 550 P SEE FIGURE 14 3B Ij FOR 10 550 ENGINE MOUNTS FIGURE 16 3B ENGINE MOUNTS CRANKSHAFT SEAL amp GOVERNOR COVER I0 550 G N P R 1 Mount Engine 7 Gasket 13 Retainer 2 Mount Engine 8 Cover Governor Pad 14 Bolt 3 Insert 9 Spacer 15 Plate ID 4 Washer 10 Washer 16 Screw Drive 5 Screw 11 Washer Lock 6 Screw 12 Nut 16 8 OCTOBER 2000 16 4 CRANKCASE STUDDING DISASSEMBLY See Figure 6 4 ae cL 1 Crankcase studs dowels and helical inserts should only be removed for replacement when they are found to be loose corroded pitted or damaged Remove starter shaft gear roller bearing 2 Crankcase plugs 20 23 through 27 and 32 must be removed to allow pressure flushing of crankcase 4 Do not attempt to remove oil squirt nozzles 29 Field replacement is not possible NOTE When plugs are removed they must be identified by tagging During crankcase sub assembly all plugs must be placed back in the same crankcase location from which they were removed to prevent oil pressure loss FIGURE 16 4 CRANKCASE STUDDING ASSEMBLY Crankcase 8 Stud 15 Stud 22 Stud 29 Nozzle Squirt Bearing Needle 9 Stud 16 Stud 23 Plug 30 Washer Plain Dowel 10 Stud 17 Stud 24 Plug 31 Bolt Helical Coil 11 Stud 18 Stud 25 Plug 32 Plug Helical Coil 12 Stud 19 Stud 26 Plug Helical Coil 13 Stud 20 Plug 27 Plug Stud 14 Stud 21 Stud 28 Gasket
9. 13 15 13 5A Shaftgear Drum Dimensions 13 16 13 5B Worm Wheel Drum Dimensions 13 16 13 6 Starter Adapter Needle Bearing Installer 13 18 13 7 Worm Wheel Roller Bearing Installation 13 20 13 8A Threading Diagram For Starter Adapter Cover 13 21 13 8B Seal Installation 13 22 OCTOBER 2000 13 1 13 1A STARTER AND STARTER ADAPTER REMOVAL See Figure 13 1A 1 Remove attaching parts 31 32 and pull starter 30 from starter adapter Remove and discard o ring 29 Place the starter motor in a clean protected area until it is ready to be overhauled 2 Remove four sets of attaching parts 2 3 4 two on outside of crankcase between cylinder No 1 and starter and two on cover assembly remove starter adapter assembly from crankcase Discard lock washers 3 Place the starter adapter in a clean protected area until it is ready to be overhauled Nomenclature for Figure 13 1A Gasket Washer Plain Washer Lock Nut Adapter Housing Stud Stud Stud Stud 10 Bearing Needle 11 Gear Worm Wheel OCAONOARWN gt 13 2 MAY 1998 Bearing Needle Shaftgear Spring Clutch Washer Tab Screw Special Bearing Ball Ring Retainer Shaft Spring Key Woodruff Gear Worm Bearing Ball Ring Ret
10. 2 Install gasket 1 on crankcase CAUTION Sealant must be applied sparingly to prevent contamination of the engine oil system 3 Lubricate teeth on starter shaftgear with clean 50 weight aviation engine oil and mesh with crankshaft gear as starter adapter is placed in position Seat adapter against gasket Secure adapter assembly to crankcase with washers 2 28 new lock washers 3 and nuts 4 29 Torque 5 16 24 nuts to 180 220 inch pounds Torque 3 8 16 nuts to 200 220 inch pounds 4 Lubricate o ring 47 with clean 50 wt aviation engine oil and install on starter pilot Turn starter shaft until tongue aligns with worm drive shaft slot Mount starter 48 and secure with washers 49 and nuts 50 Torque nuts 50 to 200 220 inch pounds 18 18 OCTOBER 2000 18 9 OPTIONAL COMPRESSOR BRACKET 1 If optional air conditioning compressor is to be utilized see Figure 13 1 Remove nut 46 and spacer 45 Install drive sheave in place of spacer 45 Discard spacer 45 Temporarily secure drive sheave with nut 46 Do not torque at this time See Figure 16 1A Remove nut 14 washer 13 and spacer 12 Inspect o ring 11 and replace if necessary See Figure 11 1 Install bracket 1 on crankcase upper hole to through bolt See Figure 16 1 Loosely install washer 13 and nut 14 Discard spacer 12 See Figure 11 1 Align lower bracket bolt holes with crankcase bolt bosses Install two each kit supplied washers 17 an
11. 22 4 0012 10 9 Induction System Inspection 10 9 Induction System Component Repair And Replacement 10 11 Induction System 10 11 Induction System For 10 550 10 2 Induction System For 10 550 10 3 Induction System For 10 550 10 4 Induction System For 10 550 P amp 10 5 Throttle Assembly 10 550 A amp 10 6 Throttle Assembly 10 550 C 10 7 Throttle Assembly 10 550 amp 10 8 Throttle Body Fits amp 10 10 General Lever Bushing 10 11 Staking Throttle Plate Screws 10 13 Staking Tool SpecificaUors 10 14 General Link Rod 4 2 2 10 17 OCTOBER 2000 10 1 10 1A INDUCTION SYSTEM REMOVAL AND DISASSEMBLY See Figure 10 1 1 Remove duct 24 Remove nut 23 washer 22 bolts 20 bracket 19 and spacers 21 Discard duct 24 Loosen clamps 8 and remove
12. 10 4 INDUCTION SYSTEM INSPECTION VISUAL INSPECTION 1 The visual inspection must be performed in accordance with the instructions in section 6 8 Visual Inspection and the following 2 Visually inspect induction tubes risers and intake manifold for cracks dents and chafing Check tube ends and flanges on a surface plate for warpage and out of roundness Components exhibiting cracks dents chafing warpage or out of roundness must be discarded Inspect tapped holes and helical coils for distorted or stripped threads Inspect all induction system clamps for cracks corrosion and damaged screw threads The screw mechanism must operate without any binding Inspect the clamp for broken loose rivets or spot welds Clamps exhibiting any of the above conditions must be discarded FLUORESCENT PENETRANT INSPECTION Fluorescent penetrant inspection must be performed on all aluminum alloy induction system components by a certified technician in accordance with the instructions in section 6 12 Fluorescent Penetrant Inspection MAY 1998 10 9 DIMENSIONAL INSPECTION The following new parts limits must be used for dimensional inspection Components that do not meet the following specifications must be discarded All components must be thoroughly cleaned and air dried prior to dimensional inspection NEW PARTS DESCRIPTION MIN MAX Diameter 0 0020T 0 0040T Diameter 0 0005L 0 0025L Clearance 0 0010L 0 0060L
13. 4 Coat oil pump gear cavity flange with 3 aviation permatex Apply silk thread to oil pump housing flange as shown in Figure 14 9 Apply TCM gasket maker to the portion of the tach drive housing that will mate with the oil pump housing where the Permatex and silk thread is applied Install electrical tach drive housing on oil pump making sure tach gear shaft and bevel gear properly mesh As tach drive housing is being installed make sure silk thread is not displaced Secure using washers 22 new lock washers 23 amp nuts 24 Torque nuts 24 to 90 110 inch pounds 5 Using new gaskets 26 31 install covers 27 32 secure with washers 28 33 new lock washers 24 29 amp nuts 23 screws 30 Torque nuts 23 to 75 85 inch pounds torque Torque screws 30 to 21 25 inch pounds torque 6 Oil pump filter adapter and oil filter assembly will be installed during final engine assembly Cover components and store in a clean protected area until final assembly MAY 1998 14 23 OIL PUMP FOR 10 550 A4B A5B A6B A7B 10 550 B5F B12F B13F B17B B18B B20B B22B B24B B25B B26B B27B B28B B31B B34B B36B 10 550 16 C17B C21B C22B 10 550 G1B G2B G4B 10 550 10 550 10 550 1 See Figure 14 1B Oil Pump Install oil pump housing 2 in a suitable fixture Lubricate cavity gear contact areas and oil pump gears 4 15 with clean Molyshield grease Install oil pump drive and driven gears in oil pump
14. BRAKE HORSEPOWER FULL THROTTLE HORSEPOWER AT ZERO RAM 280 aH 280 LTE 260 gt H 260 D AE 240 H 240 220 44 220 200 200 180 H 180 160 H 160 D 140 H 140 H 120 H 120 100 H 100 80 H 80 60 17 18 19 20 21 22 23 24 25 26 27 28 29 30 ABSOLUTE DRY MANIFOLD PRESSURE IN FIGURE 19 16 CONSTANT SPEED SEA LEVEL PERFORMANCE 10 550 MAY 1998 BRAKE HORSEPOWER 19 27 FUEL FLOW LBS HR e e T e e e e e e e v v N i5 25 Rich of Peak 280 Peak EGT Minimum BSFC 50 Lean of Peak 260 200 220 240 BRAKE HORSEPOWER 10 550 G FUEL FLOW VS BRAKE HORSEPOWER 180 LLL FIGURE 19 17 FUEL FLOW VS OBSERVED BRAKE HORSEPOWER 10 550 160 140 19 28 MAY 1998 2 o gt x D o X 2 X Lu Te 2 METERED FUEL PRESSURE PSI x N e o lt N e N N vr v T 25 psi 140 160 tolerance 25 120 0 _ NELLE _ _ 100 EU FUEL FLOW LBS HR i rx As manifold valve and without influ
15. Fuel pressure gauge at same elevation As manifold valve and without influence of differential fuel head in gauge line Note this data is approximate with EE N N e N N N lt um m _ FIGURE 19 21 FUEL FLOW VS METERED PRESSURE IO 550 N R 19 32 OCTOBER 2000 40 60 80 100 120 140 160 FUEL FLOW LBS HR 20 OPERATIONAL TEST FORM Aircraft Make amp Model Aircraft Registration Engine Model Engine Position Left Right Front Engine Serial Number Engine Total Time New Overhaul Fuel System Adjustment Record engine specifications and actual gauge indications F 8 EE Pressure Altitude Set CHT altimeter to 29 92 Hg Spec Actual Spec Actual Spec Actual Remarks Idle RPM mixture rise magneto drop etc Signature 19 33 MAY 1998 19 17 OVERHAUL TEST RUN STANDARD ACCEPTANCE TEST PERIOD RPM 1200 25 RPM 1600 25 RPM 2100 25 RPM 2400 25 RPM Rated Power RPM 75 Power RPM Check Fuel and Oil Pressures Check Temperatures Idle RPM cooling period Re check idle adjustments Stop engine and perform leak check 15 75 Power RPM 75 Power RPM NOTES one check on performance of each magneto alone at 2100 RPM Clear spark plugs by operating with both magnetos on for a few seconds between ch
16. Full Throttle Gallons Per Hour 24 2 25 6 24 9 26 6 25 9 27 3 21 3 22 1 25 6 27 3 Metered Fuel Pressure at Full Throttle 17 7 20 0 16 5 18 4 17 6 19 6 14 7 16 0 19 0 21 3 mee Unmetered 8 0 10 0 Throttle Unmetered 32 0 36 0 29 2 36 2 31 6 37 8 22 0 26 0 28 0 32 0 245004942 25 50 240 F 100 10 550 N 8 Sump Capacity Quarts 12 12 12 10 550 10 10 550 12 2 4190RPM SO Magneto Drop 150 RPM Max Magneto Spread 50 RPM Cylinder Head Temperature with Bayonet Thermocouple Limit 460 F Proceed to standard acceptance and oil consumption determination as required for engine overhaul NOTE Test flight and documentation of all test flight operating parameters is MANDATORY before engine can be returned to service See section 19 20 Test Flight OCTOBER 2000 19 13 Table 19 2 Compensation Table For Static Ground Setup Metered Pressure Vs RPM 70 F Fuel Temperature Corrected Metered Static Engine RPM Correction Factor Pressure Metered Pressure x Correction Factor NOTE All values are approximate Variations may be noticed due to engine and installation specific influences Example 10 550 Maximum Rated RPM 2700 Metered Fuel Pressure Limits 16 5 18 4 If maximum static engine RPM 2640 60 RPM use Correction Factor 973 Metered Fuel Pressure Limits x Correction Factor Corrected Metered Pressure Limits 16 5 x 973 16 0545 Minimum Metered Pressure Limit 264
17. MAY 1998 16 9 16 5 CRANKCASE AND ASSOCIATED PARTS CLEANING 16 10 1 The crankcase halves must be cleaned in accordance with the instructions in section 6 7 General Cleaning and the following special instructions All through bolts bushings bearings thrust washers gaskets packings o rings seals lock washers and self locking nuts removed from the crankcase must be replaced 100 at overhaul Cleaning these parts is not required The crankcase oil passages must be pressure flushed with mineral spirit solvent and inspected with the aid of a flashlight The crankcase oil squirt nozzles must be flushed with mineral spirit solvent to insure they are not obstructed Use caution when flushing the oil squirt nozzles because they are not field replaceable The engine mount brackets must be cleaned using mineral spirit solvent If the crankcase castings are immersed in an alkaline bath they must be sprayed with steam to remove all traces of alkaline After the castings dry inspect them for any alkaline residues If necessary re spray with steam to remove remaining residue The crankcase and all oil passages must be thoroughly flushed with mineral spirit solvent after any alkaline cleaning process has been used CAUTION Alkaline cleaning solutions will cause corrosion to metals if not completely removed MAY 1998 16 6 CRANKCASE AND ASSOCIATED PARTS INSPECTION VISUAL INSPECTION The crankcase and associated components
18. Start the engine in accordance with the airframe manufacturer s Airplane Flight Manual AFM Operate the engine at 750 RPM for one minute gradually increasing RPM to 1000 RPM in three minutes Check the magneto circuit for proper grounding prior to a normal shut down Allow the engine to cool adequately and make a visual inspection for any discrepancies If engine exhibits any discrepancies return to the applicable chapter to correct the discrepancy All discrepancies must be corrected prior to engine adjustment Oil Pressure Check If no oil pressure is noted within 30 seconds shut engine down and investigate CAUTION Operation of engine without oil pressure may result in engine malfunction or failure When propeller stops rotating place ignition switch master switch and fuel selector in off position OIL PRESSURE ADJUSTMENT The adjusting screw is turned clockwise to increase oil pressure and counterclockwise to decrease oil pressure With normal operating oil temperature adjust oil pressure to 10 pounds per square inch idle minimum 30 60 pounds per square inch normal operation Torque locknut and safety as required OIL PUMP OIL PRESSURE ADJUSTMENT FIGURE 19 1 OIL PRESSURE ADJUSTMENT MAY 1998 19 5 19 16 Fuel System Adjustment WARNING The procedures and values provided apply to TCM fuel injected engines that have not been modified from their type design Refer to supplemental type certificate STC holder in
19. e N e N v v v e 3 psi tolerance 3 NATRE AARE BRENNEN INEE HAH N e N Fuel pressure gauge at same elevation As manifold valve and without influence of differential fuel head in gauge line Note this data is approximate with POCO TTT TTT TT TT FIGURE 19 10 FUEL FLOW VS METERED PRESSURE 550 MAY 1998 180 160 140 120 100 80 60 40 20 FUEL FLOW LBS HR 19 21 199 epniniv 00071 0006 0000 00011 0000 0006 0008 0001 0009 0006 0007 00 2 IINA g 0SS Ol Heyo Buruee epnyniv 000 0002 0001 e N jen4 FIGURE 19 11 AUTO LEANING SCHEDULE 550 WITH lt ALTITUDE COMPENSATING FUEL PUMP 49 22 OCTOBER 2000 BRAKE HORSEPOWER n FULL THROTTLE HORSEPOWER AT ZERO RAM A E a A a d E E 2 a A 54 rE TN AN ANT TE 17 18 19 20 21 22 23 24 25 26 27 28 29 30 ABSOLUTE DRY MANIFOLD PRESSURE HG FIGURE 19 12 SEA LEVEL PERFORMANCE 10 550 MAY 1998 BRAKE HORSEPOWER 19 23 FUEL FLOW LBS HR YAMOdASHOH on
20. 210 inch pounds Safety wire plug in accordance with section 5 2 Lockwire Procedure Install new felt pad 13 OIL SUMP IO 550 G amp P See Figure 14 3C Coat oil sump flange with TCM gasket sealant 642188 1 Install new gasket 9 and oil sump 10 on crankcase If using beaded style gasket 9 install it with beaded side toward sump Secure oil sump with attaching hardware 11 through 13 install new gasket 14 splitline toward sump and plug 8 Using the sequence in Figure 18 10 torque bolts 13 to 83 inch pounds preliminary torque Torque bolts 13 to 155 175 inch final torque Torque plug 8 to 190 210 inch pounds Safety wire plug in accordance with section 5 2 Lockwire Procedure OIL PUMP 10 550 A 2 10 550 B1F B2F B3F B4F B5F B6F B9B B11B B14B B15B B16B B19B B21B B23B B29B B30B B32B B35B B37B 10 550 C C2F C2U C3F C6F C8B C11B 12 C13B C15B C18B C19B C25B C26B C27B C28B C29B C30B See Figure 14 1A 1 Remove plug 42 gasket 41 from protruding end of oil suction tube 2 Apply TCM gasket maker to silk thread and split line of crankcase at oil pump bore Place silk thread ends into split line of oil pump bore 3 Place new oil pump gasket 20 and oil pump assembly 1 on crankcase studs Secure with attaching hardware 22 23 24 4 Torque nuts 24 to 90 110 inch pounds Install new gasket 34 and oil filter adapter 36 o
21. 3814384 87 2 GOilCoolerMountPad 3816384 2 48 2 E 1 studs 6 studs 6 For 550 B31B B36B B39B B46B B48B B49B 51 B52B B53B B54B 56 B58B B59B B60B B62B 16 16 OCTOBER 2000 5 25 S FAN ND LA EV CN AND Sor SW Nw 52 A PAN 3549 24 D 4 g 207122222222 4 1 3 5 HALF 3 LA 5 j d seco C 3 SECTION 2 4 6 CASE HALF 1 3 5 CASE HALF section 13 13 FIGURE 16 7B CRANKCASE STUD SETTING HEIGHTS ALL IO 550 B EXCEPT 550 9 14 B19B B30B a MAY 1998 16 17 CRANKCASE STUD SETTING HEIGHTS 550 NOTE All studs helical coils and plugs must be installed in accordance with the instructions sections 6 21 6 22 and 6 25 See Figure 6 2 Standard And Oversize Stud Identification ITEM SETTING HEIGHT LOCATION THREAD SIZE IN INCHES Bearing Starter Shaft Gear See section A A Helical Coil E Install in accordance with section 6 21 3 Helical Coil Install in accordance with section 4 6 21 __ 00004 1 6 Magneto Mount Pad 5 16 18 5 1624 67 4 8 Accessory Drive rear 5 16 18x5 16 24 75 1 3 9 Drive rear 5 16 18 5 16 24 1746 2 P o S e G 7 7 e i E o _ Pug 1162
22. 6 Magneto MountPad 561856642 1 84 7 Accessory Drive rear 384384 2 4 2 8 Accessory Drive rear 5 16 18 5 16 24 75 Idler PinPad 7 1420x428 56 Fuel Pump Pad 50161856664 GH Starter AdapterPad Starter Adapter Pad o age epe 5 16 18x5 16 24 Oil Pump Pad 0 550 2 5 16 18x5 16 24 Pug 20 118 27 o 1 16 27 1 8 27 as 9 1 4 20 1 4 28 Install in accordance with section 6 75 56 75 81 21 oom i Cylinder 7th Stud 7 16 14 7 16 20 i 88 38 1 8 27 Alternator Pad 5 16 18x5 16 24 Ed Helical Coil p e 36 Cooler Mount Pad 3 8 16 3 8 24_ _ Oil Cooler Mount Pad 3 8 16 3 8 24 20 Pug BP 1 MEAT studs item no 6 studs item no 6 For IO 550 B9B 14 B19B B30B 550 550 N2B N6B N8B 550 16 20 OCTOBER 2000 23 26 25 26 2 AI 2 lt N A Se 29 gt 9 LL em 7 25 25 25 2 1 3 5 CASE HALF 3 1 010 5 015 sgcrioN C 3 SECTION 2 4 6 CASE HALF 1 3 5 CASE HALF 13 13 FIGURE 16 70 CRANKCASE STUD SETTING HEIGHTS 10 550 N P R AND 550 9 B14B B19B B30B OCTOBER 2000 16 21 7 A proper chamfer at the crankcase main bearing feed holes must maintained
23. Clean all pushrods and rocker arms using mineral spirits Using a small squirt bottle insure all pushrod and rocker arm oil passages are open by flushing with mineral spirits Discard MAY 1998 15 7 6 any pushrod rocker arm that has obstructed oil passages that cannot be cleared by solvent action DO NOT CLEAN PUSHRODS AND ROCKER ARMS BY BLASTING Dry all components completely and thoroughly coat with clean 50 weight aviation engine oil Clean all cylinder baffles and associated hardware using mineral spirits 15 5 CYLINDER AND ASSOCIATED PARTS INSPECTION VISUAL INSPECTION Visually inspect the cylinder assembly and associated components in accordance with the instructions in section 6 8 Visual Inspection and the following special instructions CYLINDER BARREL 1 Power Stroke Stress Area of the cylinder barrel Visual inspection must include a detailed external inspection of the areas of the cylinder barrel which experience the highest operational stresses from the piston power stroke These areas are the 12 o clock area of the first six fins below the head on one side of the engine and the 6 o clock area on the other side as described in Figure 15 2 Power Stroke Stress Area of the cylinder barrel Inspect the cylinder barrel areas including the cylinder barrel fins and the areas between and adjacent to the fins for cracks sharp indentations rust pitting broken or bent fins including bent fins that have been s
24. 0 8mm BEARING INSTALLATION TOOL d lt i ar d 2 NN rS Worm Wheel Gear PRESS BEARING IN TO 06 OF AN INCH FIGURE 13 7 WORM WHEEL GEAR ROLLER BEARING INSTALLATION 13 7A STARTER ADAPTER ASSEMBLY See Figure 13 1A 1 Press new bearing 23 onto worm shaft 19 Press bearing until seated against flange Assemble shaft 19 new woodruff key 21 new spring 20 and worm gear 22 Coat the worm gear teeth with clean molyshield grease Insert assembly into adapter housing and install new retaining ring 24 Insure that retaining ring 24 is properly seated 2 Using an arbor press and an installation tool conforming with the specifications in Figure 13 7 remove roller bearing 12 from worm wheel 11 and discard Install a new roller bearing 12 in worm wheel 11 to the required specifications Install new clutch spring 14 on worm wheel 11 Turn spring so it tends to unwind until offset end drops into the worm wheel gear land Position spring on gear so screw notch is aligned with screw hole in gear web Install new tab washer 15 and screw 16 Torque screw 16 to 75 0 85 0 inch pounds torque and bend tab up against screw head 3 Lubricate spring and shaft gear liberally with clean 50 weight aviation engine oil Press worm wheel and spring assembly onto shaft gear 13 Install new ball bearing 17 on shaftgear 13 and secure with new retaining ring 18
25. 12 14 SECTION SECTION FIGURE13 4A STARTER ADAPTER FITS AND LIMITS FOR 10 550 10 550 9 B9B B9F 14 B19B B30B B35B B36B 10 550 10 550 10 550 10 550 10 550 R 13 13 ANNAN NEW PARTS DESCRIPTION MIN MAX From center line of worm gearshaft to starter adapter thrust pads 0 2460 0 2480 When sand blasted diameter finish is smoother than 75 RMS replace sleeve 13 14 MAY 1998 SHS 7 S Sm gt 66 Ta AAAS N See aoe Sa SECTION B B M 7 SM 22 7222222 02 2 222755 K ony 277 5557 Nv SECTION FIGURE 13 4B STARTER ADAPTER FITS amp LIMITS 10 550 B1F B2F B4F B5F B6F B11F B12B B13B 15 B16B B17B B18B B20B B21B B22B B23B B24B B25B B26B B27B B28B B29B B31B B32B B33B B34B B37B MAY 1998 13 15 2 Dac 2 2 TIEN ITE VOD OREERT DEMARE ET T a 22522277 CERT TET 27 eS m Naga DIAMETER DETAIL FIGURE 13 5 SHAFTGEAR DRUM DIMENSIONS DESCRIPTION A DIAMETER SEE DETAIL SMOOTH TAPER BETWEEN DIAMETERSB amp C SURFACE 32 RMS A DIAMETER B DIAMETE
26. 13 2A Starter and Starter Adapter Disassembly 13 6 13 2B Starter and Starter Adapter Disassembly 13 7 13 3 Starter Motor 88472 13 7 13 4 Starter Adapter 5 13 7 13 5 Starter and Starter Adapter Inspection 13 8 13 6 X Starter and Starter Adapter Repair And Replacement 13 17 13 7A Starter Adapter 13 20 13 7B Starter Adapter 13 21 FIGURE PAGE 13 1A Starter and Starter Adapter for 10 550 10 550 B9B B9F B14B B19B B30B B35B B36B 10 550 10 550 G 10 550 10 550 10 550 13 3 13 1B Starter and Starter Adapter for 10 550 B1F B2F B3F B4F B5F B6F B11F B12B B13B B15B B16B B17B B18B B20B B21B B22B B23B B24B B25B B26B B27B B28B B29B B31B B32B B33B B34B B37B 13 5 13 2 Starter Adapter Disassembly 13 6 13 3A Starter and Accessory Drive Adapter 13 9 13 3B Starter and Accessory Drive Adapter 13 10 13 4A Starter and Accessory Drive Adapter Fits and Limits 13 13 13 4B Starter and Accessory Drive Adapter Fits and Limits
27. 15 into oil cooler 3 Torque plugs 13 14 in accordance with Table 6 2 Pipe Plug Torques Torque fitting 12 in accordance with Table 6 3 Torque Specifications for Fittings Torque oil temperature control valve to 440 460 inch pounds Safety wire oil temperature control valve in accordance with section 5 2 Lockwire Procedure 2 The oil cooler will be installed on the engine during final engine assembly Cover oil cooler and store in a clean protected area until final engine assembly Oil Cooler 10 550 C See Figure 14 2B NOTE Before installing fittings in oil cooler insure they are free of any debris by thoroughly flushing them with an approved solvent WARNING Never use teflon tape on lubrication system fittings 1 Install plugs 8 amp 9 Install new gasket 10 and new oil temperature control valve 11 into oil cooler 3 Torque plugs 8 9 in accordance with Table 6 2 Pipe Plug Torques Torque oil temperature control valve 11 to 440 460 inch pounds Safety wire oil temperature control valve in accordance with section 5 2 Lockwire Procedure 2 The oil cooler will be installed on the engine during final engine assembly Cover oil cooler and store in a clean protected area until final engine assembly Oil Cooler 10 550 G5B G6B 10 550 10 550 P 10 550 See Figure 14 2C NOTE Before installing fittings in oil cooler insure they are free of any debris by thoroughly flushing them with an approved sol
28. 17 14 OCTOBER 2000 17 15 through 17 18 2000 17 19 through 17 22 MAY 1998 17 23 OCTOBER 2000 17 24 OCTOBER 2000 17 25 OCTOBER 2000 17 26 MAY 1998 17 27 OCTOBER 2000 17 28 MAY 1998 18 1 through 18 3 OCTOBER 2000 18 4 MAY 1998 18 5 through 18 7 OCTOBER 2000 PAGE 18 8 MAY 1998 18 9 through 18 18 OCTOBER 2000 18 19 MAY 1998 18 20 through 18 34 OCTOBER 2000 18 35 MAY 1998 18 36 MAY 1998 18 37 OCTOBER 2000 18 38 OCTOBER 2000 18 39 MAY 1998 18 40 OCTOBER 2000 19 1 MAY 1998 19 2 OCTOBER 2000 19 3 OCTOBER 2000 19 4 MAY 1998 19 5 MAY 1998 19 6 OCTOBER 2000 19 7 MAY 1998 19 8 OCTOBER 2000 19 9 MAY 1998 19 10 MAY 1998 19 11 through 19 13 OCTOBER 2000 19 14 through 19 17 MAY 1998 19 18 OCTOBER 2000 19 19 through 19 21 MAY 1998 19 22 OCTOBER 2000 19 23 through 19 25 MAY 1998 19 26 OCTOBER 2000 19 27 through 19 29 MAY 1998 19 30 through 19 32 OCTOBER 2000 19 33 MAY 1998 19 34 OCTOBER 2000 19 35 OCTOBER 2000 19 36 OCTOBER 2000 19 37 OCTOBER 2000 19 38 MAY 1998 19 39 MAY 1998 19 40 MAY 1998 STATUS PAGE STATUS 20 1 through 20 4 OCTOBER 1998 OCTOBER 2000 WARNING Use only parts meeting the engine type design Replacement Parts Beware of replacement parts materials and accessories that may be sold as aircraft quality but whose origin and quality are not known These parts may be deceptively advertised as unused like new or remanufactured and purchasers a
29. 946 9000 a 1 calibrated 0 60 PSI gauge graduated 1 PSI increments This gauge will be used for unmetered pressure measurement b One 1 calibrated 0 30 PSI gauge graduated in 1 PSI maximum increments This gauge will be used for metered pressure measurements and verification of aircraft fuel flow gauge indications 19 6 OCTOBER 2000 Two 2 P N 51523 4 swivel tee These fittings will be used to tee into fuel lines for unmetered and metered pressure reference Hoses of appropriate diameters and sufficient lengths to keep personnel and equipment away from propeller arc area Common hand tools including 7 8 11 16 9 16 1 2 3 8 7 16 11 32 and 5 16 wrenches A 1 4 drive ratchet and sockets universal swivel extension and a 5 32 allen wrench common screw driver a calibrated torque wrench an oil can mirror and flashlight Safety equipment including hearing and eye protection Tachometer verification instrument various types are available Verify aircraft tachometer accuracy prior to fuel system adjustment Pre Setup Procedures 1 Insure that the test stand fuel supply is not contaminated If the engine is installed in the airframe for testing flush the aircraft fuel system by first removing the engine driven fuel pump inlet hose and terminating the end into a large clean container Operate the aircraft boost pump and allow a minimum of one gallon fuel to flow through t
30. C30B 1 See Figure 14 1A Oil Pump Install oil pump housing 2 in a suitable fixture Lubricate cavity gear contact areas and oil pump gears 4 15 with clean Molyshield grease Install oil pump drive and driven gears in oil pump housing Using a new pin 16 install bevel gear 17 on oil pump drive gear 15 2 Assemble pressure relief valve housing 11 and adjusting screw 9 Turn adjusting screw into housing about halfway Secure adjusting screw using new copper washer 13 and new nut 14 Assemble plunger 6 new spring 7 new washer 8 and slide into relief valve opening in oil pump housing Install new gasket 10 on pressure relief valve housing 11 Coat housing threads with TCM P N 646943 Anti Seize Lubricant Insure that adjusting screw aligns with plunger spring and washer Screw relief valve housing into oil pump housing Torque housing to 240 260 inch pounds Safety wire housing 11 in accordance with section 5 2 Lockwire Procedure 3 To assemble the electrical tach drive housing to the oil pump housing press a new oil seal 19 into electrical tach drive housing until it bottoms out using an arbor press and proper driving tool Coat the inside diameter of oil seal 19 with with clean Molyshield grease Make sure oil seal is squarely seated before pressing Coat tach drive shaft gear 25 with with clean Molyshield grease Install tach drive shaft gear 25 into tach drive housing through end opposite of oil seal
31. FIGURE 18 14 ALTERNATOR HOUSING MODIFICATION 18 11 MAGNETO AND ACCESSORY DRIVE ADAPTERS 550 G1B G2B G4B G6B 550 550 550 See Figure 8 2A WARNING Oil pressure is applied to the face of the accessory drive pads Apply proper gasket and torquing procedures 18 22 OCTOBER 2000 Place two new gaskets 1 on the two upper mount pads at the rear of the crankcase The oil holes in gaskets must be aligned with the crankcase oil outlet holes Install two adapter assemblies 2 on the crankcase mount pads The adapter oil holes must be aligned with the crankcase oil outlet holes Attach both adapters to crankcase using plain washers 6 7 lock washers 8 9 and nuts 10 11 Torque 5 16 nuts to 180 220 inch pounds and 3 8 nuts to 275 325 inch pounds Using new gaskets 16 install covers 17 and secure using attaching hardware 18 19 amp 20 Torque nuts 20 to 90 110 inch pounds If installing an airframe supplied accessory insure that the proper gasket is used and install in accordance with the airframe manufacturer s instructions 18 118 MAGNETO AND ACCESSORY DRIVE ADAPTERS 10 550 5 See Figure 8 2B WARNING Oil pressure is applied to the face of the accessory drive pads Apply proper gasket and torquing procedures Place two new gaskets 1 on the two upper mount pads at the rear of the crankcase The oil holes in gaskets must be aligned with the crankcase oil o
32. Lockwire bolts 2 in accordance with section 5 2 Lockwire Procedure See Figure 16 1A install and finger tighten hardware 29 through 33 Proceed to 10 550 amp cylinder installation OCTOBER 2000 18 7 ALTERNATOR DRIVE GEAR p iN ee CRANKSHAFT OIL SEAL FIGURE 18 5 ALTERNATOR DRIVE GEAR AND CRANKSHAFT OIL SEAL INSTALLED FIGURE 18 6 CRANKCASE ASSEMBLED ON STAND 18 8 MAY 1998 10 550 Cylinder Installation NOTE See Chapter 3 for lubricant specifications and suppliers WARNING The improper use of sealants and lubricants may cause engine malfunction or failure a b Insure that the rocker shafts are temporarily installed in their boss bores prior to installing the cylinders Verify that all cylinder valve keepers have been properly installed Insure that each cylinder has a new cylinder base packing properly installed as described in section 15 7 Carefully rotate the crankshaft placing the number 1 and number 2 connecting rods in their outer most position Lubricate all cylinder through bolt and deck stud threads using clean 50 weight aviation engine oil Back the number 1 piston pin far enough out to allow the piston to be installed on the number 1 connecting rod Place the number 1 cylinder and piston assembly on the number 1 connecting rod and slide the piston pin into the connecting rod and piston Using a ring compressor compress the number 4 pist
33. STD STEEL STD STEEL STD STEEL STD STEEL 2X 4 1 2 X 1 2 2 X 4 1 2 X 1 2 1 2 X 1 3 4 X 4 7 8 1 2 X 1 3 4 X 4 7 8 3 4 O D X 12 GA X 8 1 4 X 28 1 4 X 28 X 5 8 5 16 DIA X 3 4 LONG 5 16 I D X 1 16 E TYPE 5 16 1 4 DIA X 3 4 LONG 141 0 X 1 16 THK 1 4 Note See the following pages for machining specifications FIGURE 10 6 STAKING TOOL SPECIFICATIONS 1 4 28 THREAD THROUGH 38 SYM 219 S F FHE DET 5 amp 20 85 16 THROUGH 425 S F FOR 9 40 3 8 1 4 QD 4 E 9 16 1 050 R 1 4 1 8 7 3 16 11 16 A 91 4 THROUGH BLEND S F FOR 11 DJAW 2 3 16 11 32 4 00 21 4 THROUGH S F FOR 12 R 1 4 1 050 5 8 R 11 32 5 16 THROUGH S F FOR 9 2 JAW 2 49 OCTOBER 2000 10 15 4 718 1 5 8 1 4 DIA THROUGH a 2 HOLES SLIP FIT FOR 11 1 1 4 GRIND AS REQUIRED PRESS FIT IN 5 1 050 11 32 RADIUS 2 PLACES FOR 11 52 1 7116 1 4 DIA THROUGH 35 2 HOLES SLIP FIT TO PRESS FIT IN 5 m GRIND AS REQUIRED 11 32 RADIUS 4 7 8 4 JAW ACTUATOR 1 64 ptent 8 amp 11 PIN FLAT HEAD ae FOR 10 amp 13 FIGURE 10 6 STAKING TOOL SPECIFICATIONS continued 10 16 OCTOBER 2000 Throttle And Fuel Control Unit Assembly NOTE TCM requires that the air throttle fuel control unit be assembled and calibrated by an FAA approved fuel inje
34. Screw the expanding tool into the new insert until its final thread forces the teeth firmly into the cylinder head metal See Figure 15 6C Expanding Spark Plug Hole Helical Coil Insert See Figure 15 3 Cylinder Stud Setting Heights for proper spark plug helical coil depth CAUTION Replacement helical coils must be stainless steel WARNING The helical coil insert end must not protrude into the combustion chamber after it has been installed MAY 1998 15 31 FIGURE 15 6B INSTALLING SPARK PLUG HELICAL COIL FIGURE 15 6C EXPANDING SPARK PLUG HOLE HELICAL INSERT 15 32 MAY 1998 CYLINDER STUD INSTALLATION Install new exhaust flange studs rocker shaft hold down studs and new intake flange studs of the appropriate oversize as determined by dimensional inspection in accordance with Figure 15 3 and sections 6 22 6 23 ROCKER SHAFT RETENTION IMPROVEMENT PROCEDURE The latest cylinder assembly part numbers that are not required to comply with the cylinder modification instructions and have had this operation performed are a Cylinder assembly part numbers 652953 and higher This would also include any of these numbers which a letter or number suffix such as 652953A1 b Any cylinder assemblies which are identified with the letter B stamped on the cylinder rocker cover flange See Figure 15 6E Parts Required For One 1 Cylinder Helicoil 2 ea 521209 4 15 72 20 Bolt 2 ea 90725 12 Fla
35. Sleeve 24 Nut 4 Seal Oil 11 Washer Plain 18 Retainer 25 Screw 5 Stud 12 Washer Lock 19 Bushing 6 Adapter Assembly 13 Washer Lock 20 Gasket 7T Bushing 14 Nut 21 Cover 18 Lf FIGURE 8 2B MAGNETO AND ACCESSORY DRIVE ASSEMBLY 10 550 G5B MAY 1998 8 15 8 3A MAGNETO ACCESSORY DRIVE DISASSEMBLY 1 See Figure 8 2 Remove attaching hardware 18 19 20 and remove covers gaskets 16 17 from accessory drive adapters Discard gaskets 1 16 and lock washers 8 9 19 2 Separate rubber drive bushings 15 retainers 14 and drive gear assemblies 12 Discard rubber drive bushings 15 8 3B MAGNETO ACCESSORY DRIVE DISASSEMBLY 3 See Figure 8 2B Remove attaching hardware 22 23 24 and remove covers gaskets 1 20 from accessory drive adapters Discard gaskets 1 20 and lock washers 12 13 23 4 Separate rubber drive bushings 19 retainers 18 and drive gear assemblies 16 Discard rubber drive bushings 19 8 44 CLEANING 1 Discard all magneto accessory drive parts listed in section 6 6 100 Replacement Parts Clean the magneto drive gear assemblies and adapters using mineral spirit solvent or by immersion in an alkaline stripping bath if mineral spirits solvent is not effective After cleaning with alkaline solution the parts must be sprayed with steam to remove all traces of alkaline After steam rinsing the parts must be thoroughly flushed with mineral spirits so
36. The oil pump housing oil filter adapter and oil cooler adapter exterior cavities and all oil passages must be thoroughly flushed with mineral spirit solvent after any alkaline cleaning process has been used Clean the oil suction tube assembly using mineral spirit solvent All oil passages must be clear and free flowing Clean gears that have bushings using mineral spirit solvent and a brass wire brush Gears with bushings must not be cleaned using alkaline solutions Gears that do not have bushings can be cleaned using mineral spirit solvent or by immersion in a alkaline stripping bath if mineral spirit solvent is not effective After cleaning with alkaline solution the gears must be sprayed with steam removing all traces of alkaline After steam rinsing the gears must be thoroughly flushed with mineral spirit solvent MAY 1998 14 15 14 5 CAUTION Alkaline cleaning solutions will cause corrosion to metals if not completely removed WARNING Do not pressure blast gears with an abrasive media Blasting will remove surface hardening LUBRICATION SYSTEM INSPECTION VISUAL INSPECTION The lubrication system components must be visually inspected in accordance with instructions in section 6 8 Visual Inspection Special attention must be given to the following components and areas 1 Using a flashlight and a 10X power magnifying glass visually inspect the exterior and the cavity of the oil pump oil pump cover and tach drive hou
37. Torque ignition lead coupling nuts to 110 120 inch pounds 18 38 OCTOBER 2000 The mechanic must consult all related service information issued by the ignition harness Spark Plug Coupling Torque inch pounds Thread manufacturer 5 8 24 90 95 3 4 20 110 120 TABLE 19 1 COUPLING NUT TORQUE UPPER UPPER SPARK PLUGS SPARK PLUGS ENGINE FIRING ORDER 11613 1215 4 5 MAGNETO FIRING ORDER 1 2 3 4 5 6 FIGURE 18 21 IGNITION WIRING DIAGRAM MAY 1998 18 39 INTENTIONALLY LEFT BLANK 18 40 OCTOBER 2000 SECTION 19 1 19 2 19 3 19 4 19 5 19 6 19 7 19 8 19 9 19 10 19 11 19 12 19 13 19 14 19 15 19 16 19 17 19 18 19 19 19 20 19 21 FIGURE 19 1 19 2 19 3 19 4 19 7 19 8 19 11 19 12 19 15 19 16 19 18 19 19 19 21 CHAPTER 19 POST OVERHAUL ADJUSTMENT AND TEST PAGE Testing After 19 2 Engine 19 2 6 sie ir EE 19 2 TOSUC IUD 19 2 Cooling Air SCOOP 19 3 Induction Air 19 3 a 19 3 Gers 19 3 Electrical VVIFITIg iuit ce tee te ota ead 19 3 Instruments nennen enne ener nnns 19 3 Breathe rics iden cerei et cin tear reet 19 4 gti ez ciiin PRI E 19 4 Governor Pad 19
38. piston rings 56 through 59 8 Using a retrieval magnet remove all of the hydraulic tappets 53 54 from the crankcase tappet bores Discard hydraulic tappets 53 54 Nomenclature for Figure 15 1B 1 Cylinder Assembly 18 Key Retainer 35 Housing Push Rod 52 O Ring Cyl Base 2 Cylinder 19 Roto Coil 36 Washer 53 Tappet Hyd Int 3 Insert Spark Plug 20 Rocker 37 Seal O Ring 54 Tappet Hyd Exh 4 Guide Intake 21 Bushing Valve Rocker 38 Packing 55 Piston 5 Guide Valve Exhaust 22 Screw Drive 39 Spring 56 Ring Comp 6 Stud 23 Washer Thrust 40 Push Rod 57 Ring Comp 7 Stud 24 Shaft Valve Rocker 41 Nut Flanged 58 Ring Oil Control 8 Stud 25 Retainer 42 Nut Flanged 59 Ring Scraper 9 Insert Helical Coil 26 Washer Tab 43 Baffle 60 Pin Piston 10 Insert Intake Valve 27 Screw 44 Spring 61 Bolt 11 Insert Exhaust Valve 28 Gasket Rocker Cover 45 Tube Drain 62 Washer 12 Valve Intake 29 Cover Valve Rocker 46 Seal 63 Support 13 Valve Exhaust 30 Washer 47 Bracket 7th Stud 64 Screw 14 Spring Inner 31 Washer Lock 48 Bracket 7th Stud 65 Washer 15 Spring Outer 32 Screw 49 Nut Flanged 66 Baffle 16 Sleeve 33 Gasket Exh Flange 50 Seal 67 Baffle 17 Retainer Lower 34 Nut 51 Retainer 68 Spring 15 4 OCTOBER 2000 D NES 2 FIGURE 15 1B CYLINDER AND PISTON ASSEMBLY FOR 10 550 N P R OCTOBER 2000 15 5 15 2 CYLINDER AND ASSOC
39. protected area until it is to be overhauled Remove nuts 36 lock washers 35 and hold down washers 34 Remove fuel pump assembly 3 and gasket 3A Reach into crankcase fuel pump cavity and remove drive coupling 2 Discard fuel pump gasket 3A and lock washers 35 Place the fuel pump in a clean protected area until it is to be overhauled Nomenclature for Figure 9 1B Fuel Injection System 13 Screw 25 Washer Lock 38 Clamp Coupling 14 Rod And Link Assy 26 Nut 39 Clamp Fuel Pump Rod And Link 27 Fuel Manifold Valve 40 Screw Gasket 14B Nut 28 Hose 41 Washer Throttle Assembly 15 Pin Cotter 29 Hose 42 Washer Lock Throttle And Control Unit 16 Spring 30 Tube Fuel Cyl 1 amp 6 43 Shroud Fuel Control Unit 17 Rod End 31 Nozzle Fuel 44 Grommet Shield 18 Nut Self Locking 32 Bracket 45 Tube Fuel Cyl 2 Screen 19 Washer Wave Bracket 46 Tube Fuel Cyl 5 Jet 20 Washer 33 Clamp 47 Tube Fuel Cyl 3 amp 4 Nozzle 21 Pin 34 Washer Hold Down Washer Tab 22 Spring 35 Washer Lock Screw 23 Shroud 36 Nut Plain Washer 24 Washer 37 Bracket OCTOBER 2000 FIGURE 9 1B FUEL INJECTION SYSTEM FOR 10 550 9 5 MAY 1998 9 1C FUEL INJECTION SYSTEM REMOVAL AND DISASSEMBLY See Figure 9 1 9 6 1 Mark each fuel injection line 26 35 36 37 with its cylinder number to facilitate re installation WARNING Fuel injection lines must not be bent or deformed Discard and replace be
40. to 75 85 inch pounds Torque nuts 22 to 90 110 inch pounds Bend tab of tab washer up against bolt 9 to safety 18 30 OCTOBER 2000 18 170 FUEL INJECTION SYSTEM 550 N P amp 1 See Figure 9 10 Apply TCM gasket maker to silk thread and split line of crankcase at fuel pump bore Place silk thread ends into split line of fuel pump bore Apply molyshield grease to fuel pump drive coupling 2 Install fuel pump drive coupling 2 in fuel pump 3 Install new gasket 2A on fuel pump Lubricate fuel pump cavity with clean 50 weight aviation engine oil Install fuel pump on crankcase Secure fuel pump using attaching hardware 4 5 amp 6 Torque nuts 6 to 180 220 inch pounds Apply 646943 anti seize lubricant to fuel nozzle threads cylinder end in accordance with Figure 9 9 General Sealant Application Install new fuel nozzles 28 in cylinders 1 through 6 Torque nozzles to 55 65 inch pounds CAUTION Never use teflon tape on fuel injection system fittings 4 5 Install manifold valve and bracket 12 13 on intake manifold secure with attaching hardware 16 17 18 Torque bolts 18 to 155 175 inch pounds Install brackets 26 between induction tube hoses and clamps relative to the fuel lines they will support Position brackets so they will align properly with fuel line clamps 27 WARNING Fuel injection lines must not be bent or deformed The fuel injection lines must be securely cla
41. 1 OCTOBER 2000 2 1 ORIGINAL 8 2 OCTOBER 2000 10 3 through 14 2 trough 2 2 MAY 1998 8 3 MAY 1998 10 6 OCTOBER 2000 14 4 MAY 1998 2 3 through OCTOBER 2000 10 7 MAY 1998 14 5 OCTOBER 2000 2 6 OCTOBER 2000 8 5 through 10 8 OCTOBER 2000 14 6 MAY 1998 3 1 MAY 1998 8 9 MAY 1998 10 9 through 14 7 MAY 1998 3 2 through 8 10 through 10 11 MAY 1998 14 8 OCTOBER 2000 3 6 OCTOBER 2000 8 14 OCTOBER 2000 10 12 through 14 9 MAY 1998 MAY 1998 MAY 1998 10 16 OCTOBER 2000 14 10 OCTOBER 2000 ORIGINAL OCTOBER 2000 10 17 OCTOBER 2000 14 11 MAY 1998 ORIGINAL 8 17 through 10 18 MAY 1998 14 12 OCTOBER 2000 MAY 1998 8 20 MAY 1998 11 1 ORIGINAL 14 13 MAY 1998 5 3 trough 8 21 OCTOBER 2000 11 2 MAY 1998 14 14 OCTOBER 2000 5 5 ORIGINAL 8 22 MAY 1998 11 3 MAY 1998 14 15 MAY 1998 5 6 through 9 1 OCTOBER 2000 11 4 ORIGINAL 14 16 OCTOBER 2000 5 8 OCTOBER 2000 9 2 MAY 1998 12 1 through 14 17 MAY 1998 6 1 OCTOBER 2000 9 3 MAY 1998 12 5 MAY 1998 14 18 OCTOBER 2000 6 2 OCTOBER 1998 9 4 OCTOBER 2000 12 6 ORIGINAL 14 19 OCTOBER 2000 6 3 OCTOBER 2000 9 5 through 13 1 OCTOBER 2000 14 20 OCTOBER 1998 6 4 through 9 7 MAY 1998 13 2 MAY 1998 14 21 OCTOBER 2000 6 8 MAY 1998 9 8 OCTOBER 2000 13 3 OCTOBER 2000 14 22 OCTOBER 1998 6 9 OCTOBER 1998 9 9 OCTOBER 2000 13 4 MAY 1998 14 23 MAY 1998 6 10 MAY 1998 9 10 MAY 1998 13 5 MAY 1998 14 24 OCTOBER 2000 6 11 MAY 1998 9 11 MAY 1998 13 6 OCTOBER 2000
42. 10 550 14 12 Sump 10 550 G amp ova dome E ee dear dett vos 14 13 Oll Sumip I0 550 P us sd 14 14 Oil Pump Oil Filter Adapter And Electrical Tach Drive Housing Stud Setting 6 0022 222 22 14 17 Oil Sump Stud Setting Heights 10 550 14 18 Oil Pump and Tach Drive Fits and Limits 14 20 Stud Identification 14 22 Oil Filter Adapter Stud Replacement 14 22 Oil Pump Housing Threading Diagram 14 25 OCTOBER 2000 14 1 14 1 OIL PUMP REMOVAL See Figure 14 1 1 Cut lockwire and remove filter 35 Remove attaching parts 37 38 39 Separate adapter 36 and gasket 34 from oil pump housing 2 Discard lock washers 38 and gasket 34 Remove attaching hardware 22 23 24 and tach drive assembly 18 Discard lock washers 23 Remove shaftgear 15 and bevel gear 17 Remove driven gear assembly 4 5 from oil pump housing Remove oil pressure relief valve 6 through 14 from oil pump housing 2 Discard spring 7 gasket 10 and self locking nut 14 Remove plug 42 and gasket 41 Discard gasket 41 Remove remaining attaching parts 22 23 24 and remove oil pump housing 2 from crankcase studs Remove and discard gasket 20 Place the oil pump components i
43. 11 Plate Counterweight 22 Screw Drilled Head 33 Crankshaft 17 4 OCTOBER 2000 FIGURE 17 2 CRANKSHAFT ASSEMBLY MAY 1998 17 5 17 2 ENGINE DRIVE TRAIN CLEANING 1 The camshaft crankshaft connecting rods and their associated parts must be cleaned in accordance with the instructions in section 6 7 General Cleaning and the following special instructions All hydraulic tappets rubber oil seals springs crankshaft main bearings thrust washers connecting rod bearings counterweight pins retainer plates and snap rings removed from the crankhaft and o rings removed from the oil transfer collar must be replaced 100 at overhaul Cleaning of these parts is not required Crankshaft counterweight hanger blade bushings counterweight bushings and connecting rod bushings must also be replaced 100 at overhaul All areas of the camshaft and crankshaft must be degreased by brushing or spraying with mineral spirit solvent The crankshaft crank pins main journals oil seal race oil transfer collar area and camshaft journals and gear mount flange must be smoothed with crocus cloth moistened in mineral spirits This is to be accomplished while the shaft is rotated in a lathe at approximately 100 RPM All gum varnish deposits must be removed to permit reliable magnetic indications during magnetic particle inspection Flush the internal portion of the camshaft using mineral spirit solvent Insure that all threads oil passages and rece
44. 14 25 MAY 1998 ii OCTOBER 2000 CURRENT STATUS OF PAGES CONTINUED PAGE 14 26 15 1 15 2 15 3 15 4 15 5 15 6 15 7 15 8 15 9 15 10 STATUS OCTOBER 2000 OCTOBER 2000 OCTOBER 2000 MAY 1998 OCTOBER 2000 OCTOBER 2000 OCTOBER 1998 MAY 1998 OCTOBER 2000 MAY 1998 MAY 1998 15 11 through 15 18 15 19 15 20 OCTOBER 2000 MAY 1998 OCTOBER 2000 15 21 through 15 23 15 24 15 25 OCTOBER 2000 MAY 1998 OCTOBER 2000 15 26 through 15 28 15 29 MAY 1998 OCTOBER 1998 15 30 through 15 32 15 33 15 34 MAY 1998 OCTOBER 2000 OCTOBER 2000 15 35 through 15 37 15 38 MAY 1998 OCTOBER 2000 15 39 through 15 42 15 43 15 44 15 45 15 46 15 47 15 48 16 1 16 2 16 3 16 4 16 5 16 6 16 7 16 8 MAY 1998 OCTOBER 2000 OCTOBER 2000 MAY 1998 OCTOBER 2000 MAY 1998 MAY 1998 OCTOBER 2000 OCTOBER 2000 MAY 1998 OCTOBER 2000 OCTOBER 2000 MAY 1998 MAY 1998 OCTOBER 2000 PAGE STATUS 16 9 MAY 1998 16 10 MAY 1998 16 11 OCTOBER 2000 16 12 MAY 1998 16 13 MAY 1998 16 14 OCTOBER 2000 16 15 MAY 1998 16 16 OCTOBER 2000 16 17 through 16 19 MAY 1998 16 20 through 16 26 OCTOBER 2000 16 27 MAY 1998 16 28 OCTOBER 2000 16 29 OCTOBER 2000 16 30 MAY 1998 17 1 OCTOBER 2000 17 2 MAY 1998 17 3 MAY 1998 17 4 OCTOBER 2000 17 5 MAY 1998 17 6 MAY 1998 17 7 OCTOBER 2000 17 8 OCTOBER 2000 17 9 MAY 1998 17 10 OCTOBER 2000 17 11 OCTOBER 2000 17 12 OCTOBER 1998 17 13 OCTOBER 1998
45. 1998 8 17 Inspect all studs for looseness and distorted or stripped threads Inspect studs for corrosion pitting incomplete threads and looseness Replace studs with any of these indications Check studs with tool makers square for alignment The magneto adapter studs must have their setting heights checked for indications of backing out See Figure 8 4 for drive adapter stud setting heights ITEM NO LOCATION THREAD SETTING QUANTITY SIZE HEIGHT Accessory to 1 4 20 X 1 4 28 87 90 4 Adapter See Item 1 FIGURE 8 4 ACCESSORY DRIVE ADAPTER STUD SETTING HEIGHTS FLUORESCENT PENETRANT INSPECTION Aluminum alloy components such as the magneto accessory drive adapters must be fluorescent penetrant inspected by a certified technician in accordance with section 6 12 Fluorescent Penetrant Inspection Adapters exhibiting cracks must be discarded MAGNETIC PARTICLE INSPECTION Magneto drive gears and drive bushing retainers must be inspected by a certified technician in accordance with section 6 9 Magnetic Particle Inspection Magneto drive gears and retainers that exhibit cracks must be discarded 8 18 MAY 1998 DIMENSIONAL INSPECTION The following new parts limits must be used for dimensional inspection Components that do not meet the following specifications must be discarded All components must be thoroughly cleaned and air dried prior to dimensional inspection New Parts Description Diameter Diameter Diamet
46. 3 ENGINE DRIVE TRAIN INSPECTION WARNING Use only crankshafts that are manufactured from VAR forgings identified by the letters VAR forged into a crankshaft cheek VISUAL INSPECTION The crankshaft camshaft connecting rods and associated engine drive train components must be visually inspected in accordance with the instructions in section 6 8 Visual Inspection and the following special instructions 1 Visually inspect the camshaft journals and lobes using 10 magnifying glass Inspect the camshaft journals and lobes for scoring pitting corrosion and any indications of wear Camshafts exhibiting scoring pitting corrosion or wear indications must be repaired or discarded Inspect the camshaft gear splines for wear Discard camshafts with worn splines Inspect the camshaft gear flange for nicks peening and other irregularities The flange must be smooth to align gear Inspect the camshaft gear flange bolt holes for distorted or stripped threads Camshaft repairs must be accomplished using a procedure and process which meets the requirements of the applicable federal aviation regulations Using Borrough s 8087A polishing tool or equivalent rotate the crankshaft in a lathe and polish the mains and crank pins to a finish of 8 maximum Inspect the finish using a profilometer Dimensionally inspect the crankshaft mains and crank pins for required specified size Visually inspect the crankshaft main journals crankpins and oil
47. 4 Engine Tes oscuro ial tne 19 5 Oil Pressure Adjustmert corr Deren deberet ventis 19 5 Fuel System 22 1110 19 6 Overhaul Test Run Standard Acceptance 19 34 Oil Consumption Determination 19 35 Engine Preservation for Storage or Installation After Overhaul 19 36 19 36 Continued Airworthiness 19 40 PAGE Oil Pressure 2 4 2 2111 19 5 Throttle Fuel Control and Metering Unit Adjustments 19 8 Fuel Pump Adjustments 19 11 550 Performance 19 15 19 18 550 Performance 19 19 19 22 550 Performance 19 23 19 26 O 550 G Performance 19 27 19 29 550 P R Performance 19 30 19 32 Operational Test 19 33 PAGE Test Operating 19 13 Compensation Table for Static Ground Setup 19 14 Altitude Fuel Schedule 0 550 19 37 Altitude Fuel Schedule 0
48. 550 19 38 Altitude Fuel Schedule 550 19 38 MAY 1998 19 1 19 1 19 2 19 3 19 4 TESTING AFTER OVERHAUL WARNING During engine test run do not stand or allow anyone else to stand in the propeller arc area ENGINE PRE OILING All engine internal moving parts must be properly lubricated before initial running of engine after overhaul Pre oil the engine upon completion of engine re assembly Engine pre oiling must be accomplished in accordance with the following procedure 1 Pre oiling be accomplished using a bladder type pressure pot capable of holding at least 1 gallon of clean aviation engine oil with an output pressure of 50 not to exceed 60 pounds per square inch See chapter 3 for proper oil grade and for approved oil products 2 Remove rocker box covers from cylinders Connect pre oiler supply hose to engine oil pressure gauge line connection fitting Open pre oiler valve and watch cylinder rocker areas for indication of oil flow Some engines may take as long as 20 minutes for oil indication depending on oil temperature 3 After oil flow has been confirmed re install gaskets and rocker box covers Torque rocker cover screws to 55 65 inch pounds Close valve on pre oiler Disconnect pre oiler supply hose and cap or re install engine oil pressure gauge on pressure gauge line connection fitting as applicable 4 Check engine oil quantity an
49. 6 10 550 10 550 10 550 8 3 5 6 3 5 6 1556 sy 26 27 28 16 17 18 19 29 3233 29 32 3 30 31 32 33 15 5 36 5 35 5 FIGURE 16 14 CRANKCASE ATTACHING PARTS 550 amp C Bolt 10 Bolt Through 19 Nut 28 Nut Bolt 11 O Ring 20 Support Baffle 29 Bolt Bolt 12 Spacer 21 Bolt Through 30 Bolt Bolt 13 Washer 22 Washer 31 Spacer Washer 14 Nut 23 Washer 32 Washer Nut 15 Bolt 24 Nut 33 Nut Fuel Manifold Valve 16 Bolt Through 25 Bolt Through 34 Support Baffle Eye Lifting 17 O Ring 26 Bolt 35 Bolt Bracket Ignition 18 Washer 27 Washer 36 Bolt This hardware attaches oil suction tube assembly to crankcase MAY 1998 16 3 16 1 CRANKCASE DISASSEMBLY AND DRIVE TRAIN REMOVAL 550 1 See Figure 16 2 Oil Filler Idler Support Pin amp Camshaft Cover Remove attaching hardware 13 14 15 Remove cover 12 and gasket 11 Discard gasket 11 Remove attaching hardware 19 20 Remove idler gear support pin 18 gasket 17 and bushing 16 Discard gasket 17 and bushing 16 See Figure 16 3B Engine Mounts Crankshaft Seal Retainer amp Governor Cover 550 G N P R Remove bolts 14 and oil seal retainer plates 13 See Figure 16 1B Crankcase Attaching Parts 10 550 Remove crankcase backbone attaching hardware 2 through 6 Remove lifting eyes 7 8 ignition bracket 9 and fuel manifold valve Remove attaching hardware
50. 6150 AISI 7 OR EQUIVALENT ROUND STOCK TOOL STEEL HARDEN GRIND AND DRAW AS SHOWN FIGURE 16 12 CRANKCASE NEEDLE BEARING INSTALLER OCTOBER 2000 16 29 INTENTIONALLY LEFT BLANK 16 30 1998 17 ENGINE DRIVE TRAIN SECTION PAGE 17 1 Camshaft and Crankshaft Disassembly 17 2 17 2 Engine Drive Train 17 6 17 3 Engine Drive Train 17 7 Visual Inspection 17 7 Crankshaft Ultrasonic Inspection 17 10 Magnetic Particle Inspection 17 10 Dimensional Inspection 17 11 17 4 Engine Drive Train Repair amp Replacement 17 15 17 5 Engine Drive Train 17 25 FIGURE PAGE 17 1A Camshaft Assembly Old 17 2 17 1 Camshaft Assembly New Style 17 3 17 2 Crankshaft Assembly ended erbe totas ote td sauce 17 5 17 3 Control Collar Stud and Dowel Setting Heights 17 9 17 4A Crankshaft Camshaft and Connecting Rod Fits And Limits 17 12 17 4B Crankshaft Camshaft and Idler Gear Backlash 17 13 17 5 Connecting Rod Dimensions
51. 9 1D 1 Fuel Injection System 11 Elbow 22 Tube Fuel Cyl 3 35 Washer 2 Coupling 12 Fuel Manifold Valve 23 Tube Fuel Cyl 2 36 Washer Copper 2A Gasket 13 Bracket 24 Tube Fuel Cyl 1 37 Hose 3 Fuel Pump Bracket 25 Bracket 38 Elbow 4 Washer Hold Down Bumper Rubber 26 Bracket 39 Adapter 5 Washer Lock 14 Washer 27 Clamp 40 Tube 6 Nut 15 Screw 28 Nozzle 40A Sleeve 7 Protector 16 Spacer 29 Jet 41 Cap 8 Throttle And Met Unit 17 Washer 30 Nozzle Fuel 42 Tee 8A Lever 18 Bolt 31 O Ring 8B Bushing 19 Tube Fuel Cyl 6 32 Screen 9 Elbow 20 Tube Fuel Cyl 5 33 Shield 10 Cap 21 Tube Fuel Cyl 4 34 Washer 9 8 OCTOBER 2000 P R 550 G 1D FUEL INJECTION SYSTEM FOR I0 FIGURE 9 9 9 OCTOBER 2000 9 2 FUEL INJECTION SYSTEM COMPONENT DISASSEMBLY FUEL MANIFOLD VALVE 1 See Figures 9 2A 2B amp 2C as applicable Remove fittings A through C The fuel manifold valve must be overhauled in accordance with TCM Fuel Injection Systems Overhaul Manual and Parts Catalog Form X30593A or replaced with a serviceable unit See section 1 5 Related Publications for ordering information Teledyne Continental Motors offers factory rebuilt fuel injection system components at exchange prices as an alternative to field overhaul of these units COVER ORIENTATION FIGURE 9 2A MANIFOLD VALVE FITTING ORIENTATION 10 550 A ENGINE Fitting Fitting Fitting MODEL A C Metered
52. AND REPLACEMENT Any lubrication system component worn beyond new parts limits or failing to meet the inspection criteria in section 14 5 must be replaced unless repair is possible with the following instructions 1 Oil pump housings with gear shafts that exceed the specifications in section 14 5 must be discarded The oil pump housing driven gear shaft is pressed into the pump housing and is not field replaceable 2 Oil pump housings that are cracked must be discarded Oil pump housings with enlarged or scored gear chambers must be discarded 3 Oil pump covers with scored gear contact surfaces must be discarded unless the parting surface can be lapped smooth and made perfectly flat 4 Oil pump covers tach drive housings and oil filter adapters exhibiting cracks must be discarded 5 Oil pump drive gears worn beyond specifications must be discarded Oil pump driven gears with bushings that are worn beyond specifications must be discarded See section 14 5 New Parts Dimensions 6 Oil sumps that leak or that are cracked must be discarded 550 550 oil sump studs that are damaged or loose must be replaced in accordance with section 6 22 Studs must be installed to the setting height specified in Figure 14 5 7 Section 6 19 Application of Accelagold applies to all aluminum alloy castings sheet metal and tubing 8 Oil pump and tach drive housing studs that are damaged or loose must be replaced in accordance with
53. Cee me Eee tt tt tt TT tT LII curs cades d 00 082 092 Ove 022 002 08 09 0S 09 E 0 193 ye d JO 4 05 SZ H 08 eJnjxijN 1seg 193 E H 06 E E E N XIN E OLL JaMOd 9q 02 051 5 AMV SA 1913 9 0SS Ol FIGURE 19 13 FUEL FLOW VS OBSERVED BRAKE HORSEPOWER 10 550 19 24 MAY 1998 550 METERED FUEL PRESSURE VS FUEL FLOW METERED FUEL PRESSURE PSI yN 3 o co N N a psi tolerance 3 80 100 i 140 60 40 o c o 2 E Z 5 Ee gt gt 3 9 o lt S oE 5 925 D E tU o 6 D 5 gt 255 c 5 Lets Note this data is approximate with 20 WI N e N FIGURE 19 14 FUEL FLOW VS METERED PRESSURE 550 MAY 1998 FUEL FLOW LBS HR 19 25 Altitude Leaning Chart 10 550 Full Rich 2700 RPM MOJ4 Jon 4 17 16 15 13 12 11 10 FIGURE 19 15 AUTO LEANING SCHEDULE 550 WITH ALTITUDE COMPENSATING FUEL PUMP 19 26 OCTOBER 2000 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 0 Pressure Altitude feet
54. Driving Stud Torques Pipe Plug Torques Torque Specifications for Fittings Hose Fittings and Specific Torques as applicable MAY 1998 6 15 TABLE 6 4 TORQUE SPECIFICATIONS FOR HOSE FITTINGS THREAD SIZE FITTING MATERIAL INCH POUNDS 5 16 24 Hose End Fitting To Brass Allum Fitting 50 80 Hose End Fitting To Steel Fitting 75 120 3 8 24 Hose End Fitting To Brass Allum Fitting 70 105 Hose End Fitting To Steel Fitting 95 140 7 16 20 Hose End Fitting To Brass Allum Fitting 100 140 Hose End Fitting To Steel Fitting 135 190 3 4 16 Hose End Fitting To Brass Allum Fitting 270 350 Hose End Fitting To Steel Fitting 470 550 7 8 14 Hose End Fitting To Brass Allum Fitting 360 430 Hose End Fitting To Steel Fitting 620 745 9 16 18 Hose End Fitting To Brass Allum Fitting 150 195 Hose End Fitting To Steel Fitting 215 280 1 1 16 12 Hose End Fitting To Brass Allum Fitting 460 550 Hose End Fitting To Steel Fitting 855 1055 Hose size Hose End Fitting Steel Fitting 170 240 WARNING Failure to lubricate threads apply the specific torque and follow the specific torquing procedure may result in damage and subsequent engine malfunction or failure 6 16 MAY 1998 TABLE 6 5 SPECIFIC TORQUES Torque Location and hardware Modei Thread ayy In Lbs Ft Lbs Cover tach drive to oil pump 25 28 90 110 7 5 9 2 A B C A B C 24x 50 Oil pressure relief valve 1 12 18 240 260 20
55. Fuel FUEL INLET Manifold Press Conn Vent 10 550 90 Elbow 90 45 Elbow 270 9 10 MAY 1998 C COVER ORIENTATION B 10 550 10 550 FIGURE 9 2B MANIFOLD VALVE FITTING ORIENTATION 10 550 amp ENGINE Fitting Fitting Fitting MODEL A B C Metered Fuel FUEL INLET Manifold Press Conn Vent 10 550 45 Elbow 270 45 Elbow 135 10 550 45 Elbow 270 45 Elbow 225 1998 9 11 270 180 180 FIGURE 9 2C MANIFOLD VALVE FITTING ORIENTATION 10 550 G N P R ENGINE Fitting Fitting Fitting MODEL A FUEL INLET Metered Fuel Manifold Press Conn Vent 10 550 N P amp R Adapter 45 Elbow 0 45 Elbow 135 90 Elbow 285 9 12 OCTOBER 2000 FUEL PUMP 1 See Figures 9 3A B amp C as applicable Remove fittings A through E The fuel pump must be overhauled in accordance with TCM Fuel Injection Systems Overhaul Manual and Parts Catalog Form X30593A or replaced with a serviceable unit See section 1 5 Related Publications for ordering information Teledyne Continental Motors offers factory rebuilt fuel injection system components at exchange prices as an alternative to field overhaul of these units FIGURE 9 3A FUEL PUMP FITTING OREINTATION 10 550 amp except 10 550 C31B C32B FITTING FITTING FITTING C FITTING D MIXTURE VA
56. INLET OUTLET RETURN DRAIN 642027 26 90 ELBOW 90 90 ELBOW 170 90 ELBOW 270 45 ELBOW 270 45 HOSE 45 ELBOW 225 45 ELBOW 125 90 ELBOW 135 FITTING 225 642027 27 90 ELBOW 90 90 ELBOW 180 45 ELBOW 225 STRAIGHT 45 HOSE 45 ELBOW 250 90 ELBOW 90 FITTING FITTING 225 STRAIGHT FITTING 642027 28 90 ELBOW 90 90 ELBOW 170 90 ELBOW 270 STRAIGHT 45 HOSE 45 ELBOW 330 45 ELBOW 125 90 ELBOW 45 FITTING FITTING 225 Use on 10 550 and B39B Use 10 550 C31B and C32B Use on 10 550 B38B B40B B41B B42B B43B 45 B46B 48 49 B51B and B52B 9 14 OCTOBER 2000 FIGURE 9 30 FUEL PUMP FITTING OREINTATION 10 550 G1B G2B G4B 10 550 1 2 N6B N7B N8B 10 550 10 550 FITTING A FITTING B FITTING D FITTING E INLET OUTLET VAPOR RETURN SEAL DRAIN 2 90 ELBOW 135 7 Straight 90 ELBOW 90 JEBON 90 ELBOW 270 Fitting OCTOBER 2000 9 15 FIGURE 9 3E FUEL PUMP FITTING OREINTATION 10 550 5 amp G6B FITTING A FITTING B FITTING D FITTING E OUTLET VAPOR RETURN SEAL DRAIN 90 ELBOW 135 90 ELBOW 90rELBOW 90 90 45 on 90 ELBOW 270 Adapter Elbow 9 16 OCTOBER 2000 FUEL CONTROL UNIT 10 550 amp 1 See Figure 9 4 Remove fittings A through E The
57. If keys drop too far they may become fouled This condition could cause them to damage the stem when the springs are released Make sure the keys are properly seated into the grooves of the valve stem before releasing pressure on springs Remove the cylinder from fixture and set it upright on the workbench Place a plastic mallet squarely on the end of the valve stem and strike the plastic mallet sharply with a rawhide mallet to insure correct seating of valve retainer keys DO NOT STRIKE ROTOCOIL Insure the valve spring retainer keys are properly positioned c Carefully position each cylinder assembly so the cylinder bore is facing upward and the cylinder is resting on the rocker shaft mounting bosses Place a new cylinder base packing 52 on the cylinder skirt and push it against the base flange Make sure the cylinder base packing is not twisted Using clean 50 weight aviation engine oil coat the cylinder barrel wall thoroughly Assemble the remaining five cylinders using the above instructions d Using the following instructions assemble each of the six new pistons and rings e Install all rings with the part number toward the top of the piston Install the expander into the third ring groove first by disconnecting it and then reconnecting it fully With a ring expander place the oil ring 58 over the expander with the ring gap positioned 180 from the expander joint With a ring expander install ring 57 into the second ring groove
58. Make sure retaining ring seats properly in it s groove Insert shaft gear and worm wheel assembly into adapter Make sure worm wheel and worm gear teeth are aligned 13 20 MAY 1998 6 Install new o ring 25 on cover 26 Install cover 26 on starter adapter housing 5 Secure using three sets of attaching hardware 27 28 Torque nuts 28 to 180 220 inch pounds Test adapter assembly for slippage by installing adapter in fixture and apply torque to input shaft Minimum allowable non slippage torque is 300 inch pounds Store the starter and starter adapter in a clean protected area until final engine assembly 13 7B STARTER ADAPTER ASSEMBLY See Figure 13 1B 1 Press new bearing 16 onto worm shaft 14 Press bearing until seated against flange Assemble shaft 14 new woodruff key 15 new spring 13 and worm gear 12 Coat the worm gear teeth with clean molyshield grease Insert assembly into adapter housing and install new retaining ring 17 Insure that retaining ring 17 is properly seated Using an arbor press and an installation tool conforming with the specifications in Figure 13 7 remove roller bearing 23 from worm wheel 20 and discard Install a new roller bearing 23 in worm wheel 20 to the required specifications Install new clutch spring 19 on worm wheel 20 Turn spring so it tends to unwind until offset end drops into the worm wheel gear land Position spring on gear so screw notch is aligned
59. Order TSO number and identification mark indicating that the part or appliance was manufactured in accordance with the requirements of FAR 21 Subpart O 3 FAA Parts Manufacturer Approval PMA symbol with the manufacturer s name part number make and model of the type certified product on which the part can legally be installed stamped on the part An FAA PMA is issued under FAR 21 305 Make and model information may be on a tag attached to the part 4 Shipping ticket invoice or other document which verifies that the part was manufactured by a facility that was holding an FAA Approved Production Inspection System Certificate issued under FAR 21 Subpart F or by a manufacturer holding an FAA Production Certificate issued under FAR 21 Subpart G 5 Certificate of airworthiness for export issued by governments in countries other than the United States of America under the provisions of FAR 21 Subpart N It s Your Responsibility The owner operator is responsible for the continued airworthiness of the aircraft In accordance with FAR certification of materials parts and appliances for return to service for use on aircraft is the responsibility of the person agency who signs the approval To insure the continued safe operation of your aircraft you must exercise great care when inspecting testing and determining the acceptability of all parts and materials A very important part of this is verifying the origin of all materials parts and acce
60. PRODUCE 40 FINISH PROCEDURE 1 CLEAN UP SEAT WITH 30 STONE 2 TOP OFF WITH 15 STONE TO ESTABLISH 2 26 MAX SEAT O D AS REQUIRED NOTE SEAT MUST BE REPLACED IF 2 48 DIA MAX IS EXCEEDED 3 UNDERCUT SEAT WITH 45 STONE TO ESTABLISH 07 12 SEAT WIDTH AS REQUIRED FIGURE 15 5A INTAKE VALVE SEAT REFACING 2 03 DIA MAX 07 12 EXHAUST SEAT GRINDING NOTE USE STONES THAT WILL PRODUCE A 40 Rg FINISH PROCEDURE 1 CLEAN UP SEAT WITH 45 STONE 2 TOP OFF WITH 15 STONE TO ESTABLISH 1 81 MAX SEAT O D NOTE SEAT MUST BE REPLACED IF 2 03 DIA MAX IS EXCEEDED FIGURE 15 5B EXHAUST VALVE SEAT REFACING OCTOBER 1998 15 29 CYLINDER BORE FINISH EQUIPMENT Use a wet honing process and hone stones that will produce a surface finish as specified below After honing the cylinder barrel to the required specifications inspect the cylinder barrel wall for corrosion pitting and scoring Discard cylinders exhibiting any of the above indications Surface finish measurements are to be made with a Hommel Tester T500 part number 191800 The software for receiving data from the tester is Hommel America TIOOO Turbo Both the tester and software are available from Hommel America New Britain CT The tester is to be set to inch units traverse lengths Lt of 19 and Lm of 16 a cutoff length Lc of 0 03 MI filter and R profile Prof CROSS HATCH PATTERN The bore finish shall show a cross hatch pattern
61. THREAD SETTING QTY NO SIZE HEIGHT IE NI 2 Stud Throttle Support Stud Cover to Housing roc x dirt eae KAS S NI 5 FIGURE 14 4 OIL PUMP OIL FILTER ADAPTER AND ELECTRICAL TACH DRIVE HOUSING STUD SETTING HEIGHTS MAY 1998 14 17 8 Inspect 550 and 550 oil sump studs for distorted or stripped threads Inspect studs for corrosion pitting incomplete threads and looseness Replace studs with any of these indications Check studs with a tool makers square for alignment The oil sump must have it s setting heights checked for indications of backing out See the following for stud setting heights ITEM LOCATION THREAD SETTING QTY NO SIZE HEIGHT Stud Engine Mount to Oil Sump 3 8 16 X 1 56 FIGURE 14 5 OIL SUMP STUD SETTING HEIGHTS 550 550 FLUORESCENT PENETRANT INSPECTION Aluminum alloy components such as the oil pump housing oil pump cover oil filter adapter tach drive housing and oil sump must be fluorescent penetrant inspected by a certified technician in accordance with section 6 12 Fluorescent Penetrant Inspection Pump housings adapters tach drive housings or sumps exhibiting cracks must be discarded MAGNETIC PARTICLE INSPECTION Oil pump gears bevel gears and tach drive shafts must be magnetic particle inspected by a certified technician in accordance with instructions in section 6 9
62. Torque screws 19 to 75 85 inch pounds Loosely assemble intake tubes and flanges 6 through 13 to intake manifold 2 using new hoses and clamp assemblies 17 18 Place new gaskets 12 on cylinder intake flanges With the aid of an assistant place intake spider assembly on top of engine Adjust intake tubes so they seat squarely on cylinder flanges and secure with attaching hardware 14 15 16 Torque nuts 16 to 90 110 inch pounds Torque clamps 18 to 40 50 inch pounds 18 28 OCTOBER 2000 18 17A FUEL INJECTION SYSTEM 550 fuel injection system parts must be clean and free of debris before assembly 1 See Figure 9 1A Apply TCM gasket maker to silk thread and split line of crankcase at fuel pump bore Place silk thread ends into split line of fuel pump bore 2 Apply molyshield grease to fuel pump drive coupling 2 Install fuel pump drive coupling 2 in fuel pump 3 Install new gasket 2A on fuel pump Lubricate fuel pump cavity with clean 50 weight aviation engine oil Install fuel pump on crankcase Secure fuel pump using attaching hardware 32 33 34 Torque nuts 34 to 180 220 inch pounds 3 Apply 646943 anti seize lubricant to fuel nozzle threads cylinder end in accordance with Figure 9 9 General F I Sealant Application Install new fuel nozzles 25 in cylinders 1 through 6 Torque nozzles to 55 65 inch pounds CAUTION Never use teflon tape on fuel injection system fittings WARNIN
63. amp 1 Document lever orientation for reinstallation 2 Drive pin 12 out using a 1 8 inch pin punch Loosen nut 11 and remove lever 8 Remove screws 16 and cover 15 Remove o ring 17 spring 18 o ring 19 and plug 20 Remove screws 7 and plate 6 Slide throttle shaft 3 from throttle body Remove o rings 4 washer 5 and o ring 17 Discard pin 12 o rings 4 17 19 screws 7 and spring 18 NOTE Airframe supplied parts such as switch actuating cams must be removed inspected repaired or replaced and re installed in accordance with the applicable airframe manufacturer s instructions 25 22 21 2 524 3 24 FIGURE 10 2 THROTTLE ASSEMBLY 10 550 amp Body Throttle Pin Stop Shaft Throttle O ring Washer Plate Throttle Screw Lever Bushing OND OTE GN 10 8 OCTOBER 2000 Screw Nut Pin Screw Adjusting Spring Cover Screw O ring Spnng 19 O ring 20 Plug Fuel Metering 21 Screw Idle Adjust 22 O ring 23 Bushing 24 Spring 25 Ring Retaining 10 3 INDUCTION SYSTEM CLEANING 1 All induction system components and associated hardware must be cleaned in accordance with the instructions in section 6 7 General Cleaning and the following 2 All gaskets hoses lock washers and self locking nuts removed from the induction system and components must be replaced 10096 at overhaul Cleaning these parts is not required
64. amp 38 and oil seal retainer clip 51 Tap scavenge pump body 35 using a plastic or rawhide mallet and remove Remove gear 34 oil seal 43 ball bearing 41 and spacer 42 Discard 12 point self locking nut 46 lock washers 37 oil seal 43 and ball bearing 41 NOTE Do not clamp adapter housing in vise 3 4 Remove three sets of attaching parts 28 amp 29 Using an inertia puller or other suitable tool detach cover assembly 27 and o ring 26 from starter adapter Discard o ring 26 Clamp starter shaftgear teeth in shielded vise jaws Remove and discard retaining ring 25 Use a starter adapter disassembly tool as shown in Figure 13 2 Rotate the worm wheel gear in counterclockwise direction at the same time pull axially on the worm wheel and spring to separate it from the starter shaft gear Remove starter shaft gear 18 from vise Separate shaftgear 18 from housing 5 Clamp worm wheel in shielded vise Remove clutch spring retaining screw 22 and tab washer 21 Place a straight slot screw driver through a hole in the worm wheel 20 to catch the end of spring 19 Rotate spring 19 clockwise to release it from the land in the worm wheel gear Separate spring 19 from worm wheel gear 20 Remove roller bearing 23 from worm wheel gear 20 Use a slide hammer and Borrough s 8093C Bearing Puller or equivalent to remove needle bearing 11 from housing 5 13 3 STARTER MOTOR OVERHAUL 1 Th
65. approximately 1000 feet 3 Refer to Figures 19 7 19 11 19 15 as applicable The variable orifice aneroid adjustment will move you horizontally across the chart The adjustable orifice will move you vertically 4 Adjustments to the variable orifice aneroid will affect the FULL POWER unmetered fuel pressures adjustable orifice metered pressures and fuel flows It is important to maintain the balance between these adjustments in order to achieve the specified fuel system parameters CAUTION Exercise caution when adjustments to the aneroid are accomplished The aneroid stem has an extra fine thread and over torquing of the lock nut will damage either the stem or housing threads NOTE It will be necessary to cut and remove the safety wire and manufacturer s seal from the variable orifice adjustment Cut the safety wire as close to the variable orifice stem as possible This will provide a pig tail for the fuel pump through bolts It is not necessary to re safety the aneroid after adjustments have been completed 5 Byreviewing the data recorded on the operational test flight form we can determine if the auto leaning schedule is above or below the specified limits at the various pressure altitudes 6 Adjustment of the variable orifice aneroid clockwise will decrease the altitude move horizontally to the left on the chart while counter clockwise adjustments will increase the altitude move horizontally to the right on the chart
66. baffle supports 20 34 Tap half inch through bolts 16 with a plastic or rawhide mallet and pull from opposite side of crankcase to remove Do not damage through bolt threads Remove and discard o rings 17 Remove attaching hardware 12 through 14 Tap 3 8 through bolt 10 with a plastic or rawhide mallet Remove through bolt carefully to prevent thread damage Remove support and rotate stand so that engine is in inverted position Remove attaching hardware 29 through 33 attaching hardware 26 27 28 and attaching hardware 35 36 5 Rotate engine stand placing left crankcase half downward Replace support prop 3 See Figure 16 3A Engine Mounts Crankshaft Seal Retainer amp Governor Cover 550 amp Remove bolts 19 and oil seal retainer plates 18 Disconnect right crankcase engine mounts from engine stand Carefully lift right crankcase half from left crankcase half to prevent connecting rods from hitting cylinder decks Using the proper fixtures and dial indicators check and record gear backlash before removing drive train See Chapter 17 Gear Backlash Fits and Limits Lift out camshaft and governor driven gear Remove idler gear hydraulic tappets and crankshaft assembly Place the camshaft and crankshaft assemblies on the proper holding fixtures to prevent damage Remove and discard crankshaft bearings and thrust washers 16 2 OCTOBER 2000 i o M DUO PO 2 5 6 3 5 6 4 5 6 8 9 2 5
67. elbows 10 11 and manifold 13 Remove clamps and hoses 8 9 from elbows 10 11 Remove screws that attach balance tube bracket 15 to oil sump and crankcase Remove clamp 16 and bracket 15 from balance tube 17 Remove balance tube 17 from front hoses 9 Remove screws 6 lock washers 5 and washers 4 Discard lock washers 5 Remove risers 2 3 from cylinders Remove hoses 9 and clamps 7 8 from risers 2 3 Discard all hoses 9 Place the induction elbows and risers in a clean protected area until they are ready to be overhauled 15 16 2 17 FIGURE 10 1A INDUCTION SYSTEM FOR 10 550 1 Gasket 9 Hose 17 Balance Tube 2 Elbow 10 Tube Intake 18 Plug 3 Elbow 11 Tube Intake 19 Bracket 4 Washer 12 Plug 20 Screw 5 Washer Lock 13 Riser 21 Spacer 6 Screw 14 Stud 22 Washer 7 Clamp 15 Bracket 23 Nut 8 Clamp 16 Clamp 24 Duct 10 2 MAY 1998 10 1B INDUCTION SYSTEM REMOVAL AND DISASSEMBLY See Figure 10 1B 1 Loosen clamps 7 16 and remove manifold 10 Remove clamps and hoses 7 9 from elbow riser 2 Remove oil sump screws that attach balance tube bracket 12 to oil sump and crankcase Remove clamp 13 and bracket 12 from balance tube 14 Loosen clamps 8 Remove balance tube 14 from front hoses 9 Remove screws 6 lock washers 5 and washers 4 Discard lock washers 5 Remove risers 2 3 from cylinders Remove hoses 9 and cla
68. from the accessory end The accessory end is the rear and the propeller flange is the front of the engine Cylinders are numbered starting from the rear with odd numbers on the right and even numbers on the left MANUAL REVISIONS Teledyne Continental Motors manuals are revised as necessary Revisions to this manual will be furnished to purchasers who fill out and return the registration post card located in the front of this manual Page iii Current Status Of Pages is updated at each revision Remove and discard the old page iii Insert the new page iii as a record of which revisions have been incorporated into the manual WARNING If for any reason the user of this manual is uncertain whether all current revisions have been incorporated into the manual contact Teledyne Continental Motors or a TCM Distributor to confirm the manual is the most current revision Do not use the manual and do not perform any operation maintenance or installation procedures or other operations upon the engine or accessories until the manual has been confirmed to be current This manual is current and correct to the best of Teledyne Continental Motors knowledge at the time of publication Teledyne Continental Motors solicits and encourages users comments regarding suggested changes to this manual a post card is provided at the front of the manual for this purpose Routine recommended changes or questions should be sent to Teledyne Continental Motors P O
69. fuel control unit must be overhauled in accordance with TCM Fuel Injection Systems Overhaul Manual and Parts Catalog Form X30593A or replaced with a serviceable unit See section 1 5 Related Publications for ordering information Teledyne Continental Motors offers factory rebuilt fuel injection system components at exchange prices as an alternative to field overhaul of these units MANIFOLD VALVE TO TANK TAP VALVE 10 550 A PLUG 90 ELBOW 240 90 ELBOW 235 90 ELBOW 150 90 ELBOW 260 10 550 PLUG 90 ELBOW 225 90 Bowe Mss B k C aa TO FUEL RETURN PRESSURE FUEL INLET TO MANIFOLD PLUG 90 ELBOW 165 90 ELBOW 195 10 550 PLUG 90 ELBOW 115 PLUG 90 ELBOW 240 90 ELBOW 90 THROTTLE AND FUEL METERING UNIT 10 550 P amp R MAY 1998 9 17 1 See Figure 9 5 Remove fittings 2 through 4 The throttle and fuel metering unit must be overhauled in accordance with Fuel Injection Systems Overhaul Manual and Parts Catalog Form X30593A or replaced with a serviceable unit See section 1 5 Related Publications for ordering information Teledyne Continental Motors offers factory rebuilt fuel injection system components at exchange prices as an alternative to field overhaul of these units CLOSED FIGURE 9 5 FUEL METERING UNIT FITTING ORIENTATION ITEM 1 2 FITTING 3 FITTING 4 FITTING ITEM 5 ITEM 6 FUEL INLET F
70. in accordance with the instructions in Section 6 9 Magnetic Particle Inspection Crankshafts camshafts crankshaft gears camshaft gears idler gears or drive gears exhibiting cracks must be discarded The connecting rod parts must be magnetic particle inspected by a certified technician in accordance with the instructions in Section 6 9 Magnetic Particle Inspection The connecting rod parts must be clean and free of rust scale oil or other residue that may affect reliability of magnetic particle inspection Connecting rods will be inspected using both the circular and longitudinal method of magnetization Acceptable indications must be associated with steel inclusions or shallow imperfections on the forging surface Accept light indications running parallel to the rod axis or around the pin boss and cap ends less than 1 2 inch in length Indications associated with forging laps or with heat treatment are deemed cracks and are not acceptable The area of blend between the piston pin boss extending one inch into the channel section of the connecting rod the bolt spot face areas and the channel rail edges are critical and must be free of any indications Any indication transverse to the rod axis is not acceptable Reject and scrap connecting rods exhibiting unacceptable indications CRANKSHAFT ULTRASONIC INSPECTION The crankshaft must be ultrasonic inspected by a certified technician in accordance with section 6 10 17 10 OCTOB
71. instructions in section 6 22 Studs must be installed to the specified height in Figure 14 4 9 A new oil filler adapter stud P N 653490 must be installed if the old stud is a plain steel color with a length of 1 440 inch if it is found to be loose or it is installed beyond the stud setting height specified in Figure 14 8 Oil Filter Adapter Stud Replacement If required install new stud in accordance with the following procedure a Remove old stud and inspect the threads in the adapter housing for damage Replace the adapter housing if any thread damage is evident OCTOBER 2000 14 21 STAMP THE LETTER 5 IN THIS LOCATION OIL FILTER STUD OIL FILTER ADAPTER ASSEMBLY FIGURE 14 7 STUD IDENTIFICATION NOTE Oil filter adapters that incorporate this modification can be determined by the letter S stamped into the adapter housing see Figure 14 7 Stud Identification b Clean the adapter housing threads thoroughly to remove any remaining thread adhesive and oil c Install the applicable new stud P N 653490 and confirm that the incomplete thread on the stud stops at the first thread in the adapter housing and does not continue into the housing below the minimum 0 500 inch extension See Figure 14 8 Oil Filter Adapter Stud Replacement Replace the adapter housing if the extension is less than the specified 0 500 inch minimum d After extension height inspection remove the stud from the adapter Clean the
72. internal oil pressure with little or no lubrication of internal moving engine parts and engine failure FIGURE 17 1A CAMSHAFT ASSEMBLY OLD STYLE 1 Camshaft Assembly 5 Bolt 9 Tappet Hydraulic 2 Plug Pipe 6 Key Woodruff 10 Ring Retaining 3 Plug Expansion 7 Gear Governor Drive 4 Gear Camshaft 8 Gear Governor Driven 17 2 MAY 1998 1 See Figure 17 1B Camshaft Assembly New Style Remove the governor drive gear 6 Cut and remove lockwire from bolts 5 Remove four bolts 5 and camshaft gear 4 Using the correct size tool remove the front and rear plug WARNING Failure to replace camshaft plugs at reassembly will result in loss of internal oil pressure with little or no lubrication of internal moving engine parts and engine failure FIGURE 17 1B CAMSHAFT ASSEMBLY NEW STYLE 1 Camshaft Assembly 5 Bolt 2 Plug 6 Gear Gov Drive 3 Plug 7 Gear Gov Driven 4 Gear Camshaft MAY 1998 17 3 CRANKSHAFT 1 See Figure 17 2 Crankshaft Assembly Use wooden support blocks under the front and rear main journals of the crankshaft during disassembly Remove nuts 4 and bolts 5 Separate connecting rod caps 6 and rod 7 Remove bearing inserts 8 Loosely reassemble rods caps bolts and nuts with their position numbers matched Remove and discard retaining rings 10 plates 11 and pins 12 13 14 Lift counterweight assemblies 15 from crankshaft Remove nuts 17 and separ
73. leaking oil not seeping FIGURE 16 6 INSPECTION OF CRANKCASE CRITICAL WHITE AND NON CRITICAL SHADED AREAS 3 Visually inspect the breather for cracks and dents Inspect tube ends for scoring and out of roundness that may have caused a bad seal and oil leakage Discard components with any of these indications 16 12 MAY 1998 4 Visually inspect all pipe plugs for stripped or distorted threads and damaged wrench flats Pipe plugs exhibiting damaged threads or wrench flats must be discarded 5 Inspect engine mount brackets for cracks dents and wear Inspect hardware for distorted stripped threads and damaged wrench flats Components exhibiting any of the above indications must be discarded Inspect tapped holes and helical coils for distorted or stripped threads 6 Visually inspect all crankcase helical coils and studs for stripped or distorted threads Inspect studs for corrosion rusting pitting incomplete threads and looseness Check all studs with a tool maker s square for alignment Check studs for looseness All studs must have their setting heights checked for indications of backing out See Figure s 16 7A through 16 7D for crankcase stud setting heights MAY 1998 16 13 CRANKCASE STUD SETTING HEIGHTS 550 NOTE All studs helical coils and plugs must be installed in accordance with the instructions sections 6 21 6 22 and 6 25 See Figure 6 2 Standard And Oversize Stud Identification ITEM SET
74. mallet sharply with a rawhide mallet to insure correct seating of valve retainer keys DO NOT STRIKE ROTOCOIL Insure the valve spring retainer keys are properly positioned c Carefully position each cylinder assembly so the cylinder bore is facing upward and the cylinder is resting on the rocker shaft mounting bosses Place a new cylinder base packing 25 on the cylinder skirt and push it against the base flange Make sure the cylinder base packing is not twisted Using clean 50 weight aviation engine oil coat the cylinder barrel wall thoroughly Assemble the remaining five cylinders using the above instructions d Using the following instructions assemble each of the six new pistons and rings MAY 1998 15 45 e Install all rings with the part number toward the top of the piston Install the expander into the third ring groove first by disconnecting it and then reconnecting it fully With a ring expander place the oil ring 51 over the expander with the ring gap positioned 180 from the expander joint With a ring expander install ring 50 into the second ring groove install ring 49 into the first ring groove and install ring 52 into the fourth ring groove f Inspect all ring side clearances with the ring edge flush with the piston outside diameter All ring side clearances must conform with the dimensions in Cylinder And Associated Parts Fits And Limits NOTE Weight differences of piston pairs in opposing bays must not
75. must be visually inspected in accordance with instructions in section 6 8 Visual Inspection and the following special instructions 1 Visually inspect the inside and outside of both crankcase halves for cracks Pay particular attention to areas on and adjacent to the cylinder mount flanges tappet guides case flange nose seal land and bearing bosses Look for scoring in the old crankshaft bearings Look for scoring in the tappet guides and camshaft bearings Inspect main bearing boss parting surfaces for fretting Inspect the bearing saddles for bearing lock slot elongation and any indication of bearing movement Visually inspect all machined surfaces for nicks and roughness Use the following inspection to determine if a cracked crankcase can be repaired See Figures 16 5 and 16 6 If a crack is observed in any non critical shaded area that is more than two 2 inches in length or if a previously observed crack has progressed to two 2 or more inches in length the crankcase must be repaired or replaced If any crack is observed in a critical white area the crankcase must be discarded Cracks less than 2 inches in length and located in shaded areas as illustrated FIGURE 16 5 INSPECTION OF CRANKCASE NON CRITICAL AREA OCTOBER 2000 16 11 Reasons for crankcase replacement 1 Any crack in the critical white areas 2 crack two 2 inches or more in length in the non critical shaded areas 3 Any crack that is
76. or deformed The fuel injection lines must be securely clamped to the fuel line support brackets Do not assemble in a binding configuration OCTOBER 2000 18 29 4 Install fuel injection lines 30 45 46 47 between nozzles 31 and fuel manifold valve 27 Torque fuel line B nuts at nozzles to 40 45 inch pounds Torque fuel line B nuts at manifold valve to 55 60 inch pounds Attach clamps 33 to fuel lines Snap clamps 33 into brackets 32 32A Install fuel hoses 28 between fuel pump and fuel control unit fittings Torque hose B nuts to the specified limit in Table 6 4 Torque Specifications for Hose Fittings Install brackets 37 using existing oil sump bolts Using clamps 38 secure fuel hoses 28 to brackets 37 using attaching hardware 40 41 42 Install fuel hose 29 between fuel manifold valve 27 and fuel control unit 5 fittings Torque hose B nuts to the specified limit in Table 6 4 Torque Specifications for Hose Fittings Using clamp 39 secure fuel hose 29 to bracket 37 using attaching hardware 40 41 42 18 17C FUEL INJECTION SYSTEM 550 1 2 See Figure 9 1C Apply TCM gasket maker to silk thread and split line of crankcase at fuel pump bore Place silk thread ends into split line of fuel pump bore Apply molyshield grease to fuel pump drive coupling 2 Install fuel pump drive coupling 2 in fuel pump 3 Install new gasket 3A on fuel pump Lubricate fuel pump ca
77. point leads are connected to the ground terminals of the magnetos The timing light breaker point leads are connected so that the light on the right side of the timing light box represents the right magneto and the light on the left side of the timing light box represents the left magneto The timing lights should indicate that the points in both magnetos are closed Tap the right magneto up with a non marring hammer until the light indicates points just opening Tap the left magneto down until the light indicates points just opening Secure magnetos Watch the lights on the magneto timing light Turn the crankshaft a few degrees counterclockwise then clockwise until the timing indicator s pointer is pointing to the correct degree As the pointer aligns with the correct degree both lights on the magneto timing light must indicate that the points just open within one degree of crankshaft rotation If timing light does not indicate the above adjust the magnetos NOTE Point opening is indicated by light illumination on some timing lights while other timing lights operate in the reverse manner i e the light goes out when the points open CAUTION When installing the magneto on the engine using the specified nuts and clamps take the following precautions Tighten both nuts by hand to finger tightness Torque each nut alternately to 100 to 120 inch pounds Exceeding 120 inch pounds torque may cause the mounting flange to crack 11 12 Torque
78. remove scoring or indications of overheating which render the crankshaft unserviceable 4 The crankshaft hanger blade and counterweight bushings must be replaced 100 at engine overhaul regardless of condition Crankshaft hanger blade bushing replacement must be performed using the specified procedure and the following special tool a Borrough s 8077A Crankshaft Hanger Blade Bushing Removal Installation Set or equivalent WARNING Removing and replacing bushings with makeshift tools and methods may result in irreparable damage to the crankshaft and crankshaft malfunction CRANKSHAFT COUNTERWEIGHT HANGER BLADE BUSHING REMOVAL Using the specified tool remove the crankshaft counterweight hanger blade bushings CRANKSHAFT COUNTERWEIGHT HANGER BLADE BUSHING HOLE INSPECTION After removal of the crankshaft counterweight hanger blade bushings measure the inside diameter of the bushing holes The replacement bushings must have an interference fit of 0015 to 003 inch into the bushing holes The bushing holes must be smooth Crankshafts with worn pitted fretted or out of round bushing holes must be discarded OCTOBER 17 15 CRANKSHAFT COUNTERWEIGHT HANGER BLADE BUSHING INSTALLATION After serviceability of crankshaft has been determined new bushings must be installed in the crankshaft counterweight hanger blades Install the new bushings using the same tools that were used for bushing removal The new bushings must be installed in accordance w
79. required will require twisting at a rate of 9 to 12 twists per inch Lockwire must be new at each application Lockwire must be pulled taut while being twisted and caution must be exercised during the twisting operation to keep the lockwire tight without overstressing See Figure 5 1 General Lockwire Procedure for steps in applying lockwire 13 jo 1 LOCKWIRE 2 INSERTING 3 BENDING WIRE 4 TWISTING WIRE 5 PULLING HOLES WIRE AROUND BOLT WIRE PARALLEL 6 BENDING WIRE 7 TWISTING WIRE 8 BENDING 9 CUTTING AROUND BOLT TWISTED WIRE EXCESS WIRE FIGURE 5 1 GENERAL LOCKWIRE PROCEDURE Various examples of lockwiring are shown in Figure 5 2 General Lockwire Patterns 1 Check the units to be lockwired to insure they have been correctly torqued Applying torque that is above or below specified limits to obtain alignment of the holes is not permitted It is desirable to have the holes parallel but this is not a necessity For right hand threads the lockwire shall be installed in such a manner that the strand through the hole will have a tendency to pull the unit clockwise Insert half of the required length of lockwire through the first unit and bend around the head of the unit The direction of wraps and twist of strands shall be such that the loop around the unit comes under the strand protruding from the hole so that the loop will stay down and will not tend to slip up and leave a slack loop Twist the
80. system and components must be replaced 100 at overhaul Cleaning these parts is not required 1 The fuel pump fuel manifold valve fuel control metering unit and fuel nozzles must be cleaned inspected overhauled and tested in accordance with the instructions in TCM Fuel Injection Systems Overhaul and Parts Catalog Form X30593A unless factory rebuilt units are purchased for replacement FUEL INJECTION SYSTEM INSPECTION VISUAL INSPECTION The visual inspection must be performed in accordance with the instructions in section 6 8 Visual Inspection Special attention must be given to the following components and areas 1 Visually inspect all fuel injection system plumbing for cracks dents chafing flared ends for cracks and out of roundness Inspect fittings for distorted or stripped threads and damaged wrench flats Components exhibiting any of the above indications must be discarded 2 Inspect brackets for cracks dents and wear Inspect hardware for distorted stripped threads and damaged wrench flats Components exhibiting any of the above indications must be discarded 3 Visually inspect the fuel pump throttle metering unit manifold valve and fuel nozzle outside areas for evidence of wear deterioration and leakage Inspect tapped holes and helical coils for distorted or stripped threads Inspect for cracks and dents Further inspection of the fuel pump throttle metering unit manifold valve and nozzles must be performed in ac
81. temperatures maintaining above the minimum recommended operating range NOTE Avoid long descents at low manifold pressure which can result in excessive engine cooling Satisfactory engine acceleration may not occur when power is applied Any discrepancies detected during test flight must be corrected and the aircraft again test flown prior to approval of engine for return to service The appropriate logbook entries must be made in accordance with Part 43 of the Federal Aviation Regulations FAR before the engine can be returned to service AUTO LEAN OPERATION FOR ENGINES WITH ALTITUDE COMPENSATING FUEL PUMPS In addition to the above 10 550 amp engines with altitude compensating fuel pumps require a flight test every 100 hours or annual inspection and anytime an adjustment is made to the fuel injection system to insure proper operation of the fuel pump auto leaning feature OCTOBER 2000 10 Tables 19 2 19 3 19 4 and the Auto Leaning Charts Figures 19 7 19 11 19 15 provide fuel flow vs pressure altitude specifications Insure the accuracy of aircraft fuel flow gauge and tachometer have been verified These gauges must be accurate or the data recorded during flight test will not be valid Locate the correct table and auto leaning chart for the aircraft and engine On the operational test form provided in this chapter record all pressure altitudes and corresponding minimum and maximum fuel flows as specified In acco
82. the magneto attaching hardware to 100 120 inch pounds Disconnect timing light from magnetos Insure that connections between magneto and ignition switch are secure IGNITION HARNESS PRE INSTALLATION INSTRUCTIONS The ignition harness assembly must be replaced 100 at engine overhaul Clean the mating surfaces grommets and inside of the outlet plate with a lint free cloth moistened with isopropyl alcohol Apply MS 122DF Spray before installing harness on magneto MS 122DF Spray Miller Stephenson Chemical Co Inc 16 Sugar Hollow Road Danbury Connecticut 06810 Carefully place the harness outlet plate onto the magneto insuring the grommets enter the distributor block towers Install and torque nuts around plate alternately to seat cover squarely on magneto For TCM S 200 series magnetos apply 25 to 35 inch pounds to screws For TCM S 1200 series magnetos apply 18 22 inch pounds to nuts On Slick Magnetos torque screws according to the magneto manufacturer s instructions The harness assemblies are constructed of a lightweight flexible silicone coated cable Because the harness assemblies are lightweight and flexible the following must be observed when installing the harness on an engine a Support leads with the necessary clamps and cable ties to prevent any whipping or chafing action OCTOBER 2000 18 37 FIGURE 18 20 COATING INSULATING SLEEVE b Route leads as far away as possible from exhaust manifold to insure th
83. thread sizes They are made of either carbon steel phosphor bronze or stainless steel as specified by part number They are supplied with or without a notch above the driving tang The notch is provided to facilitate breaking off the tang in open holes Helical coil inserts are helical coils of wire with a diamond shaped cross section forming both a male and female thread When compressed into a special tapped hole at the widest part of the wire between male and female threads the diameter of the insert is equal to the nominal screw size The special finishing taps size the casting hole so the pitch diameter of the female thread of the installed insert conforms to Class 3 fit with standard bolt threads or class 4 tight fit with standard size studs The difference in fit is due to a difference in pitch diameters of bolts and studs Only one set of helical coil special taps is required for installation of these inserts in both bolt holes and stud holes Tap drilling depths and tapping depth for helical coil inserts to be installed in blind holes should conform to the recommendations relative to inserts of length equal to 2 times nominal diameter as tabulated in the manufacturer s Bulletin Numbers 1000 and T4000 latest revision Helical coil tap drills and special taps must be run in perpendicular to the machined surface of the casting Drilling must be done in a drill press after the casting is firmly supported clamped and alignment checked The tap w
84. threads of the adapter housing and stud with Loctite Primer T TCM P N 646944 and allow to dry OIL FILTER STUD APPLY LINE OF LOCTITE HERE INCOMPLETE THREAD 700 LOCATION 500 2 OIL FILTER ADAPTER ASSEMBLY STUD LARGE END FIGURE 14 8 OIL FILTER ADAPTER STUD REPLACEMENT e Apply a line of Loctite 271 TCM P N 646941 along the large threads 8125 16 end of the stud and install into the adapter finger tight to 30 inch pounds torque Check for proper stud extension height in accordance with Figure 14 8 continued f Allow the parts to cure a minimum of 30 minutes prior to installation of the oil filter 14 22 OCTOBER 1998 14 7 CAUTION Curing times may vary depending on ambient temperature Consult Loctite instructions 9 After installation of a new oil filter adapter stud stamp 0 125 inch high letter 5 in the location shown in Figure 14 7 Stud Identification LUBRICATION SYSTEM SUB ASSEMBLY NOTE All lubrication system components must be clean and free of debris before assembly NOTE Before assembly insure all parts listed in section 6 6 100 Replacement Parts have been replaced OIL PUMP FOR 10 550 2 10 550 B1F B2F B3F B4F B5F B6F B9B B11B B14B B15B B16B B19B B21B B23B B29B B30B B32B B35B B37B 10 550 C C1F C2F C2U C3F C6F C8B C9B C11B C12B C13B C15B C18B C19B C25B C26B C27B C28B C29B
85. to reduce the possibility of crankcase cracking in that area INSTRUCTIONS a Inspect the number one two and three main bearing oil feed passages and determine if they conform to the illustration in Figure 16 8 The subject passages are located in the left 2 4 6 case half and begin in the rear main bearing saddle counting forward b Any of the above mentioned oil feed passages which do not conform to the illustration in Figure 16 8 must be modified to conform Deburr sharp edges after modification for smooth transition After the modification has been accomplished clean crankcase and flush oil passages using mineral spirit solvent All debris from modification procedure must be removed 80 90 430 AT EXISTING OIL GROOVE MAIN BEARING SADDLE FIGURE 16 8 CRANKCASE MAIN BEARING OIL FEED HOLE CHAMFER 16 22 OCTOBER 2000 FLUORESCENT PENETRANT INSPECTION The crankcase halves and all aluminum alloy brackets must be fluorescent penetrant inspected by a certified technician in accordance with the instructions in section 6 12 Fluorescent Penetrant Inspection Crankcase halves that exhibit cracks must be discarded or repaired in accordance with the instructions in section 16 7 DIMENSIONAL INSPECTION The following new parts limits must be used for dimensional inspection Components that do not meet the following specifications must be discarded All components must be thoroughly cleaned and air dried pri
86. to appropriate setting height See Figures 16 7A through 16 7D e Wipe excess Loctite from cylinder deck f Allow two hours minimum setting time before testing stud break away torque g Test studs after they have cured The studs must not break away under a torque load of 100 inch pounds h Studs conforming with the break away toque test can be utilized for cylinder installation 4 Crankcases with crankshaft or camshaft bearing bores that exceed the specified critical new parts diameter must be discarded or line bored oversize Line boring may be accomplished by a repair facility certified for specialized crankcase repairs See section 16 6 for new parts dimensions 5 Crankcase halves exhibiting fretting must be discarded or machined Crankcase machining may be accomplished by a repair facility certified for specialized crankcase repairs The crankcase parting line to cylinder deck new parts dimension is 4 560 minimum to 4 565 maximum After machining process the service minimum cylinder deck height dimension must not exceed 4 5540 minimum Crankcase halves exceeding this dimension must be discarded CAUTION Gear backlashes must not be less than the specified minimum after machining 6 The case half parting line surface must be flat within 005 true indicator reading but not to exceed cumulative of 008 true indicator reading with mating crankcase half Crankcase halves exceeding these dimensions must be discarded After all machinin
87. to the engine and remove fuel manifold valve 23 Place the fuel manifold valve in a clean protected area until it is to be overhauled 7 Remove nuts 32 lock washers 31 and hold down washers 30 Remove fuel pump assembly 3 and gasket 3A Reach into crankcase fuel pump cavity and remove drive coupling 2 Discard fuel pump gasket 3A and lock washers 31 Place the fuel pump in a clean protected area until it is to be overhauled MAY 1998 FIGURE 9 1C FUEL INJECTION SYSTEM 10 550 1 Fuel Injection System 2 Coupling 3 Fuel Pump 3A Gasket 4 Throttle Assembly 4A Throttle And Control Unit 5 Fuel Control Unit 6 Lever 6A Bushing 7 Washer Tab 8 Screw 9 Screw 10 Rod And Link 10A Rod And Link Assembly 11 Nut Plain 12 13 Spring Rod End A Pin Nut Self Locking Washer Wave Washer Pin Cotter Spring Shroud Washer Washer Lock Nut Fuel Manifold Valve Hose Hose Tube Fuel Cyl 1 amp 6 41 Nozzle Nozzle Fuel 42 Bracket Bracket 43 Spacer Clamp 44 Washer Washer Hold Down 45 Bushing Washer Lock 46 Sleeve Nut 47 Bracket Shroud 48 Bracket Grommet 49 Bolt Tube Fuel Cyl 2 50 Nut Self Locking Tube Fuel Cyl 5 51 Bracket Tube Fuel Cyl 3 amp 4 52 Spacer Shield 53 Gasket Screen Jet OCTOBER 2000 9 7 9 10 FUEL INJECTION SYSTEM REMOVAL AND DISASSEMBLY See Figure 9 10 1 Ma
88. washers 19 from cable outlet plate Remove plates from magnetos 2 c Remove ignition harness assembly from engine and discard 2 Disconnect magneto sensor unit 29 from airframe connector in accordance with the airframe manufacturer s instructions Disconnect ground terminal kit 28 from magnetos 2 in accordance with airframe manufacturer s instructions 3 Remove nuts 5 lock washers 4 and magneto holding washers 3 from each magneto 4 Remove both magnetos 2 from the engine Discard cable ties 27 and lock washers 4 19 CAUTION Use care to avoid dropping magneto drive bushings and retainers into the engine See Figure 8 2B 5 Magneto assemblies must be overhauled in accordance with the magneto manufacturer s instructions see TCM ignition systems Master Service Manual Form No X40000 See Section 1 5 Related Publications for ordering information Nomenclature for Figure 8 1F 8 12 OCTOBER 2000 1 Gasket 11 Lead 3B 21 Clamp 2 Magneto 12 Lead 3T 22 Clamp 3 Washer Holding 13 Lead 4B 23 Nut 4 Washer Lock 14 Lead 4T 24 Clamp 5 Nut 15 Lead 5B 25 Screw 6 Sparkplug 16 Lead 5T 26 Bracket 7 Lead 1B 17 Lead 6B 27 Tie Cable 8 Lead 1T 18 Lead 6T 28 Kit Ground Terminal 9 Lead 2B 19 Washer Lock 29 Mag Sensor Unit 10 Lead 2T 20 Screw FIGURE 8 12 IGNITION SYSTEM FOR 10 550 G5B G6B 10 550 2 N6B N8B OCTOBER 2000 8 13 8 2A ACCESSORY DRI
89. 0 21 7 Starter adapter to crankcase 31 24 180 220 15 18 3 Starter motor to starter adapter 375 24 200 220 16 7 18 3 75 85 6 3 7 1 375 41 Cover to starter adapter Nut 550 375 16 3 200 220 16 7 18 3 A C G 24 1 180 220 15 0 18 3 Sheave to starter shaftgear Nut 12 point self locking 550 5625 18 1 450 500 _ 37 5 41 6 Alternator drive gear to crankshaft 31 24 140 150 11 7 12 5 Collar assembly governor transfer 25 28 75 85 6 3 7 1 Accessory drive gear to crankshaft Bolt Hardness 31 24 380 420 31 7 35 0 R 38 42 Connecting rod Nut 6 Point Hex All 44 20 2 550 600 45 8 50 0 Connecting rod Nut 12 Point All 44 20 2 690 710 57 5 59 2 Cylinder to crankcase 7th stud 4420 6 490 510 40 8 42 5 An 3124 4 Al 50 20 4 615 635 512 529 crankshaft at crankcase nose 44 20 440 460 36 7 38 3 4 4 4 R H side crankcase below crankshaft 31 18 2 155 175 12 9 14 6 1 Crankcase flange backbone Nut All with 31 24 180 220 15 0 18 3 1 2 Cover to starter adapter 550 80 22 15 0 18 3 Scavenge pump cover to scavenge pump housing Nut 550 31 24 Stainless Steel Nuts 131 24 12 240 280 20 23 3 275 325 Through Bolt Crankcase Upper Rear 38 24 2 275 325 22 9 27 1 155 175 12 9 14 6 2 2 3 1 5 Tie Bolt Crankcase Rear 31 18 3 9 14 Through stud at oil cooler 31 24 1 180 220 15 0 18 3 S
90. 0 RPM 18 4 x 973 17 9032 Maximum Metered Pressure Limit 2640 RPM 19 14 MAY 1998 BRAKE HORSEPOWER 300 280 260 240 220 200 180 160 140 4 120 H 4 100 80 17 FULL THROTTLE HORSEPOWER AT ZERO RAM COT 18 19 20 21 22 23 6 27 28 29 30 ABSOLUTE DRY MANIFOLD PRESSURE IN HG TTE T 24 25 2 FIGURE 19 4 SEA LEVEL PERFORMANCE 10 550 MAY 1998 BRAKE HORSEPOWER 19 15 FUEL FLOW LBS HR 0S 09 02 08 06 001 OLL 01 051 OSL 00 08c 092 orz 0cc 002 081 edd UBD d 06 SC uiouo23 sag JoMOd 1seg AMV SA T3613 V 0SS Ol 09 FIGURE 19 5 FUEL FLOW VS OBSERVED BRAKE HORSEPOWER 10 550 MAY 1998 19 16 550 METERED FUEL PRESSURE VS FUEL FLOW METERED FUEL PRESSURE PSI yN 3 o co N N 3 psi tolerance 3 o c o 2 E Z 5 Ee gt gt 3 9 o lt S oE 5 925 D E tU o 6 D 5 gt 255 c 5 Lets Note this data is approximate with ARAI N e N D FIGURE 19 6 FUEL FLOW VS METERED PRESSURE 550 MAY 1998 a 140 120 100 80 60 40 20 FU
91. 000 Slick Ignition Systems Master Service Manual Index and Order Form No F 1100 Order through Slick Aircraft Products Unison Industries 530 Blackhawk Park Avenue Rockford Illinois 61104 ATTN Subscription Department Telephone 815 965 4700 American Society for Testing and Materials ASTM Order through ASTM 1916 Race Street Philadelphia PA 19103 1187 USA Ph 215 299 5400 1 6 1 7 1 8 SERVICE DOCUMENTS Teledyne Continental Motors service documents are divided into six categories 1 Mandatory Service Bulletin 2 Critical Service Bulletin 3 Service Bulletin 4 Service Information Directive 5 Service Information Letter and 6 Special Service Notice SSN See Section 1 5 Related Publications for service document ordering information SERVICE DOCUMENT CATEGORY DEFINITIONS CATEGORY 1 MANDATORY SERVICE BULLETIN MSB Service documents relating to known or suspected hazards to safety that have been incorporated in whole or in part in an Airworthiness Directive AD issued by the FAA or have been issued at the direction of FAA by the manufacturer in order to require compliance with an already issued AD or an equivalent issued by another country s airworthiness authority CATEGORY 2 CRITICAL SERVICE BULLETIN CSB Service documents not included in Category 1 that have been determined by the product manufacturer to constitute a threat to continued safe operation of an aircraft or to person
92. 013T LINKAGE END NEW BUSHING MUST BE INSTALLED FROM SIDE OPPOSITE CHAMFER INSTALL NEW BUSHING FLUSH WITH THIS SIDE FIGURE 10 4 GENERAL LEVER BUSHING REPLACEMENT 3 Section 6 19 Application Of Accelagold applies to all aluminum alloy castings sheet metal and tubing INDUCTION SYSTEM SUB ASSEMBLY See Figure 10 6 WARNING Never use teflon tape on induction system component fittings Note All induction system components must be clean and free of debris before assembly The throttle must be assembled using the following procedures and special tool 1 Staking Tool conforming with the specifications in Figure 10 6 See Figure 10 2A Throttle Assembly 10 550 A amp B Slide throttle shaft 14 into throttle body Using SHELL 5 grease or LUBRIPLATE 630 or equivalent lubricate shaft at both bushings Install plate 15 into shaft Secure using new screws 16 Snug screws 16 hand tight using a screwdriver The throttle plate screws are designed with a hollow end that must be expanded to safety the throttle plate screws in place Using a staking tool conforming with the specifications in Figure 10 6 stake both throttle plate screws in accordance with the instructions in Figure 10 5 Install new washers 4 5 on the throttle shaft Install collar 2 MAY 1998 10 11 Secure collar with new 3 Spread both ends of pin 3 using a punch and ball hammer Install adjusting screw and spring 8 9 in lever
93. 10 7 5 9 2 1 90 110 7 5 9 2 5555 a UJ drive Upper throttle support brackets Nut 550 25 28 together Fuel control to throttle Bolt 550 25 20 Shroud to fuel control Nut 550 25 28 G N P R A B C Intake tube flange to cylinder Nut 550 25 2 G N P R Fuel pump to crankcase Nut 31 24 Fuel nozzle to cylinder Nozzle 1 90 110 7 5 9 2 75 85 6 3 7 1 90 110 7 5 9 2 75 85 6 3 7 1 4 85 110 7 0 9 2 8 90 110 7 5 9 2 2 180 220 15 18 3 55 65 4 6 5 4 6 18 OCTOBER 2000 Thread Torque Fuel nozzle to cylinder Nozzle 550 31 24 55 65 4 6 5 4 G N P R Bracket to fuel manifold valve 550 10 24 21 25 1 7 2 0 valve B C G N P R ues jene intake manifold Bolt G N P R 31 18 2 155 175 12 9 14 6 Harness plate to magneto 10 32 6 20 22 1 7 1 8 75 20 110 120 9 2 10 0 300 360 25 0 30 0 Lead to spark plug Spark plug per Fuel injection line to fuel nozzles 31 32 6 40 45 3 3 3 8 37524 6 55 60 4 6 5 0 Cover to magneto accessory dive 25 28 8 90 110 75 92 Series Series Torque loads listed are for use with oil on threads If cotter pin holes must be aligned set torque wrench at low limit and torque nut to first hole beyond this torque Stud driving torques apply when studs are coated with lubricant or sealer Do not exceed the high limit torque Housing utilizes l
94. 11 AIR CONDITIONING PAGE Air Conditioning System Disassembly 11 2 Optional Compressor Mounting Kit Disassembly 11 2 Compressor Mounting Kit 11 3 Compressor Mounting Kit 11 3 Compressor Mounting Kit Repair And Replacement 11 3 Compressor Mounting Kit Sub assembly 11 3 PAGE Optional Compressor Mounting Bracket 11 2 11 1 AIR CONDITIONING SYSTEM DISASSEMBLY See Figure 11 1 1 Loosen attaching hardware 8 9 13 14 15 Turn tensioning bolt 10 counterclockwise and relieve belt tension Remove compressor drive belt 18 Remove attaching hardware 13 14 15 and separate compressor not shown from mounting bracket 1 Further compressor removal must be performed in accordance with the airframe manufacturer s instructions FIGURE 11 1 OPTIONAL AIR CONDITIONING COMPRESSOR MOUNTING BRACKET 1 Bracket 9 Washer special 17 Washer 2 Sheave 10 Bolt Special 18 Belt Drive 3 Ball Bearing 11 Nut 19 Sheave 4 Retaining Ring 12 Nut Rectangular 20 Nut 12 Point Self Locking 5 Bracket Idler Sheave 13 Nut 21 Shim 6 Sheave Support Bolt 14 Washer Plain 22 Shim 7 Spacer 15 Bolt 8 Bolt 16 Bolt 11 2 OPTIONAL AIR CONDITIONING COMPRESSOR MOUNTING KIT DISASSEMBLY 1 Remove the through bolt
95. 21 22 23 Carefully tap through bolts 20 24 and remove Remove three bolts 14 and washers 4 NOTE Do not attempt to remove bolt and washer adjacent to right magneto upper stud The bolt and washer are installed before the upper magneto mounting stud and cannot be removed without causing damage to the bolt hole Rotate the engine stand placing the right crankcase half downward Support the engine with a prop under the right crankcase half A length of 2 X 4 lumber with the end supporting the crankcase padded may be used Remove remaining half inch nuts 18 and washers 17 Remove baffle support 19 Tap half inch through bolts 15 with a plastic or rawhide mallet and pull from opposite side of crankcase to remove Do not damage through bolt threads Remove and discard o rings 16 Remove attaching hardware 11 through 13 Tap 3 8 through bolt 10 with a plastic or rawhide mallet Remove through bolt carefully to prevent thread damage Remove support and rotate stand so that engine is in inverted position Remove six sets of attaching hardware 28 29 30 and four sets of attaching hardware 25 26 27 Rotate engine stand placing left crankcase half downward Replace support prop See Figure 16 3B Engine Mounts Crankshaft Seal Retainer amp Governor Cover 550 G N P R Disconnect right crankcase engine mounts from engine stand Carefully lift right crankcase half from left crankcase half to prevent connecting rods from h
96. 25 Timing Indicator or equivalent Ignition Timing Compression stroke breaker opens Right Magneto degrees 22 1 Left Magneto degrees 22 1 1 Remove all top spark plugs Rotate the crankshaft in the direction of normal rotation until the number one piston is at top dead center on the compression stroke Rotate the crankshaft in the opposite direction of normal rotation until the piston is far enough down the barrel to allow the TDC locator to be installed Install the top dead center locator into No 1 cylinder top spark plug hole Install timing disc of indicator being used on the crankshaft flange Turn crankshaft slowly in direction of normal rotation until piston lightly touches TDC locator Rotate disc of timing indicator until the 0 degree mark aligns with the pointer Slowly turn crankshaft in opposite direction of normal rotation until the piston lightly touches TDC locator POSITIVE DEAD CENTER LOCATOR INSTALLED ADJUST THE PROTRAC TOR TIMING INDICATOR DIAL TO THE 07 INDICA NUMBER ONE Ki CYLINDER PISTON LIGHTLY TOUCHING NORMAL DIRECTION OF ROTATION NOTE THE PROTRACTOR TIMING INDICATOR SHOWN IS USED WITH THE PROPELLER AND SPINNER INSTALLED FIGURE 18 18A TIMING PROCEDURE STEP 1 18 32 OCTOBER 2000 7 Observe reading on the disc under the pointer and move the disc to exactly one half of the number of degrees observe
97. 28 6 12 14 2022 FIGURE 18 10 OIL SUMP TORQUE SEQUENCE OIL SUMP 550 amp See Figure 14 3A Coat oil sump flange with TCM gasket sealant 642188 1 Install new gasket 9 and oil sump 10 on crankcase If using beaded style gasket 9 install it with beaded side toward sump See Figure 10 1A install balance tube bracket 15 centered on front oil sump flange See Figure 14 3A Secure oil sump and brackets with attaching hardware 11 through 13 install new gasket 14 splitline toward sump and plug 8 Using the sequence in Figure 18 10 torque bolts 13 to 83 inch pounds preliminary torque Torque bolts 13 to 155 175 inch final torque Torque plug 8 to 190 210 inch pounds Safety wire plug in accordance with section 5 2 Lockwire Procedure OCTOBER 2000 18 15 18 6 18 6 18 7 OIL SUMP 550 550 See Figure 14 3B Coat oil sump flange with TCM gasket sealant 642188 1 Install new gasket 6 and oil sump 7 on crankcase If using beaded style gasket 6 install it with beaded side toward sump See Figure 10 1B install balance tube bracket 12 centered on front oil sump flange See Figure 14 3B Secure oil sump and bracket with attaching hardware 10 11 12 install new gasket 9 splitline toward sump and plug 4 Using the sequence in Figure 18 10 torque bolts 12 to 83 inch pounds preliminary torque Torque bolts 12 to 155 175 inch final torque Torque plug 4 to 190
98. 3 Adapter Oil Filter 8 Bolt 13 Washer Plain 18 Pin Idler Support 4 Gasket Oil Filter 9 Gauge amp Assy 14 Washer Lock 19 Washer Lock 5 Oil Filler Assy 10 Gasket 15 Nut Plain 20 Nut Plain 16 6 MAY 1998 16 3A ENGINE MOUNTS AND GOVERNOR COVER REMOVAL 550 amp See Figure 16 3A 1 10 550 engines remove attaching hardware 8 9 and engine mounts 6 7 2 550 engines engine mount 3 attaching hardware was removed with oil cooler Remove mount 3 and o rings 1 Discard o rings 1 Remove remaining hardware 8 through 11 Remove engine mount legs 2 4 amp 5 3 On 10 550 B engines the engine mount legs were removed during oil sump disassembly 4 Remove attaching hardware 14 through 17 Remove cover 13 and gasket 12 Discard gasket 12 FIGURE 16 3A ENGINE MOUNTS CRANKSHAFT SEAL amp GOVERNOR COVER 10 550 amp C 1 O Ring 8 Washer 15 Washer 2 Mount Engine 9 Nut 16 Washer Lock 3 Mount Engine 10 Washer 17 Nut 4 Mount Engine 11 Nut 18 Retainer 5 Mount Engine 12 Gasket 19 Bolt 6 Mount Engine 13 Cover 20 Plate ID 7 Mount Engine 14 Spacer 21 Screw Drive MAY 1998 16 7 16 38 ENGINE MOUNTS AND GOVERNOR COVER REMOVAL 10 550 G N P R See Figure 16 3B 1 Remove attaching hardware 4 5 6 and engine mounts 1 2 2 Remove attaching hardware 9 through 12 Remove cover 8 and gasket 7 Discard gasket 7
99. 3 thousandths of an inch below inner surface Any studs found to be damaged or loose must be replaced in accordance with the instructions in section 6 22 See Figures 13 3A or 13 3B Starter and Accessory Drive Adapter Stud Setting Heights as applicable for proper stud setting heights Section 6 19 Application Of Accelagold applies to all aluminum alloy castings sheet metal and tubing MAY 1998 13 17 Standard Briney Bushing 63 3 A 17 32 Drill 3 4 DRILL oe 6 pm Bil 2 SSS Locator Cold Rolled Steel 5 S OL 5 Post Cold Rolled Steel NS NFA 6 Adapters Cold Rolled Steel N oE S OQ N S SS 2 R N 4 560 000 1 2 13 TAP 1 SEE LN NOTE DIMENSIONS ARE IN INCHES FIGURE 13 6 STARTER ADAPTER NEEDLE BEARING INSTALLER 13 18 MAY 1998 3 4 FLAT CENTER HARDEN END ONLY 1 8 MACHINE END 6 TO SUIT PRESS RAM 1 4 20 UNC THROUGH 2 PLACES 1 4 20 UNC I THROUGH 2 PLACES MACHINE END TO SUIT PRESS RAM 6 Hydraulic Ram Adapter Cold Rolled Steel NOTE DIMENSIONS ARE IN INCHES GA Hydraulic Ram Adapter Cold Rolled Steel 6B Hydraulic Ram Adapter Cold Rolled Steel FIGURE 13 6 STARTER ADAPTER NEEDLE BEARING INSTALLER continued 1998 13 19 A 1 64 0 4mm Less Than Housing Bore B 003 0 08mm Less Than Shaft Diameter C Pilot Length Should Be Length of Bearing Less 1 32
100. 3428 x Sm AO N Cs AN Ewer O exu SETS 4 26 2 eO TY 6 21 25 4 4 3 5 3 HALF A S s 5 i SECTI C 2 3 SECTION 2 4 6 CASE HALF 1 3 5 CASE HALF section 13 13 FIGURE 16 7A CRANKCASE STUD SETTING HEIGHTS 550 MAY 1998 16 15 CRANKCASE STUD SETTING HEIGHTS ALL 550 EXCEPT 550 B14B B19B B30B NOTE All studs helical coils and plugs must be installed in accordance with the instructions in sections 6 21 6 22 and 6 25 See Figure 6 2 Standard And Oversize Stud Identification ITEM SETTING HEIGHT LOCATION THREAD SIZE IN INCHES Bearing Starter Shaft Gear See section A A 1 Helical Coil poe Install in accordance with section E 6 21 3 Helical Coil Install in accordance with section 4 6 21 s09 1 5 Stud Through 5 16 18 5 16 24 54 11 6 MountPad 5 16 18 5 1624 7 Accessory Drive rear 93846384 2 4 2 8 Accessory Drive rear 5 16 18 5 16 24 75 6 9 lderPinPad 1 420x1428 56 2 10 FuelPumpPad 5 16 18 5 1624 2 75 2 4 5 16 18 5 16 24 1 8 27 Pug 1 16 27 NIN Camshaft Cover Pad Pe Helical Coil Install in accordance with section 6 21 PT ae eee 26 Cylinder 7thStud 1 716 14 716200 HT 6 Oil Cooler MountPad
101. 5 11 Using new gaskets 28 install rocker covers 29 and secure with attaching hardware 30 31 32 Do not torque screws 32 at this time The rocker covers will be removed for engine pre oiling in section 19 2 5 FIGURE 18 17 INSTALLING PUSHROD HOUSING 18 13 CYLINDER BAFFLING IO 550 G P amp See Figures 15 1B amp 9 10 1 See Figure 15 1B Assemble baffle 67 and baffle base using screw and washer 64 65 2 Position baffle assembly 66 67 below and between cylinders 4 and 6 Place baffle support 63 above and between cylinders 4 and 6 Line up bolt holes on bracket 25 of Figure 9 1D with bolt holes on baffle support 63 of Figure 15 1B so that they are centered with anchor nuts on lower baffle assembly 67 of Figure 15 1B Install bolt and washer 61 62 securing lower baffle assembly 66 67 to baffle support and fuel injection line bracket Using same procedure as above install remaining baffles between cylinders 2 4 5 3 and 1 3 18 14 CYLINDER DRAIN ASSEMBLY 550 P amp See Figure 15 1B 1 Coat the male tapered threads of fittings 16 with Loctite pipe sealant with teflon P S T Coat the male tapered threads only Install fittings 16 in cylinders Torque to limit specified in Table 6 3 Torque Specifications for Fittings Install cylinder drain tube assembly 45 on cylinders Torque drain tube B nuts to the limit specified in Table 6 3 Torque S
102. 50 10 550 10 550 10 550 P 10 550 R OCTOBER 2000 13 9 STARTER ADAPTER HOUSING BODY SCAVENGE PUMP FIGURE 13 3B STARTER AND ACCESSORY DRIVE ADAPTER STUD SETTING HEIGHTS FOR 10 550 B1F B2F B3F B4F B5F B6F B11F B12B B13B B15B B16B B17B B18B B20B B21B B22B B23B B24B B25B B26B B27B B28B B29B B31B B32B B33B B34B B37B HEIGHT 1 Stud Starter Adapter to Crankcase 5 16 18 X5 1624 132 1 2 Stud Starter Adapter to Crankcase 56 18 X5 16 24 3 Stud Cover to Adapter 51618 51624 4 Stud Cover amp Scavenge Body to Adapter 5 16 18 X 5 16 24 5 6 Stud Cover to Scavenge Body 5 16 18 X 5 16 24 Stud Cover to Scavenge Body 5 16 18 X 5 16 24 8 Stud Cover to Scavenge Body 5 16 18 X 5 16 24 Stud Starter Motor to Adapter 3 8 16 X 3 8 24 13 10 MAY 1998 FLUORESCENT PENETRANT INSPECTION Aluminum alloy components such as the starter adapter housing scavenge pump body and adapter covers must be fluorescent penetrant inspected by a certified technician in accordance with section 6 12 Fluorescent Penetrant Inspection Housings or covers exhibiting cracks must be discarded MAGNETIC PARTICLE INSPECTION The shaft gear worm shaft and worm gear must be inspected by a certified technician in accordance with the instructions in section 6 9 Magnetic Particle Inspection Gears or shafts exhibiting cracks must be discarded DIM
103. 550 10 550 550 550 18 18 18 8 Starter And Starter Adapter 10 550 B1F B2F B3F B4F B5F B6F B11F 12 B13B B15B B16B B17B B18B B20B B21B B22B B23B B24B B25B B26B B27B B28B B29B B31B B32B B33B B34B B37B 18 9 Optional Compressor 18 18 18 10 Alternator Assembly 5l utetur tono iic Nue e 18 21 18 11A Magneto And Accessory Drive Adapters 10 550 B C G1B G2B G4B G6B 18 22 18 11B Magneto And Accessory Drive Adapters I0 550 G5B 18 23 18 12 Valve Mechanism 10 550 amp 18 23 18 12 Valve Mechanism 10 550 amp 18 24 18 13 Cylinder Baffling 10 550 P amp 18 26 18 14 Cylinder Drain Assembly IO 550 G P amp 18 26 18 15 Exhaust ys COTY uibus dct ii paire oed etat teg e pendit 18 27 18 16A Induction System 10 550 18 27 18 16B Induction System 10 550 18 27 18 16C Induction System 10 550 18 28 18 16D Induction System 10 550 amp 18 28 2000 18 1 18 17 18 17 18 17 1
104. 6 Install new washer 5 and lever 6 on shaft Secure lever with new pin 3 Spread both ends of pin 3 using a pin punch and a ball peen hammer Adjust set screw 11 to position throttle plate 15 full open when set screw is contacting stop pin 17 Hold set screw 11 in position using a screw driver and torque nut 10 to 17 5 22 5 inch pounds Install lever 12 on throttle shaft and secure using new nut 13 Adjust lever 12 as required Torque nut 13 to 100 120 inch pounds torque See Figure 10 2B Throttle Assembly 10 550 Slide throttle shaft 15 into throttle body Using SHELL 5 grease or LUBRIPLATE 630M or equivalent lubricate shaft at both bushings Install plate 16 into shaft Secure using new screws 17 Snug screws 17 hand tight using a screwdriver The throttle plate screws are designed with a hollow end that must be expanded to safety the plate screw in place Using a staking tool conforming with the specifications in Figure 10 6 stake both throttle plate screws in accordance with the instructions in Figure 10 5 Install a plain washer 5 and new wave washer 4 on the throttle shaft Install collar 2 Secure collar with new pin 3 Spread both ends of pin 3 using a pin punch and a ball peen hammer Install adjusting screw and spring 12 11 in lever 9 Install new washer 5 and lever 9 on shaft Secure lever with new pin 3 Spread both ends of pin 3 using a pin punch and a ball peen hammer Adjust s
105. 6 OCTOBER 1998 3 If the cylinder deck stud nuts have been properly torqued during operation when the cylinder is removed a contact pattern can be observed around the stud holes and between the stud holes of the cylinder contact flange If the engine has operated with loose cylinder deck studs fretting and galling will be present in this area Inspect the cylinder to crankcase mating flange for fretting and galling indicating cylinder movement If movement has occurred replace all cylinder deck studs on the corresponding cylinder deck of the crankcase 15 4 CYLINDER AND ASSOCIATED PARTS CLEANING WARNING Do not use sand glass shot or metal grit for cleaning 1 Clean cylinder assemblies and associated parts in accordance with the instructions in section 6 7 General Cleaning and the following special instructions 2 Precautions applicable to both aluminum and steel must be exercised in cleaning the cylinder assembly Remove oil and loose material with a mild alkaline cleaner by spraying or brushing Remove all traces of the alkaline by spraying with steam After the cylinder dries inspect it for any alkaline residues and if necessary respray with steam to remove CAUTION Alkaline cleaning solutions will corrode metals if not completely removed 3 Remove all paint varnish and carbon from the cylinder assembly to allow complete inspection The cylinder assembly may be dry blasted Use blasting techniques to remove hard carbon depo
106. 7 80 0 O CamshaftCoverPad 14204428 69 Pug 4827 Helical Coil Loree Install in accordance with section 6 21 14 15 16 17 19 20 21 22 23 Cylinder Mount Pad 7 16 14 7 1620 41 Cylinder 7th Stud 7 16 14 71620 095 2 SU Bg _ 31 5 16 18x5 16 24 32 Bolt Backbone 5 16 24 Must be installed prior to installing studs item no 6 33 Washer 5 16 1 0 Must be installed prior to installing 1 81 81 36 95 25 26 27 28 9 N 16 18 MAY 1998 32 33 2 4 6 CASE HALF i KD 26 27 26 27 26 6 77 2 4 1 3 5 HALF 3 E TA 5 4 section 3 SECTION 2 4 6 CASE HALF 1 3 5 CASE HALF section 13 13 FIGURE 16 7C CRANKCASE STUD SETTING HEIGHTS 550 MAY 1998 16 19 CRANKCASE STUD SETTING HEIGHTS 10 550 6 P AND 550 9 14 B19B B30B NOTE All studs helical coils and plugs must be installed in accordance with the instructions sections 6 21 6 22 and 6 25 See Figure 6 2 Standard And Oversize Stud Identification ITEM SETTING HEIGHT LOCATION THREAD SIZE IN INCHES Bearing Starter Shaft Gear See section A A 1 Helical Coil Le Install in accordance with section 6 21 3 Install in accordance with section 4 6 21 309 1 5 Stud Through 1 5 16 18 5 16 24 454 11
107. 8 170 18 18 FIGURE 18 1 18 2 18 3 18 4 18 5 18 6 18 7 18 8 18 9A 18 9B 18 10 18 11 18 12 18 13 18 14 18 15A 18 15B 18 16 18 17 18 18A 18 18B 18 18C 18 18D 18 18E 18 19 18 20 18 21 TABLE 18 1 18 2 OCTOBER 2000 Fuel Injection System 1 0 550 18 29 Fuel Injection System 0 550 18 29 Fuel Injection System 0 550 18 30 Fuel Injection System IO 550 G 18 31 Magneto To Engine 18 32 Magneto Timing And Installation On Engine 18 35 Ignition Harness Pre Installation Instructions 18 37 Ignition Harness 18 38 PAGE Left Crankcase And Shafts Assembled On Stand 18 4 Alignment Of Timing Marks eee 18 4 Crankcase Sealant And Threading Procedure 18 6 O Ring Installation 2 02404 1011 18 7 Alternator Drive Gear and Crankshaft Oil Seal Installed 18 8 Right Side View Of Permold Crankcase On Stand 18 8 Bottom View With Oil Suction Tube Installed 18 12 Torquing 18 13 Installing No 6 2 18 14 Torquing Cylinder Base 2 2 2 2 18 14 Oil S
108. ALLING NO 3 FIGURE 18 9B TORQUING CYLINDER CYLINDER BASE NUT 2 Install engine oil coolers using the following instructions Oil Cooler 550 IO 550 G G1B G2B amp G4B See Figure 14 2A slide gaskets 1 and gasket 2 onto crankcase studs Install oil cooler 3 with baffle 4 attached onto crankcase studs Secure with attaching hardware 5 through 11 Torque 3 8 nuts to 275 325 inch pounds Torque 5 16 nuts to 180 220 inch pounds Oil Cooler 550 NOTE Use engine mount bracket P N 653305 which replaces P N 630694 See Figure 16 3A install o rings 1 and engine mount leg 3 on crankcase engine and oil cooler mount studs See Figure 14 2B install gaskets 1 and o rings 2 onto crankcase studs Install oil cooler 3 with baffle 4 attached onto crankcase studs Secure with attaching hardware 5 through 7 in Figure 14 2B and 8 through 11 in Figure 16 3A Torque 3 8 nuts to 275 325 inch pounds Torque 5 16 nuts to 180 220 inch pounds Oil Cooler IO 550 G5B G6B 550 550 550 See Figure 14 2C slide gaskets 1 and gasket 2 onto crankcase studs Install oil cooler 3 with baffle 4 attached onto crankcase studs Secure with attaching hardware 5 through 11 Torque 3 8 nuts to 275 325 inch pounds Torque 5 16 nuts to 180 220 inch pounds 18 14 OCTOBER 2000 18 5 IDLER GEAR SUPPORT PIN CAMSHAFT COVER CRANKSHAFT OIL SEAL RETAINER AND OIL FILLER TUBE NOTE Silk threa
109. AMEL COATINGS Ferrous parts when painted with gold enamel must be baked with infra red equipment for 15 minutes at 275 300 F following the application of each coat NOTE If a part which was originally alodized is to be refinished with enamel it is not necessary to apply zinc chromate primer unless surface areas have been completely stripped of Accelagold CAUTION Before application of primer and enamel to a part carefully mask all connection joints and mating surfaces No primer or enamel is permissible on interior surfaces of any parts contacted by engine lubricating oil after assembly OCTOBER 1998 6 9 6 21 HELICAL COIL INSERT REPLACEMENT Helical coil inserts are installed at the factory in various tapped holes of some engine components Stainless steel helical coil inserts of special design are installed in all spark plug holes Any of these inserts may be replaced if damaged Tools inserts and information are available through HeliCoil Emhart Fastening Teknologies Contact HeliCoil Applications Engineering or customer service at 203 924 4737 for local distributor information The manufacturer s Bulletins 959A 995 943 T4000 and 1000 latest revisions list manual and power driven installing tools tang break off tools special taps plug gauges and tap drill information Helical coil inserts are available in both National Course and National Fine series in lengths equal to 1 1 1 2 and 2 times nominal diameter and in pipe
110. APPLICATION 642188 Gasket Sealant May be purchased through your Cam bore cover gasket except TCM 1 5 oz tube local TCM Distributor or beaded gaskets idler pin gasket K amp W Copper Coat oil filler neck gasket pressed in For Distributor information r all plugs 2 bolt suction tube gasket K amp W Products Customer intake manifold gasket all Phone 1 800423 9446 pressure type plugs Hubbard etc Loctite Pipe Sealant with For Distributor information Pipe threads except fuel system Teflon PS T 592 Loctite Customer Service fittings pressure relief valve Phone 1 800 243 4874 housing threads stud holes that are exposed to oil 2 studs engine mount 1 3 5 side bottom 3 4 OCTOBER 2000 OCTOBER 2000 SUGGESTED SOURCES APPLICATION All pipe thread fittings in fuel 646940 Sealant id Sii injection system use sparingly on y male threads only Apply in or accordance with Figure 9 9 Loctite Hydraulic Sealant 569 For Distributor information Loctite Customer Service Phone 1 800 243 4874 Miller Stephenson For Distributor information Ignition harness terminals at MS 122 2 Spray Miller Stephenson Customer magneto Service block end Phone 1 800 992 2424 TYPE SUGGESTED SOURCES APPLICATION 646941 High Strength May be purchased through your Cylinder deck studs squirt nozzles Adhesive local TCM Distributor fuel manifold valve diaphragm and Sealant or Loctite 271 plunger assembly cr
111. Aerospace Fastener Division 8074 Rosan Lock Ring Installer available from Kent Moore 8118 Rocker Arm Bushing Remover Installer available from Kent Moore 7232 Reamer Rocker Arm Bushing available from Kent Moore DA 200 Contour Probe available from Parker Research Corporation CRANKCASE Borrough s 8114 Crankcase Through Bolt Removers or equivalent L423 Crankcase Splitter available from Kent Moore Borrough s 505 Stud Drivers or equivalent ENGINE DRIVE TRAIN Borrough s 8117A Runout Block Set or equivalent for crankshaft inspection Wheel Fax Jr Mark IV Model O for Crankshaft Ultrasonic Testing available from Fax Corporation Operator must be certified by TCM standards See possible sources on page 2 3 for tool procurement 2 5 Borrough s 8087 Polishing Tools for Crankshaft Bearings or equivalent 4965A Crankshaft Blade and Damper Bushing Remover Replacer available from Kent Moore Borrough s 8077A Bushing Remover amp Replacer Counterweight or equivalent Borrough s 8111A Connecting Rod Fixture or equivalent Borrough s 8042C Adapter Kit or equivalent for connecting rod inspection 5008 Reamers for connecting rod bushing available from Kent Moore D 4000 Federal Dimension Air Gauge for connecting rod bushing inspection available from Federal Tool Supply Co Inc 1 1268 Setting Ring for checking 1 1267 to 1 1269 tolerance available from Federal Tool Supply Co Inc 1 1268 Air Plug for check
112. All 3125 and larger studs unless otherwise specified All mechanical tach drive housing threads not through to an oil source Air reference fittings on all throttle bodies Lubricants SUGGESTED SOURCES APPLICATION Approved Clean 50 Weight See Aviation Engine Oil Ashless Cylinder stud and through bolt Non Compounded or Ashless Dispersant Table threads connecting rod bolt and Dispersant Oil nut threads and engine accessory stud threads unless otherwise specified Approved Clean 50 Weight See Break In Oil Table Crankshaft bearings connecting Break In Non Compounded Oil rod bearings camshaft bearings tachometer gears and adapters accessory spur gear teeth starter cone bushing and nut starter adapter clutch spring ID amp OD sealing surface of valve guide seals pistons piston pins and piston rings rocker arms pivots valves and tappets thrust washers and o rings prop governor transfer collar and sleeve oil filter adapter seals CHAMPION Spark Plug For Champion Products Spark plugs Thread Lubricant No 2612 Distributor information CHAMPION is a registered Phone 803 843 5400 trademark of Cooper Industries WD 40 or Chesterton No 4 Chesterton Technical Product Induction system hose Information connections Phone 508 469 6783 Dow Corning No 4 For Distributor information call 1 Spin on oil filter rubber seals 800 248 2481 have state amp city Magneto adapter gaskets both information ava
113. Box 90 Mobile Alabama 36601 ATTN Technical Publications Department If the user observes incorrect information or mistakes in this publication that may affect safety in any manner immediately call the Technical Publications Department of Teledyne Continental Motors at 334 438 3411 or contact a Teledyne Continental Motors Distributor or the Federal Aviation Administration OCTOBER 2000 1 3 1 5 RELATED PUBLICATIONS The following is a listing of related manuals 1 2 gt 9x 9 Maintenance Manual for 10 550 A B C G N P Form X30634A Illustrated Parts Catalog for 10 550 A B C G N P and R Aircraft Engine Form X30569A Operator and Installation Manual Form X30565 Teledyne Continental Motors Aircraft Engine Service Documents including service bulletins Fuel Injection Manual Form X30593A Starter Service Instructions Form X30592 Ignition Systems Master Service Manual Form X40000 Alternator Service Instructions Form No X30531 3 Equipment Kit Catalog Form X30687A The above publications can be ordered through your Teledyne Continental Motors Distributor or ordered directly if prepaid from Teledyne Continental Motors P 0 Box 90 Mobile Alabama 36601 ATTN Publication Sales Department Telephone 334 438 3411 For price information on the above publications request TCM Publications Pricing Index of Current Publications and Optional Publications 10 11 1 4 OCTOBER 2
114. CEMENT Remove damaged whole studs with a stud remover turning slowly to avoid heating the casting Remove broken studs which cannot be gripped with a standard stud extractor by drilling on center to the correct diameter and unscrewing with a splined stud extractor Splined extractors and drills are usually sold in sets Examine the course thread end of the damaged stud before discarding it to determine its size Standard studs have no marking For oversize stud identification see Figure 6 2 Standard And Oversize Stud Identification Clean the casting tapped hole with solvent and blow dry with compressed air Then examine the thread If it is not torn install the next larger oversize stud If the old stud was of the maximum oversize or if the thread is damaged the hole may be tapped and a helical coil insert installed for a standard size stud provided sufficient stock is available NOTE Cylinder rocker shaft retaining bolt positions are eligible for repair by helical insert provided that a minimum wall thickness of greater than 1 2 times thread diameter remains after tapping for helical coil insert See Chapter 16 for specifications Example T Identification Part Number Identification Color Code XXXXXX Standard FIGURE 6 2 STANDARD AND OVERSIZE STUD IDENTIFICATION ith MAY 1998 6 11 Coat the new stud s course thread with High Strength Adhesive P N 646941 if the hole is blind or if the hole goes through to a cavity subject to leakag
115. CTION REPAIR AND INSTALLATION 17 18 OCTOBER 2000 S A E 6140 HARDEN R C 47 51 amp GRIND 5 46875 4 950 002 S A E 4140 HARDEN amp DRAW FOR MAXIMUM 375R 1 975 1 1875 875 TOUGHNESS amp GRIND 25 1 25 0625 1875 002 REL 4980 000 000 001 1 574 001 1 729 1 3125 750 275 30 005 000 45 375 1 25 749 001 1 71875 DIA SHANK 001 1 105 005 750 00 DIA TO DEPTH SHOWN FIGURE 17 8 OIL CONTROL PLUG INSTALLATION TOOL 6 Loose or leaking crankshaft oil control plugs must be replaced The oil control plug replacement must be performed using the specified procedure and the following special tools 4375 20 diameter bolt approximately eight inches long with 4375 20 NF threads b Aninstallation tool conforming with the specifications shown in Figure 17 8 Oil Control Plug Installation Tool Two inch Merrit Wheel A leak test fixture conforming with the specifications shown in Figure 17 9 Oil Control Plug Leak Test Fixture WARNING Removing and replacing the crankshaft oil control plug with makeshift tools and methods may result in irreparable damage to the crankshaft and crankshaft malfunction MAY 1998 17 19 CEMENT 25 NEOPRENE RUBBER PAD HERE A Miri 0 100 PSI GAGE 125 NPT 50 THK COLD ROLLED STEEL FRAME TAP 125 PIPE 76 FROM CENTER LINE 50 13 BOLT 5 LONG THREADS 3 125 LONG UNDERCUT BOLT
116. E GRINDING 1 2 10 Clean the intake valves with mineral spirits Using a valve grinding machine and proper valve grinding wheel grind the intake valve contact seat at 59 45 to 60 15 to remove any indication of wear This will increase the distance from the new gauge line to the valve stem tip See Figure 15 9 Intake Valve Refacing Clean the valve using mineral spirits Using the gauge line inspection fixture measure the dimension from the gauge line to the bottom of the valve This dimension must be no less than 100 Reground valves not conforming to this criteria must be discarded Valves conforming to this criteria must have the tip ground to maintain the tip to gauge line dimension of 4 714 to 4 724 After valve tip grinding measure the intake valve overall length The valve overall length cannot be less than 4 804 Discard valves that are less than 4 804 in length After grinding process thoroughly clean the valve with mineral spirits and air dry Using a vee block with a surface plate and a dial indicator inspect each intake valve face for run out eccentricity Intake valves exceeding 0015 total indicator reading must be discarded Using an optical comparator inspect the valve contact seat angle Intake valve face angles which do not conform to 59 45 to 60 15 must be discarded Using a profilometer inspect the valve contact seat finish Intake valves exceeding 25 RMS must be discarded Per
117. EL FLOW LBS HR 19 17 RR vete d Altitude Leaning Chart 550 Full Rich 2700 RPM PA yaa Mo 4 ona 90 160 150 110 100 FIGURE 19 7 AUTO LEANING SCHEDULE 550 WITH ALTITUDE COMPENSATING FUEL PUMP 19 18 OCTOBER 2000 13000 14000 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 0 Pressure Altitude feet BRAKE HORSEPOWER FULL THROTTLE HORSEPOWER AT ZERO RAM MN EI 22 EM ce M EI T Ed a zl a E E E 2 ET A 1 LE 17 18 19 20 21 22 23 24 25 26 27 28 29 30 ABSOLUTE DRY MANIFOLD PRESSURE IN HG FIGURE 19 8 SEA LEVEL PERFORMANCE 10 550 MAY 1998 BRAKE HORSEPOWER 19 19 FUEL FLOW LBS HR 06 09 0 08 06 00 0 06 051 06 09 005 082 YAMOdASHOH 092 0 72 ozz 002 081 09 Lbs Derr 193 te Cee 9Jnjxi N uiouo23 1 JoMOd 1seg A a Ea AMV SA 1915 G 0SS Ol FIGURE 19 9 FUEL FLOW VS OBSERVED BRAKE HORSEPOWER 10O 550 B 19 20 MAY 1998 550 METERED FUEL PRESSURE VS FUEL FLOW METERED FUEL PRESSURE PSI
118. ENSIONAL INSPECTION The following new parts limits must be used for dimensional inspection Components that do not meet the following specifications must be discarded All components must be thoroughly cleaned and air dried prior to dimensional inspection MAY 1998 13 11 DESCRIPTION NEW PARTS MIN MAX Starter shaftgear needle bearing hole crankcase Diameter Starter shaft gear front bearing journal Diameter Starter shaftgear in clutch drum bearing Diameter Clutch spring sleeve in starter adapter Diameter Starter shaft gear in ball bearing Diameter Bearing in starter adapter cover Diameter Worm wheel gear End Clearance Worm wheel drum Diameter Starter Shaft gear drum Diameter Clutch spring in clutch spring sleeve Diameter From center line of worm gearshaft to starter adapter thrust 0 2460 0 2480 Needle bearing hole starter adapter Diameter Ball bearing in starter adapter Diameter gearshaft in needle bearing area Diameter gearshaft in ball bearing Diameter Starter worm gear on shaft Diameter Starter spring on worm drive shaft Diameter Starter pilot to starter drive adapter Diameter Starter drive tongue to worm shaft drive slot Side Clearance Starter worm wheel gear and worm gear Backlash Starter adapter Cover Pilot In Adapter Housing Diameter When sand blasted diameter finish is smoother than 75 RMS replace sleeve 13 12 MAY 1998
119. ER 2000 DIMENSIONAL INSPECTION The following new parts limits must be used for dimensional inspection Components that do not meet the following specifications must be discarded All components must be thoroughly cleaned and air dried prior to dimensional inspection Description 0 0010L 0 00401 0 0000 0 0005 0 0000 0 0005 2 352 2 376 2 373 2 375 2 623 2 625 Crankshaft run out at center main journals shaft supported at thrust and rear journals full indicator 222 0 0000 0 0020 0 000 0 003 Damper pin in counterweight 0 0090L 0 0390L Clearance 0 0005T 0 0035T 0 0000 0 0020T Crankshaft in thrust bearing 0 004 0 016 Clearance 0 0005L 0 0018L 0 0010L 0 0030L 0 005 0 012 Camshaft run out at center journals shaft support at end journals full indicator reading etre tt ent tic itat ct ac cu 0 0000 0 0010 0 0005 0 0015T 0 0010 0 0030 Clearance 0 0000 0 0018L 0 0009L 0 00341 Connecting on crank Clearance Connecting rod bearing and bushing twist or convergence per inch of 0 0000 0 0005 OCTOBER 2000 17 11 If crankshaft is worn beyond these limits it may be repaired by grinding crank pins and journals to 0 010 under new shaft limits and re nitriding Crankshaft machining may be accomplished by a repair facility certified for specialized crankshaft repa
120. ERWEIGHT BUSHING REMOVAL Using the specified tools remove the counterweight bushings COUNTERWEIGHT BUSHING HOLE INSPECTION After removal of the counterweight bushings measure the inside diameter of the bushing holes The replacement bushings must have an interference fit of 0015 to 003 inch into the bushing bores The bushing holes must be smooth Counterweights with worn pitted fretted or out of round bushing holes must be discarded Carefully inspect the counterweight counterbores for signs of wear in the wall that retains the counterweight pin retaining plates The area referred to is immediately adjacent to the inside edge of the retaining ring groove It may appear as an additional step and or a taper of the hole into the retaining ring groove If any wear is evident the counterweight must be discarded See Figure 17 7 Counterweight Inspection Repair and Installation If no plate wear is evident check the retaining ring groove in each hole for distorted width depth or other types of wear patterns which can affect the seating of the retaining ring Any worn condition that may affect retaining ring seating will require replacement of the counterweight Crankshaft counterweights are matched in pairs with a maximum weight variation of two grams and the complete crankshaft counterweight assembly is dynamically balanced As a result if either counterweight is damaged a matched pair must be procured and replaced on that cheek COUNTERWEIGHT B
121. Engine Oil Phillips 66 Aviation Oil Type A X C Aviation Multiviscosity Oil SAE 20W50 SAE 20W60 Quaker State AD Aviation Engine Oil Red Ram X C Aviation Cil 20W50 Aeroshell R W Aeroshell Oil W Aeroshell Oil W 15W50 Anti Wear Formulation Aeroshell Oil W 15W50 Aeroshell Oil W Aeroshell Oil W 15W50 Anti Wear Formulation Aeroshell Oil W 15W15 Sinclair Avoil Texaco Aircraft Engine Oil Premium AD Total Aero DM 15W50 Union Aircraft Engine Oil HD Break in Oil MIL C 6529 Type II Corrosion preventive mineral oil NOTE Mineral oil conforming with MIL C 6529 Type II contains a corrosion preventive additive and must not be used for more than 25 hours or six months whichever occurs first If oil consumption has not stabilized in this time drain and replenish the oil and replace the oil filter MAY 1998 3 1 Preservative Oil TYPE SUGGESTED SOURCES APPLICATION MIL C 6529 Type II Aeroshell Fluid 2F or For Temporary storage up to 90 equivalent days MIL P 46002 Grade 1 oil NOX RUST VCI 105 For Indefinite storage equivalent May be purchased through Rock Island Lubricant amp Chemical Co P O Box 5015 1320 1st Street Rock Island Illinois 61204 Phone 1 800 522 1150 SUGGESTED SOURCES APPLICATION Molyshield Grease May be purchased Needle bearings and ball bearings through American Lubricants 1227 Deeds Valve stems Dayton Ohio 45401 Phone 513 222 2851 All ACC drive splines and couplings Idle
122. FOR 1875 PIN CLEARANCE 375 mc HN 21 WELD 50 13 NUT WELD 375 FOR 6 HANDLE DRILL 5625 THRU 125 X 1 50 NIPPLE DILL TR 572 TRUCK TIRE VALVE STEM CUT TO 2 LONG amp THRD 0625 27 125 X 0625 BUSHING FIGURE 17 9 OIL CONTROL PLUG LEAK TEST FIXTURE 17 20 MAY 1998 CRANKSHAFT OIL CONTROL PLUG REMOVAL Remove crankshaft oil control plug using a 4375 20 diameter bolt approximately eight inches long with 4375 20 NF threads and a slide hammer OIL CONTROL PLUG HOLE CLEANING Inspect the inside diameter of the crankshaft for rust and rust pits Discard crankshafts with rust or rust pits The inside diameter of the crankshaft must be clean and free of any sludge residue prior to new plug installation Clean crankshaft inside diameter using a pneumatic drill and a two inch Merrit Wheel C CLAMP NOTE NEOPRENE RUBBER PADS MUST BE INSTALLED BETWEEN C CLAMP SPINDLES AND CRANKSHAFT OIL CONTROL PLUG LEAK TEST FIXTURE CRANKSHAFT NEOPRENE RUBBER PADS NEOPRENE RUBBER PAD CHARGE TO 100 PSI AIR PRESSURE OIL CONTROL PLUG MUST MAINTAIN 60 PSI MIN NOTE FIXTURES MUST BE INSTALLED CAREFULLY TO PREVENT CRANKSHAFT DAMAGE FIGURE 17 10 CRANKSHAFT LEAK TEST MAY 1998 17 21 OIL CONTROL PLUG INSTALLATION Using an air impact tool and the special oil control plug installation tool carefully drive in the new oil control plug WARNING The use o
123. G Fuel injection lines must not be bent or deformed The fuel injection lines must be securely clamped to the fuel line support brackets Do not assemble in a binding configuration 4 Install fuel injection lines 19 through 24 between nozzles 25 and fuel manifold valve 18 Torque fuel line B nuts at nozzles to 40 45 inch pounds Torque fuel line B nuts at manifold valve to 55 60 inch pounds 5 Attach clamps 30 to fuel lines Snap clamps 30 into brackets 31 Install fuel hoses in accordance with the airframe manufacturer s instructions 18 17B FUEL INJECTION SYSTEM 550 1 See Figure 9 1B Apply TCM gasket maker to silk thread and split line of crankcase at fuel pump bore Place silk thread ends into split line of fuel pump bore 2 Apply molyshield grease to fuel pump drive coupling 2 Install fuel pump drive coupling 2 in fuel pump 3 Install new gasket 3A on fuel pump Lubricate fuel pump cavity with clean 50 weight aviation engine oil Install fuel pump on crankcase Secure fuel pump using attaching hardware 34 35 amp 36 Torque nuts 36 to 180 220 inch pounds 3 Apply 646943 anti seize lubricant to fuel nozzle threads cylinder end in accordance with Figure 9 9 General F I Sealant Application Install new fuel nozzles 31 in cylinders 1 through 6 Torque nozzles to 55 65 inch pounds CAUTION Never use teflon tape on fuel injection system fittings WARNING Fuel injection lines must not be bent
124. G Clean engine exterior by spraying or brushing with a solvent used for general cleaning of engine parts Remove caked dirt on bolt heads and nuts At the same time remove the oil sump drain plugs and drain any remaining oil CAUTION Do not use any alkaline cleaning solutions for external engine pre cleaning these solutions will remove the alodized finish of aluminum parts EXTENT OF DISASSEMBLY Exploded parts illustrations used in the engine system chapters are similar to those used in the parts catalog Use the illustrations along with the written procedures to disassemble the engine systems and components Disassemble the engine systems and components to the extent specified in the written procedure of the applicable engine system chapter WARNING Do not attempt to identify components using the illustrations in this manual Component identification must be accomplished using the nomenclature and part numbers in the related parts catalog PARTS TO BE DISCARDED Discard all parts listed in Section 6 6 100 Replacement Parts in such a manner they will not be used again inadvertently Care must be taken in removing gaskets from aluminum parts Such removal should be delayed until the part is to be cleaned 100 PERCENT REPLACEMENT PARTS At assembly during maintenance preventive maintenance and engine or component overhaul replace all gaskets seals packings hoses O rings cotter pins retaining rings snap rings saf
125. G Both bolts and nuts on each connecting rod must be the same type and part number OCTOBER 2000 17 27 NEW CONNECTING RODS HAVE TWO FORGED PROTRUSIONS ON CAP AND ROD NUMBERS MUST BE VIBRO ETCHED ON THIS SIDE NUMBERS MUST BE VIBRO ETCHED IN POSITIONS SHOWN FIGURE 17 13 CONNECTING ROD POSITION NUMBER 10 Remove spring 28 and reinforcing ring 29 from oil seal 30 Unhook spring ends using an unwinding motion Place spring around crankshaft in oil seal area and turn spring ends in an unwinding direction then join and allow one end to wind into the other end Apply Alvania Shell 2 to lip of oil seal and prop flange only Squeeze oil seal until egg shaped and start over flange A special tool P N5209 is available from Kent Moore to assist in oil seal installation After oil seal is on shaft wipe all grease from oil seal and shaft The oil seal outside diameter must be clean and dry before installation in the crankcase Press the reinforcing spring into the oil seal recess by moving fingers in both directions from split Insure spring is in deepest part of recess all the way around Install reinforcing ring on crankshaft and press into oil seal 30 SEAL Y ENGINE 29 SIDE REINFORCING RING FIGURE 17 14 OIL SEAL INSTALLATION 11 Store engine drive train components a clean protected area until final engine assembly 17 28 OCTOBER 2000 18 FINAL ASSEMBLY SECTION PAGE 18 1 Gen
126. G N P R CYLINDER FIGURE 15 3 CYLINDER STUD SETTING HEIGHTS ITEM SETTING 1 2 2000 15 11 PUSHRODS Visually inspect pushrod ball ends for smoothness cracks galling scoring spalling and security Inspect pushrods for bending and warping Discard pushrods with any signs of wear cracks galling scoring spalling bending or warpage Inspect pushrod oil passages for obstructions Use an oil squirt bottle and clean 50 weight aviation engine oil to check oil passages for free flow Pushrods with blocked oil passages that cannot be cleared by solvent action must be discarded PUSHROD HOUSINGS Visually inspect pushrod housings for cracks dents bending and chafing damage Discard cracked dented bent or chafed pushrod housings Discard any pushrod housings with rust pitting and missing cadmium plating CYLINDER BAFFLES Visually inspect all cylinder baffles for cracks loose rivets chafing damage and inspect anchor nuts for security and damaged threads Baffling that has chafing damage caused by cylinder barrel fins indicates that cylinder barrel fin damage may have occurred At this time inspect the corresponding cylinder barrel fins for damage in accordance with the cylinder assembly inspection procedure of this section Discard any baffles exhibiting cracks and chafing damage Replace damaged anchor nuts and loose rivets FLUORESCENT PENETRANT INSPECTION The cylinder assembly must be thoroughly cleaned pri
127. Gaskets and components must be properly positioned hardware torqued and safetied as required during assembly to prevent oil loss HOSE AND TUBING INSTALLATION It is required that the following procedure be used when hoses and tubing are removed attached and torqued to fittings contained on components such as fuel induction lubrication and turbocharger systems OCTOBER 2000 WARNING Failure to properly support component fittings can result in fitting and or component damage and a resulting loss of system pressure 1 2 3 See Figures 4 5 and 4 6 Select the proper size open end wrenches that will fit the fitting body and hose or tubing end fitting Torque or loosen as required the hose or tubing end fitting while maintaining sufficient force on the component fitting to prevent twisting and shear loads Components that contain multiple fittings coupled in one location must have the last fitting in the assembly properly supported as indicated in the preceding paragraphs DO NOT over torque fittings Consult the appropriate manufacturer s manual for specific installation procedures and torque values Figure 4 6 OCTOBER 2000 5 7 INTENTIONALLY LEFT BLANK 5 8 OCTOBER 2000 6 ENGINE OVERHAUL SECTION PAGE 6 1 General 6 2 6 2 Engine Removal Instructions 6 3 6 3 Preliminary Cleaning 2 4 2222 6 4 6 4 Extent o
128. IATED PARTS DISASSEMBLY 1 5 See Figures 15 1 amp 15 1B Cylinder And Piston Assembly Place the cylinder to be disassembled on a cylindrical block of wood anchored to a work bench See Figure 15 1A as applicable Using a valve spring compression tool carefully compress valve springs do not cock the rotocoil or retainer and score the valve stem Remove retaining keys 17 with a retrieval magnet and discard Remove and discard rotocoil 16 Remove steel retainer 26 outer springs 13 and inner springs 12 Remove inner retainers 14 Remove and discard intake valve guide seal 15 Hold the valve stems while lifting the cylinder from its support and place the cylinder on its side Remove any nicks on the valve stems using an emery stone or cloth before removing valves Discard exhaust valves 11 See Figure 15 1B as applicable Using a valve spring compression tool carefully compress valve springs do not cock the rotocoil or retainer and score the valve stem Remove retaining keys 18 with a retrieval magnet and discard Remove and discard rotocoil 19 Remove retainer 51 outer springs 15 and inner springs 14 Remove inner retainers 17 Remove and discard intake valve guide seal 50 Hold the valve stems while lifting the cylinder from its support and place the cylinder on its side Remove any nicks on the valve stems using an emery stone or cloth before removing valves Discard exhaust valves 13 Remove the c
129. ICH MIXTURE 300 BHP 2700 RPM Pressure Fuel Flow Fuel Flow Metered Fuel Altitude Set Ibs hr gals hr Pressure PSID Altimeter at Min 29 92 in Hg Gasoline 5 87 lbs per gallon 70 F Max TABLE 19 4 ALTITUDE FUEL SCHEDULE 10 550 C ENGINE FULL OPEN THROTTLE FULL RICH MIXTURE 300 BHP 2700 RPM Pressure Fuel Flow Fuel Flow Metered Fuel Altitude Set Ibs hr gals hr Pressure PSID Altimeter at Min Min 29 92 in Hg Gasoline 5 87 lbs per gallon 70 F 19 38 MAY 1998 ADJUSTMENT PROCEDURES Fuel Pump Auto Leaning Schedule 550 and C model engines do not attempt to adjust the auto leaning schedule if the aircraft is at a field with a pressure altitude greater than 1000 feet On 550 model engines do not attempt to adjust the auto leaning schedule if the aircraft is at a field with a pressure altitude greater than 3000 feet Refer to Fuel System Adjustment Setup Procedures of this chapter for installation of the required test equipment 1 If not previously accomplished adjust the engine fuel injection system in accordance with Fuel System Adjustment of this chapter using the appropriate table for the engine and aircraft 2 Adjustments to the engine driven fuel pump variable orifice aneroid will result in a change to the auto leaning schedule One complete revolution of the aneroid adjustment will increase or decrease the auto leaning schedule
130. IGURE 15 7A OLD STYLE ROCKER ARM BUSHING REPLACEMENT OLD STYLE ROCKER ROCKER ARM BUSHING REPLACEMENT 1 The same tool used to remove the old bushings from the rocker arm s if properly designed can be used to install the new bushings in the rocker arm s 2 Oil the new bushings with clean 50 weight aviation engine oil and press the new bushings in to the specifications in Figure 15 7A CAUTION Before reaming rocker arms plug the oil passages with beeswax 3 Ream the new bushings to the diameter specified in Figure 15 7A Rocker Arm Bushing Replacement Lightly break the sharp edge at each end of new bushings Inspect the bushing size and RMS finish to the required specifications CAUTION After reaming clean and flush the oil passages using clean solvent Insure that the oil passages are clear of any debris contamination or beeswax 4 Any rocker arms with obstructed oil passages must be cleared by flushing with mineral spirits Any rocker arm with obstructed oil passages that cannot be cleared must be discarded MAY 1998 15 35 NEW STYLE ROCKER ARM BUSHING REPLACEMENT CAUTION Before reworking rocker arms plug the oil passages with beeswax 1 The same tool used to remove the old bushing if properly designed can be used to install the new bushing 2 Measure rocker arm bushing bore 1 0 and insure that it conforms to the dimensions specified in Figure 15 7B or 15 7C as applicable 3 Measure the new bushing O D an
131. ING Bore the new bushing to the specified diameter of 1 1267 1 1269 inches as follows a Place the connecting rod on the base plate and secure with retainers provided b Select the correct adapter kit and boring tool for the connecting rod c Using a vertical mill or equivalent bore the connecting rod bushing to size Maintain 1750 RPM during boring process 17 24 OCTOBER 2000 17 5 CONNECTING ROD INSPECTION Using a profilometer inspect the piston pin bushing finish The required surface finish is 16 Ra Because of the close tolerances required the replaced bushings must be inspected using an air gage with correct size air plug and setting ring The bushing bore 1 0 must be 1 1267 1 1269 After connecting rod bushing inspection the connecting rod bushing alignment with the big end bearing seat must be inspected in accordance with Section 17 3 Dimensional Inspection Connecting Rod Convergence and Twist CAUTION In order to assure good dynamic balance connecting rod assemblies are selected in pairs with a maximum weight variation of 1 2 ounce in opposite bays Therefore rods are supplied in matched sets only WARNING Never remove material from any connecting rod 10 Insure that all engine drive train associated parts listed in section 6 6 10096 Replacement Parts have been replaced ENGINE DRIVE TRAIN SUBASSEMBLY NOTE All engine drive train components must be clean and free of debris before assembly N
132. ION PROTRACTOR TIMING INDICATOR SHOWN IS USED WITH THE PROPELLER AND SPINNER INSTALLED FIGURE 18 18D TIMING PROCEDURE STEP 4 10 To place the crankshaft in the correct timing position for magneto installation move the crankshaft in the opposite direction of normal rotation past the specified magneto timing setting and then back in the direction of normal rotation until the desired setting before top dead center is under the pointer This removes gear backlash NOTE DIAL INDICATOR POSITIONS SHOWN ARE EXAM PLES ONLY POSITIONS ON THE PROTRACTOR TIMING INDICATOR DISC WILL DIFFER FROM ENGINE TO ENGINE POSITIVE DEAD CENTER LOCATOR REMOVED EXAMPLE FULL ADVANCE nh FIRING POSITION 22 BEFORE NUMBER ONE iN DEAD CENTER CYLINDER E i NORMAL DIRECTION OF ROTATION PROTRACTOR TIMING INDICATOR SHOWN IS USED WITH THE PROPELLER AND SPINNER INSTALLED FIGURE 18 18E TIMING PROCEDURE STEP 5 18 34 OCTOBER 2000 MAGNETO TIMING AND INSTALLATION ON ENGINE WARNING Prior to any engine or magneto timing procedure disconnect all ignition harness spark plug leads from the spark plugs Do not attach any ignition harness spark plug leads to the spark plugs until all magneto engine timing procedures and magneto to switch connections have been entirely completed The magneto is in a SWITCH ON condition when the switch wire is disconnected To prevent poss
133. IONS 10 550 X DIAMETER DIAMETER 005 5 256 5 250 5 252 010 5 261 5 263 5 258 5 260 5 255 5 257 NOTE Dimensions shown are finish size after honing Cylinder bore out of round not to exceed new 002 service 003 15 22 OCTOBER 2000 NEW PARTS DIMENSIONS FOR 0 550 amp C Cylinder Assembly Rocker Shaft Boss Bore 0 7495 0 7510 Intake Valve Guide Bore 0 4350 0 4377 Exhaust Valve Guide Bore 0 4375 0 4395 Piston Standard Diameter at Top 5 2126 5 2166 Diameter Below 1st Groove 5 2157 5 2197 Diameter at Bottom 5 2414 5 2424 Pin Bore Diameter 1 1246 1 1250 Third Ring Groove Width 0 1910 0 1920 Fourth Ring Groove Width 0 1000 0 1010 Piston Pin Assembly Length including plugs 5 205 5 220 Diameter 1 1243 1 1245 Measure piston diameter at right angles to pin bore Measurement must be made at 165 inch from bottom of piston NEW PARTS DIMENSIONS FOR I0 550 G N P R Cylinder Assembly Intake Valve Guide Bore 0 4350 0 4377 Exhaust Valve Guide Bore 0 4375 0 4395 Rocker Arm Bushings Inside Diameter 0 7505 0 7515 Valve Rocker Shaft Outside Diameter 0 7482 0 7500 Intake Valve Stem Diameter 0 4335 0 4340 Piston Standard Diameter at Top 5 2126 5 2166 Diameter Below 1st Groove 5 2157 5 2197 2 Diameter at Bottom 5 2414 5 2424 Pin Bore Diameter 1 1246 1 1250 Third Ring Groove Width 0 1910 0 1920 Fo
134. IPLATE 630M or equivalent lubricate all lever and link rod pivot points prior to assembly Using new wave washers 19 install link rod assembly between throttle and fuel control See Figure 10 7 Secure rod ends using new plain washers 20 and cotter pins 19 See section 5 4 Cotter Pin Procedure See Figure 9 1C Fuel Injection System 10 550 as used Install fuel control unit 5 on throttle assembly 4 Secure using new tab lock washers 7 and bolts 8 Torque bolts 8 to 75 85 inch pounds torque Bend tab of washers 7 up against bolt heads to safety See section 5 3 Tab Washer Procedures Using SHELL 5 grease or LUBRIPLATE 630M or equivalent lubricate all lever and link rod pivot points prior to assembly Using new wave washers and plain washers 15 16 install link rod assembly between throttle and fuel control See Figure 10 7 Secure rod ends using new cotter pins 17 See section 5 4 Cotter Pin Procedure Store the fuel control and throttle assembly in a clean protected area until final engine assembly WARNING Install new wave washers plain washers and new cotter pins as shown COTTER PIN Note The parts depicted in this drawing COTTER PIN are larger than the actual components PLAIN WASHER FIGURE 10 7 GENERAL LINK ROD ASSEMBLY 10 550 amp OCTOBER 2000 10 17 INTENTIONALLY LEFT BLANK 10 18 MAY 1998 SECTION 11 1 11 2 11 3 11 4 11 5 11 6 FIGURE 11 1 CHAPTER
135. Install one 3 8 x 10 44 through bolt 10 two o rings 11 two washers 12 and two nuts 13 in position 64 Snug tie bolts 14 install and snug attaching hardware 21 through 23 on through bolts 20 24 This hardware will hold crankcase halves and internal mechanism together during assembly and torquing sequence Rotate engine stand to place engine in upright position as shown in Figure 18 6 with connecting rods supported by old clean cylinder o rings Secure 1 3 5 side engine mounts to engine stand Place lifting eye 8 and ignition bracket 9 at crankcase backbone position specified in Figure 16 1B Install backbone bolts 1 through 3 with washers 4 5 and nuts 6 Finger tighten nuts 6 do not torque at this time Install remaining bolts washers and nuts 1 through 6 in hole positions specified in Figure 16 1B Finger tighten but do not torque at this time Rotate stand to place engine in inverted position Install four 5 16 bolts 25 in hole positions 73 74 75 76 install and finger tighten attaching hardware 26 27 See Figure 14 3C Oil Sump For 10 550 G amp N Install gasket 6 with split line toward crankcase on suction tube 1 Insert threaded end of tube through hole provided in crankcase Install gasket 7 and plug 8 on protruding threaded end of suction tube Attach suction tube bracket to crankcase with bolt 31 washers 29 and nut 30 at position 78 in Figure 18 8 Install remaining 1 4 bolt
136. Key Retainer 31 Washer Lock 45 Tappet Hyd Exh 4 Guide Intake 18 Shaft Valve Rocker 32 Screw 46 Tappet Hyd Int 5 Guide Valve Exhaust 19 Washer Plain 33 Gasket Exh Flange 47 Insert Helical Coil 6 Stud 20 Screw Hex Head 34 Nut 48 Piston 7 Insert Intake Flange 21 Rocker 35 Housing Push Rod 49 Ring Comp 8 Insert Intake Valve 22 Bushing Valve Rocker 36 Washer 50 Ring Comp 9 Insert Exhaust Valve 23 Screw Drive 37 Packing 51 Ring Oil Control 10 Valve Intake 24 Rocker 38 Spring 52 Ring Scraper 11 Valve Exhaust 25 O Ring Cylinder Base 39 Push Rod 53 Pin Piston 12 Spring Inner 26 Retainer Intake Valve 40 Nut Flanged 13 Spring Outer 27 Washer Thrust 41 Nut Flanged 14 Retainer Lower 28 Gasket Rocker Cov 42 Bracket 7th Stud 15 2 OCTOBER 2000 FIGURE 15 1 CYLINDER AND PISTON ASSEMBLY FOR 550 CYLINDER DECK A i CYLINDER BASE PACKING FIGURE 15 1A1 CONNECTING ROD SUPPORT MAY 1998 15 3 15 1B CYLINDER ASSEMBLY REMOVAL See Figure 15 1 1 Loosen and remove cylinder drain tubes 45 Remove and discard drain tube seals 46 Remove drain tube fittings 16 2 Remove attaching hardware 30 31 32 and remove rocker covers 29 from all cylinders Remove and discard gaskets 28 3 Position the crankshaft so the piston is at top dead center and both intake and exhaust valves of cylinder to be removed are closed Bend tab of w
137. Magnetic Particle Inspection Gears or shafts exhibiting cracks must be discarded 14 18 OCTOBER 2000 DIMENSIONAL INSPECTION The following new parts limits must be used for dimensional inspection Components that do not meet the following specifications must be discarded All components must be thoroughly cleaned and air dried prior to dimensional inspection DESCRIPTION NEW PARTS MN OIL PRESSURE RELIEF VALVE ASSEMBLY aes 0 0030 0 0070 1000 22224222 0 0090 0 0130 0 0040 0 0080 SPRING TEST DATA N Oil pressure relief valve spring compressed to 1 25 inch length E 32 Ibs 37 Ibs Oil temperature control valve 0 090 inches minimum travel at 120 170 Oil temperature control valve 0 090 inches minimum travel at 168 172 OIL PRESSURE PUMP ASSEMBLY OCTOBER 2000 14 19 4 AST Ze 15 11 13 12 11 FIGURE 14 6 OIL PUMP AND TACH DRIVE FITS AND LIMITS New Parts Dimensions 14 20 OCTOBER 1998 FEATURE NEW DIMENSION INCH Oil Pump Housing and Shaft Driven Gear Shaft Diameter 0 5640 0 5650 Assembly Driver Gear Shaft Hole Diameter 0 5620 0 5630 Gear Chamber Depth 1 9985 2 0000 Oil Pump Driver Gear Shaft Diameter 0 5600 0 5605 Oil Pump Driven Gear Bushing Inside Diameter installed 0 5655 0 5665 14 6 LUBRICATION SYSTEM COMPONENT REPAIR
138. N SN FIGURE 18 2 ALIGNMENT OF TIMING MARKS CAUTION If the crankcase has been machined gear backlashes must not be less than the specified minimum after machining 6 Measure crankshaft end clearance using a dial indicator set at zero against the propeller flange it must be 0 004 to 0 016 Measure camshaft end clearance at either end of its rear main bearing it must be 0 005 to 0 012 7 See Figure 16 2 Oil Filler Idler Support Pin amp Camshaft Cover Install bushing 16 into crankcase See Figure 17 2 Crankshaft Assembly Using clean 50 wt aviation engine oil lubricate and install idler gear 3 in crankcase See Figure 16 2 Oil Filler Idler Support Pin amp Camshaft Cover Temporarily secure idler gear using new gasket 17 and support pin 18 18 4 MAY 1998 NOTE Idler gear thrust flange must be to the rear and the support pin eccentric shoulder must be away from crankshaft Using a dial indicator check crankshaft and camshaft gear backlash it must be 0 008 to 0 012 Coat camshaft lobes with Dow Corning G N Paste Dow Corning is a registered trademark of Dow Corning Corporation 18 3 CRANKCASE SEALANT AND THREADING PROCEDURE 1 NOTE Use full strength non thinned Permatex aviation grade 3D Shake or mix well before using WARNING Apply thread and permatex only as illustrated See Figure 18 3 Apply Permatex Number 3D to the 2 4 6 case half Apply Permatex only in areas where thread is shown When
139. OTE Before assembly the crankshaft and camshaft must be checked for remaining magnetism from inspection procedures If found demagnetize NOTE The standard magnetic particle inspection procedure found in the latest revision of ASTM standards on nondestructive testing describes the method of magnetization inspection and demagnetization WARNING Failure to replace plugs before the camshaft is assembled in the engine will result in loss of internal oil pressure with little or no lubrication of internal moving engine parts and engine failure OLD SYLE CAMSHAFT 1 See Figure 17 1A Camshaft Assembly Old Style Install the camshaft in a suitable holding fixture Using a rawhide mallet tap a new woodruff key 6 into camshaft groove and tap governor drive gear 7 onto camshaft 2 Install gear 4 on camshaft 1 The gear bolt holes are off set to insure proper positioning for timing Install four new bolts 5 and torque to 240 260 inch pounds Safety wire bolt heads in accordance with section 5 2 Lockwire Procedure After assembly coat camshaft with clean 50 wt aviation engine oil NEW STYLE CAMSHAFT 1 See Figure 17 1B Camshaft Assembly New Style Install the camshaft in a suitable holding fixture Lubricate gear and camshaft splines with clean 50 weight engine oil Install governor drive gear 6 onto camshaft 2 Install gear 4 on camshaft 1 The gear bolt holes are off set to assure proper positioning for timing In
140. POR a INLET OUTLET RETURN RETURN 10 550 A 90 ELBOW 90 90 ELBOW 180 ER 45 FITTING 45 ELBOW 180 90 ELBOW 90 45 ELBOW 250 90 ELBOW 270 HOSE 240 Id 90 ELBOW 180 45 ELBOW 225 Straight Fitting 45 FITTING Straight Fitting 90 ELBOW 90 HOSE 330 0 0 VO A A e o D E FIGURE 9 3B FUEL PUMP FITTING OREINTATION 10 550 B except 10 550 37 B38B B39B B40B B41B B42B B43B B45B B46B B48B B49B B51B B52B FITTING FITTING FITTING ENGINE MIXTURE VAPOR FITTING E INLET OUTLET RETURN RETURN SEAL DRAIN 90 ELBOW 90 90 ELBOW 170 S0 ELBOW 45 _ 45 FITTING 10 550 45 ELBOW 330 45 ELBOW 125 45 ELBOW 270 49 ELBOW 270 Lose 45 OCTOBER 2000 9 13 FITTING 270 180 SECOND FITTING ORIENTATION 180 SECOND FITTING ORIENTATION 90 SECOND FITTING ORIENTATION NOTE OREINT FITTINGS TO POSITIONS SPECIFIED IN TABLE AN 932 2 PLUG 180 E 270 SECOND FITTING ORIENTATION FIGURE 9 3C FUEL PUMP FITTING ORIENTATION FOR 10 550 B37B B39B B38B B40B B41B B42B B43B B45B 46 B48B 49 B51B 52 10 550 C30B C31B and C32B FITTING C FITTING D PUMP FITTING FITTING FITTING FITTING MIXTURE VAPOR ORIENTATION
141. R DETAIL FIGURE 13 5B WORM WHEEL DRUM DIMENSIONS DESCRIPTION A DIAMETER DIAMETER New Wormwheel Drum 1 931 1 932 1 955 1 960 0 015 Undersize 1 916 1 917 1 940 1 945 13 16 MAY 1998 13 6 STARTER AND STARTER ADAPTER REPAIR AND REPLACEMENT 1 Any starter or starter adapter component found to be worn beyond new parts limits or failing to meet the inspection criteria in section 13 5 must be replaced unless repair is possible with the following instructions The starter motor assembly must be overhauled in accordance with the manufacturer s instructions See TCM Form X30592 for TCM starters See section 1 5 Related Publications for ordering information Starter adapter housings accessory drive adapter housings adapter covers shaft gears worm wheel gears worm gears or worm gear shafts exhibiting cracks must be discarded and replaced Scavenge pump covers and bushings with any indications of wear must be discarded and replaced The starter adapter housing worm shaft needle bearing must be replaced using the following procedure and special tools a Arbor Press b TCM Starter Adapter Housing Needle Bearing Installer or equivalent See Figure 13 6 Starter Adapter Needle Bearing Installer See Figures 13 1 amp 13 2 Starter and Starter Adapter Using the specified tools install a new needle bearing 10 or 11 as applicable into the starter adapter housing Press the new bearing in until it is 0 0
142. RE NUMBER ANGLE PSI 25 LBS HR PSI AMBIENT 10 550 0 15 0 14 0 14 5 0 0 653353 1 9 15 0 35 5 40 1 0 0 18 15 0 64 5 68 5 0 0 30 15 0 102 0 107 0 0 0 47 15 0 145 8 150 8 0 0 55 15 0 162 4 166 9 0 0 FULL THROTTLE 15 0 180 0 187 0 0 0 SETTINGS LIMITS PART THROTTLE INLET PRESSURE FUEL FLOW METERED PRESSURE NUMBER ANGLE PSI 25 LBS HR PSI AMBIENT 10 550 N P R 0 4 4 7 4 7 9 0 0 653353 1 9 8 5 29 7 33 7 0 0 18 10 0 51 5 55 5 0 0 30 9 8 85 0 90 0 0 0 47 9 5 124 3 129 3 0 0 55 10 5 148 3 153 3 0 0 FULL THROTTLE 13 2 194 0 202 0 0 0 Store all induction system components in a clean protected area until final engine assembly THROTTLE BODY THROTTLE PLATE STAKING TOOL see the following pages for specifications CRACKED THROTTLE THROTTLE PLATE ADJUST STAKING PIN FOR CORRECT APPLICATION OF PRESSURE PLATE SCREWS MUST EXCESSIVE PRESSURE BE REPLACED WILL CRACK SCREWS FIGURE 10 5 STAKING THROTTLE PLATE SCREWS OCTOBER 2000 10 13 1 1 1 1 2 1 1 1 1 1 3 3 3 10 14 OCTOBER 2000 STAKING TOOL BILL OF MATERIAL PART NAME JAW JAW JAW ACTUATOR JAW ACTUATOR HANDLE TUBING NUT HEX SOCKET SET SCREW PIN FLAT HEAD WASHER FLAT RETAINING RING PIN FLAT HEAD WASHER FLAT RETAINING RING 2 PLACES STOCK SIZE MATERIAL INCHES 4130 STEEL 4130 STEEL 4130 STEEL 4130 STEEL 1020 STEEL STD STEEL STD STEEL STD STEEL STD STEEL
143. Rocker Arm Bushing Replacement 10550 A BO sod 15 37 15 7C Style Rocker Arm Bushing Replacement IG 550 O NP Rinne aote ire dus 15 38 15 8 Rocker Arm To Rotocoil Clearance 15 39 15 9 Intake Valve 15 40 15 10 Valve Gauge Line Inspection Fixture 15 42 15 11 Cylinder and Piston Position Number 15 43 15 12 Valve and Spring Installation 15 43 15 13A Installing Baffle tont etin 15 44 15 13B Securing Baffle 4 testae ette teet ta rettet 15 44 15 14 Valve Guide Seal Installation 15 48 OCTOBER 2000 15 1 15 1A CYLINDER ASSEMBLY REMOVAL See Figure 15 1A 1 Remove attaching hardware 30 31 32 and remove rocker covers 29 from all cylinders Remove and discard gaskets 28 Position the crankshaft so the piston is at top dead center and both intake and exhaust valves of cylinder to be removed are closed Remove screws 20 and washers 19 Slide the rocker shafts 18 out far enough to remove the rocker arms 21 24 and thrust washers 27 Repeat for all six cylinders Rotate the engine stand placing the engine in the inverted position Withdraw pushrods 39 from housings Grasp pushrod housing 35 and push inward tow
144. S Fuel pump drive coupling to crankshaft clearance 0 0095L 0 0155L Fuel pump drive coupling to fuel pump clearance 0 0030L 0 0090L 9 5 FUEL INJECTION SYSTEM REPAIR AND REPLACEMENT Any fuel injection system component worn beyond new parts limits or failing to meet the inspection criteria in section 9 4 must be replaced unless repair is possible with the following instructions 1 Any fuel system brackets hardware plumbing or couplings found to have any of the discrepancies listed in section 9 4 must be replaced 2 Fuel system component lever bushings must be replaced during engine overhaul Place the lever bushing over a ring that will allow the bushing to pass through Using the correct size tool and an arbor press remove the old bushing Inspect the lever bushing bore for a diameter of 249 251 Discard levers that exceed the specified dimension Using the correct size tool and an arbor press install the new bushing in accordance with the specifications in Figure 9 8 The lever and bushing must have a press fit of 007T to 013T MAY 1998 9 21 CHAMFERED SIDE MUST HAVE A PRESS FIT OF 007T TO 013T LINKAGE END NEW BUSHING MUST BE INSTALLED FROM SIDE OPPOSITE CHAMFER INSTALL NEW BUSHING FLUSH WITH THIS SIDE FIGURE 9 8 GENERAL LEVER BUSHING REPLACEMENT 3 Replace all fuel injection system parts listed in section 6 6 100 Replacement Parts 4 Section 6 19 Application Of Accelagold applies to a
145. SIZE AND AUTHORIZED UNDERSIZE PARTS Replacement authorized oversize AO or authorized undersize AU parts must be used with the proper AO and AU mating parts Example Use 015 oversize piston and piston rings with 015 oversize cylinder assembly PROTECTIVE COATING The manufacturer protects all aluminum alloy castings sheet metal and tubing from corrosion by treating all surfaces of the parts with Accelagold aluminum conversion coating Accelagold is manufactured by Turco Products Inc For sales and service contact Elf Atochem N A Turco Products Div P O Box 195 State Route 95 West Marion Ohio 43302 215 419 5376 APPLICATION OF ACCELAGOLD After any machining or repair operation aluminum surfaces must be treated with an aluminum conversion coating If the original aluminum conversion coating has been removed or deteriorated it must be re applied The application of Accelagold solution must be performed in accordance with the manufacturer s Technical Data Bulletin Number 108 31 TURCOAT ACCELAGOLD ALUMINUM CONVERSION COATING Wrought or die cast smooth surface parts such as valve rocker covers and intake tubes are tumble blasted prior to machining to roughen surfaces before treatment Tumble Blasting must not be applied at overhaul on parts with machined surfaces CAUTION Do not use enamel paint or primer for Internal parts The paint or primer may flake or break off during engine run and contaminate lubricating oil EN
146. Seat Grinder Set Sioux Brand available from Aircraft Tool Supply AEX 437 Valve Seat Grinder Pilot 437 Dia available from Aircraft Tool Supply K106 Intake Valve Seat Grinding Stone Roughening 45 available from Aircraft Tool Supply K46 Intake Valve Seat Grinding Stone Finishing 45 available from Aircraft Tool Supply K95 Exhaust Valve Seat Grinding Stone Roughening 45 available from Aircraft Tool Supply K25 Exhaust Valve Seat Grinding Stone Finishing 45 available from Aircraft Tool Supply NOTE See possible sources on page 2 3 for tool procurement 2 4 OCTOBER 2000 ITEM TOOL SEE NO SECTION NOTE Borrough s 5221A Holding Fixture Adapters or equivalent Borrough s 5221 13A Cylinder Holding Fixture or equivalent Borrough s 8156 Cylinder Heating Stand or equivalent Borrough s 8086 Valve Seat Insert Remover amp Replacer or equivalent Borrough s 4910 Installer Valve Seat Insert or equivalent Borrough s 4956 Installer Valve Seat Insert or equivalent Borrough s 8116 Common Parts Kit or equivalent Borrough s 8116 1 B through 15B Boring Bars or equivalent Borrough s 8116 1 R through 15R Reamers or equivalent Borrough s 8116 1 through 16 Expanding Guide Bodies or equivalent 4909 Valve Seat Straight Side Insert Cutters available from Kent Moore 4954 Valve Seat Straight Side Insert Cutters available from Kent Moore 4985 Valve Seat Straight Side Insert Cutters available from Kent Moor
147. TERED PRESSURE UNMETERED PRESSURE 10 550 G N P amp R FIGURE 19 2 THROTTLE FUEL CONTROL AND METERING UNIT ADJUSTMENTS 19 8 OCTOBER 2000 Setup Procedures 1 Locate the IDLE speed stop screw on the throttle body and turn it counter clockwise two complete turns See Figure 19 2 During fuel system adjustment IDLE RPM will be controlled manually using the cockpit throttle control WARNING During removal and installation of fuel lines and hoses failure to properly support component fittings can result in fitting and or component damage and loss of system pressure See chapter 5 Standard Practices 2 Loosen and remove the unmetered fuel supply hose from either the fuel pump outlet fitting or the fuel metering unit inlet fitting whichever is most accessible 3 Install and torque the MS51523 B4 swivel tee directly to the fuel pump outlet fitting or to the fuel metering unit inlet fitting as applicable NOTE Installation may require combinations of different fittings and hoses to facilitate installation of unmetered and metered test equipment connections 4 Attach the unmetered fuel supply hose to the straight end of the tee connector and torque 5 Connect the Unmetered test hose from the Porta Test Unit to the tee fitting and torque If using the alternative procedure connect the 0 60 PSI gauge to the swivel tee using a length of hose which will provide proper clearance from the engine cowling and propeller arc To
148. TERNATOR DRIVE HUB SLIPPAGE INSPECTION 1 The torque required to slip the elastomer coupling when new must be 180 inch pounds 15 foot pounds torque minimum measured after 45 of revolution at a rate of 1 to 2 degrees per second Slippage must occur at the outside diameter of elastomer with no damage to the elastomer Couplings which have been in service for more than 25 hours slippage torque must not be less than 140 inch pounds 11 7 foot pounds torque 2 Drive hubs that do not conform with the above specifications must be discarded ELECTRICAL CHARGING SYSTEM COMPONENT REPAIR AND REPLACEMENT Any electrical charging system component failing to meet the inspection criteria in section 12 4 must be replaced unless repair is possible with the following instructions 1 Repair and replacement procedures for the alternator assembly must be performed in accordance with the alternator manufacturer s instructions 2 Replace all electrical charging system parts listed in section 6 6 100 Replacement Parts 3 Section 6 19 Application Of Accelagold applies to all aluminum alloy castings sheet metal and tubing FIGURE 12 2 COTTER PIN INSTALLATION MAY 1998 12 6 ELECTRICAL CHARGING SYSTEM COMPONENT SUB ASSEMBLY NOTE All electrical charging system components must be clean and free of debris before assembly 1 See Figure 12 1 Alternator Assembly Install new woodruff key 3 coupling assembly 5 and washer 6 The was
149. TING HEIGHT LOCATION THREAD SIZE IN INCHES Bearing Starter Shaft Gear See section A A Helical Coil E Install in accordance with section 6 21 3 Helical Coil Install in accordance with section 4 6 21 __ 0 99 1 6 Magneto MountPad 5 16 18 5 1624 67 4 8 Accessory Drive rear 5 16 18x5 16 24 75 1 3 9 Idler Pin Pad 7 5 16 18x5 16 24 7 6 2 Fuel Pump Pad 5 16 18 5 16 24 2 75 13 3 8 Pug BT EMEN NENNEN NEM Camshaft Cover Pad 142044258 69 3 eer eee 10 11 12 14 15 16 17 18 19 20 21 1 8 27 22 Alternator 5 16 18x5 16 24 23 Helical Coil BEC TAL Install in accordance with section 21 7 8 6 1 8 27 Cylinder Mount Pad 7 16 14x7 16 20 8 36 9 Oil Cooler Mount 3 8 16x3 8 24 8 Oil Cooler Mount Pad 3 8 16x3 8 24 8 29 5 8 18 0 Propeller Governor Pad 5 16 18x5 16 24 1 Bolt Backbone Must be installed prior to installing studs item no 6 32 Washer 5 16 1 0 Must be installed prior to installing studs item no 6 33 34 3 8 16x3 8 24 5 1 Cylinder 7th Stud 7 16 14x7 16 20 24 25 26 27 28 13 74 15 20 22 24 5 28 29 16 14 2000 Pesta PST Us L fort ci anis CES 25 33
150. TS 18 If any of the recorded readings are not within specifications the fuel system will require complete adjustment ALL READINGS MUST BE TAKEN WITH MIXTURE CONTROL IN THE FULL RICH POSITION Install the engine cowling or cooling shroud during all ground operation NOTE Insure that the manifold pressure is adjusted in accordance with the aircraft manufacturer s instructions WARNING Make all adjustments with the engine stopped and the ignition and master switches in the off position 19 To adjust the IDLE RPM unmetered pump pressure loosen the lock nut on the low pressure relief valve See Figure 19 3 Turning the adjustment clockwise CW will increase pressure and counterclockwise CCW will decrease pressure Operate the engine at 1500 1800 RPM for 15 seconds after each adjustment then retard the throttle to the specified IDLE RPM Repeat this step until pressure is within specified limits NOTE It is desirable to set IDLE RPM unmetered pump pressure to the minimum limit With properly adjusted fuel air mixture this will provide a slight fuel enrichment during part throttle operations OCTOBER 2000 19 11 20 With engine operating at the specified IDLE RPM and unmetered fuel pressure slowly move the mixture control from the FULL RICH position toward IDLE CUT OFF to check fuel air mixture A rise of 25 to 50 RPM should be obtained An RPM change greater than 50 indicates the mixture is too rich and a change that is less tha
151. UEL INLET FUEL OUTLET THROTTLE TEE 30 90 ELBOW 0 LEVER 9 18 2000 FUEL NOZZLES 1 The fuel nozzles must be overhauled in accordance with TCM Fuel Injection Systems Overhaul Manual and Parts Catalog Form X30593A or replaced with a serviceable unit See section 1 5 Related Publications for ordering information Teledyne Continental Motors offers factory rebuilt fuel injection system components at exchange prices as an alternative to field overhaul of these units NOTE Further disassembly of the fuel injection system components is not advised unless the proper flow test equipment is available NOZZLE IDENTIFICATION NUMBER STAMPED ON HEX FLAT pone or eer ro FIGURE 9 6A FUEL NOZZLE 10 550 amp 1 Nozzle 3 Shield 2 Screen 4 Jet NOZZLE IDENTIFICATION NUMBER STAMPED ON HEX FLAT SSASSN qur zo a a f ID AF ARP ARP A j LAS 556 2 FIGURE 9 6B FUEL NOZZLE 10 550 amp R 1 Nozzle 3 O Ring 5 Jet 2 Screen 4 Shield OCTOBER 2000 9 19 9 3 FUEL INJECTION SYSTEM CLEANING All fuel injection system components and associated hardware must be cleaned in accordance with the instructions in section 6 7 General Cleaning and the following special instructions All gaskets packings o rings seals self locking nuts wave washers springs cotter pins and lock washers removed from the fuel injection
152. UGES OR OTHER DAMAGE PERMISSIBLE ON BORE AFTER BUSHING REMOVAL BY 45 IF ORIGINAL CHAMFER WAS COMPLETELY REMOVED BY BORING OR REAMING OF 4 00 REPLACEMENT BUSHING 4 00 L2 STAMP CYLINDER POSITION NUMBER ON CONNECTING ROD AND CAP ROD TO BE INSTALLED ON CRANKSHAFT WITH POSITION NUMBER UP 0005 INCH MAXIMUM TWIST PER INCH OF LENGTH WITH NEW BUSHING SPLIT IN BUSHING IN THIS LOCATION FIGURE 17 5 CONNECTING ROD DIMENSIONS 17 14 OCTOBER 2000 NEW PARTS DIMENSIONS Inches Crankshaft Front 2 352 2 376 Rear amp Intermediate Journals 2 623 2 625 5 amp 4 Journals 2 373 2 375 Crank pins 2 248 2 250 Crankshaft Counterweight Blade Bushing Inside Diameter 0 622 0 626 Hanger Journal Diameter 0 9980 0 9990 Connecting Rod Bushing Bore Diameter 1 1267 1 1269 Bushing Center to Crank pin 6 6230 6 6270 Center 17 4 ENGINE DRIVE TRAIN REPAIR AND REPLACEMENT 1 Any engine drive train component found to be worn beyond new parts limits or failing to meet the inspection criteria in section 17 3 must be replaced 100 unless repair is possible with the following instructions 2 The crankshaft can be repaired by grinding crank pins and journals to 0 010 under new shaft limits and re nitriding Crankshaft machining may be accomplished by a repair facility certified for specialized crankshaft repairs NOTE Reground crankshafts must be re nitrided 3 Do not attempt to
153. USHING INSTALLATION After serviceability of the counterweights has been determined new bushings must be installed in the counterweight assemblies Using the same tools that were used for bushing removal install the new bushings The new bushings must be installed into the same positions as the original bushings Replacement bushings are available in standard size only Inspect the new installed bushing inside diameter using an air gauge and with correct air plug and setting ring See Figure 17 7 for correct dimension NOTE After installation of new bushings the counterweights must be magnetic particle inspected in accordance with section 6 9 Magnetic Particle inspection No finishing operation is required The new installed bushings are made to final dimensions OCTOBER 2000 17 17 PRESS BUSHINGS FLUSH WITH THESE SURFACES MINIMUM GAP BETWEEN SNAP RING EARS 0 179 INCH INSTALLED INSTALL SNAP RINGS TOWARD THE BUSHING LEAD IN MUST BE POSITIONED TOWARD COUNTER WEIGHT DURING BUSHING INSTALLATION ASSEMBLY RETAINING RING CHECK THIS AREA FOR PLATE WEAR INSTALL SNAP RINGS WITH SHARP EDGE FLAT SURFACE FACING OUTBOARD RETAINER PLATES HAVE AN EXTRUDED POINT THAT PROVIDES INTERFERENCE FIT EXTRUDED POINT EXAGGERATED FOR CLAIRIFICATION DO NOT INSTALL RETAINER PLATES ON COUNTERWEIGHTS THAT HAVE A LOOSE FIT BETWEEN THE RETAINER PLATE AND THE COUNTERWEIGHT FIGURE 17 7 COUNTERWEIGHT INSPE
154. VE PAD REMOVAL See Figure 8 2A 1 Remove both magneto accessory drive assemblies a Carefully slide each magneto drive gear assembly 12 through 15 out of accessory drive adapter 2 Remove attaching hardware 6 through 11 and remove accessory drive assemblies from rear of crankcase 3 Place the accessory drive components in a clean protected area until they are to be overhauled Nomenclature for Figure 8 2A 1 Gasket 8 Washer Lock 15 Bushing 2 Adapter Assembly 9 Washer Lock 16 Gasket 3 Bushing 10 Nut 17 Cover 4 Seal Oil 11 Nut 18 Washer Plain 5 Stud 12 Gear Assembly 19 Washer Lock 6 Washer Plain 13 Sleeve 20 Nut 7 Washer Plain 14 Retainer 14 2 15 22 FIGURE 8 2A MAGNETO AND ACCESSORY DRIVE ASSEMBLY 10 550 G1B G2B G4B G6B 10 550 10 550 amp 10 550 R 8 14 OCTOBER 2000 8 2B ACCESSORY DRIVE PAD REMOVAL See Figure 8 2B 1 Remove both magneto accessory drive assemblies a Carefully slide each magneto drive gear assembly 16 through 19 out of accessory drive adapter 2 Remove attaching hardware 10 through 15 and remove accessory drive assemblies from rear of crankcase 3 Place the accessory drive components in a clean protected area until they are to be overhauled Nomenclature for Figure 8 2B 1 Gasket 8 Seal Oil 15 Nut 22 Washer Plain 2 Adapter Assembly 9 Helical Coil 16 Gear Assembly 23 Washer Lock 3 Bushing 10 Washer Plain 17
155. W PARTS MIN MAX 0 0060 0 0080 Second ring gap at 1 00 50 depth in cylinder barrel 0 034 0 050 Gap for second ring must be at least 006 larger than gap for top ring Diameter 1 1293 1 1295 5 0 0060 0 0110L Connecting bearing and bushing twist or convergence per inch tt T e 0 0000 0 0005 0 0010L 0 0025L Installed outer valve spring ight NOTES T Tight L Loose OCTOBER MAY 1998 15 19 CYLINDER DIMENSIONAL INSPECTION 1 Inspect cylinder bore dimensions in accordance with Figure 15 4 Cylinder Dimensions Cylinders bores that do not conform to the standard size dimensions after honing must be ground to the next oversize dimension Inspect the cylinder base flanges for flatness If cylinder base flange exceeds 001 out of flat the cylinder must be discarded Dimensionally inspect the cylinder exhaust flange stud and rocker shaft hold down stud holes using a thread gauge and determine the appropriate oversize stud for replacement If intake flange studs have been removed for replacement dimensionally inspect the intake flange stud hole s using a thread gauge and determine the appropriate oversize stud for replacement Dimensionally inspect the valve guides inside diameter Guide dimensions must be within specifications the entire length of the guide Replace all valve guides that are worn beyond the required specifications in accordance with the proce
156. YSTEM COMPONENT INSPECTION VISUAL INSPECTION 1 The visual inspection must be performed in accordance with the instructions in section 6 8 Visual Inspection Special attention must be given to the following components and areas 2 Drive Hub Inspect gear teeth for signs of overheating and excessive wear Normal wear produces a fine polish on the tooth thrust faces Gears that have alteration of the tooth profiles score marks burning or pitting must be discarded See Figure 8 3 Gear Tooth Wear for acceptable and unacceptable gear tooth wear FLUORESCENT PENETRANT INSPECTION Fluorescent penetrant inspection must be performed by a certified technician on all aluminum alloy charging system components in accordance with the instructions in section 6 12 Fluorescent Penetrant Inspection During overhaul of the alternator in accordance with the alternator manufacturer s instructions the alternator housings must be fluorescent penetrant inspected in accordance with section 6 12 Fluorescent Penetrant Inspection of this manual Any components exhibiting cracks must be discarded MAY 1998 12 3 12 5 CUT AND BEND AS SHOWN Must Not Touch Thrust Washer 12 4 MAGNETIC PARTICLE INSPECTION The alternator drive hub gear assembly must be magnetic particle inspected by a certified technician in accordance with instructions in section 6 9 Magnetic Particle Inspection Alternator drive hubs exhibiting cracks must be discarded AL
157. ace shaft 24 into mechanical tach drive housing 18 and install on oil pump housing 2 Shaft gear may have to be turned slightly to insure proper meshing with bevel gear 17 As tach drive housing is being installed make sure silk thread is not displaced Secure with washers 22 and nuts 23 Torque nuts 23 90 110 inch pounds 5 Coat cover 26 threads with Loctite Pipe Sealant with Teflon and TCM P N 646943 Anti Seize Lubricant Place a new gasket 25 on mechanical tach drive cover 26 Turning counterclockwise install left hand threaded cover 26 Torque cover 26 to 250 350 inch pounds Safety wire cover 26 in accordance with Section 5 2 Lockwire Procedure 6 Oil pump filter adapter and oil filter assembly will be installed during final engine assembly Cover components and store in a clean protected area until final assembly OIL PUMP 10 550 G5B G6B AND 10 550 2 1 See Figure 14 1C Oil Pump Install oil pump housing 2 in a suitable fixture Lubricate cavity gear contact areas and oil pump gears 4 15 with clean Molyshield grease Install oil pump drive and driven gears in oil pump housing 14 24 OCTOBER 2000 2 Assemble pressure relief valve housing 11 and adjusting screw 9 Turn adjusting screw into housing about halfway Secure adjusting screw using new copper washer 13 and new nut 14 Assemble plunger 6 new spring 7 new washer 8 and slide into relief valve opening in oil pump hous
158. ach pushrod housings new springs 39 washers 36 new packings 38 and second washer 36 with each cylinder INTAKE VALVE wa SEAL SPRING INTAKE GUIDE SEAL A S J A LES v 8 VALVE GUIDE INTAKE GUIDE INSTALLED HEIGHT ABOVE VALVE SPRING RETAINER SAASSSAASASS f FIGURE 15 14 VALVE GUIDE SEAL INSTALLATION 15 48 MAY 1998 INTENTIONALLY LEFT BLANK 15 49 16 1 16 1 16 2 16 16 3B 16 4 16 5 16 6 16 7 16 8 FIGURE 16 1A 16 1B 16 2 16 3A 16 3B 16 4 16 5 16 6 16 7A 16 7B 16 7C 16 7D 16 8 16 9 16 10 16 11 16 12 CHAPTER 16 CRANKCASE PAGE Crankcase Disassembly and Drive Train Removal IO 550 A B IG ha 16 2 Crankcase Disassembly And Drive Train Removal 16 4 Oil Filler And Gauge Housing 16 6 Engine Mounts And Governor Cover Removal 550 amp 16 7 Engine Mounts And Governor Cover Removal O 550 G N P R 16 8 Crankcase Studding 16 9 Crankcase And Associated Parts Cleaning 16 10 Crankcase and Associated Parts Inspection 16 11 Crank
159. ainer O Ring Cover Washer Plain Nut O Ring Motor Starter Washer Nut FIGURE 13 1 STARTER AND STARTER ADAPTER FOR 10 550 10 550 9 B9B B9F B14B B19B B30B B35B B36B 10 550 10 550 G 10 550 10 550 P 10 550 R OCTOBER 13 3 13 1B STARTER AND STARTER ADAPTER REMOVAL See Figure 13 1B 1 Remove attaching parts 49 50 and pull starter 48 from starter adapter Remove and discard o ring 47 Place the starter motor in a clean protected area until it is ready to be overhauled 2 Remove two sets of attaching parts 2 3 4 on outside of crankcase between cylinder No 1 and starter Remove two sets of attaching parts 28 29 from cover 27 and remove starter adapter assembly from crankcase Discard lock washers 3 Remove and discard gasket 1 Place the starter adapter in a clean protected area until it is to be overhauled Nomenclature for Figure 13 1B 1 Gasket 14 Shaft Worm 27 Cover 40 Plug 2 Washer 15 Key Woodruff 28 Washer 41 Bearing Ball 3 Washer Lock 16 Bearing Ball 29 Nut 42 Spacer 4 Nut 17 Ring Retaining 30 Stud 43 Seal Oil 5 Housing Adapter 18 Shaft Gear 31 Stud 44 Sleeve 6 Stud 19 Spring 32 Stud 45 Spacer 7 Stud 20 Gear Worm Wheel 33 Plug 46 Nut 12Point Self Locking 8 Stud 21 Washer Tab 34 Gear 47 O Ring 9 Stud 22 Screw Special 35 Body 48 Starter 10 Stud 23 Bearing Roller 36 Washer Plain 49 Washer 11 Bearing Nee
160. alled This includes precision bearing inserts and anti friction bearings Check new parts on receipt for transit damage All parts must be clean and lubricated as specified prior to installation Refer to Form X30687A Equipment Kit Catalog for part numbers of the major overhaul kits for example Top Gasket Lower End and Overhaul Hardware Kits Refer to Chapter 3 Tools Equipment Sealants And Lubricants for approved products all of which must be on hand when work is started Use only new shakeproof or split lock washers tab washers elastic stop nuts cotter pins and corrosion resistant lockwire Refer to Section 6 6 100 Replacement Parts before assembly Measure clearances of running parts as they are assembled and compare with clearances listed in the applicable component or system chapter During major engine overhaul use only NEW PARTS LIMITS See Section 6 16 Parts Limits The engine overhaul must be performed in a clean dust free environment and engine sub assemblies must be covered whenever they are not in the process of cleaning inspection repair or assembly TORQUE APPLICATIONS Prior to torquing any hardware apply the specified lubricants in accordance with Chapter 3 The accuracy of any torque indicating wrench depends on a smooth application of force and current calibration traceable to the National Bureau of Standards If a nut slot cannot be aligned with a cotter pin hole within the specified limits substitute
161. ankshaft nose seal retainer bolts For Distributor information 653696 Primer or Loctite Loctite Customer Service LocQuic Primer 7471 Phone 1 800 243 4874 649306 Sealant optional May be purchased through Through stud holes on accessory 646940 or Loctite Adhesive your local TCM end of crankcase manifold valve to Sealant 222 optional Loctite bracket screws studs 25 diameter Hydraulic Sealant 569 For Distributor information and smaller Loctite Customer Service Phone 1 800 243 4874 2 White spot Cylinder deck stud nuts through bolt nuts magneto flanges throttle body and fuel metering unit All fuel pump manifold valve throttle and control fittings OCTOBER 2000 3 5 626531 1 be purchased through High temp paint for cosmetic Enamel Gold 1 qt your local TCM Distributor and TCM P N 626531 2 corrosion protection Enamel Gold 1 gal TCM P N 535011 May be purchased through Where applicable for lockwiring Lockwire 032 inch dia Steel your local TCM Distributor Corrosion Resistant ACCELAGOLD For sales and service EIf Corrosion protection interior Turco amp Products Atochem and Tucker GA 30084 Turco Products Div Accelagold is manufactured by Box Turco Products Inc 195 State Route 95 West Marion Ohio 43302 215 419 5376 ENGINE PRESERVATION KIT May be purchased through Engine Preservation e dehydrator plugs TANAIR e desiccant bags P O BOX 117 e str
162. another serviceable nut If the cotter pin hole in stud lies beyond the nut slots when the nut has been torqued properly check stud for proper installation or backing out Check part to see if it has been reduced in thickness Check to insure nut and washer are correct parts for that location The situation must be corrected by whatever replacement is indicated by inspection NOTE See Tables 6 1 through 6 5 on the following pages for Bolt Nut and Screw Torques Driving Stud Torques Pipe Plug Torques Torque Specifications for Fittings Hose Fittings and Specific Torques 6 14 OCTOBER 2000 GENERAL USE TORQUES TABLE 6 1 DRIVING STUD TORQUES SIZE INCH POUNDS FOOT POUNDS 1 4 20 50 70 4 2 5 8 TABLE 6 1 Bolt Nut and Screw Torques SIZE INCH POUNDS FOOT POUNDS 8 32 10 24 5 16 18 100 150 8 3 12 5 3 8 16 200 275 16 7 22 9 7 16 14 300 425 25 0 35 4 NOTE Stud driving torques apply when studs are coated with lubricant or sealer as specified in chapter 3 et ERN 6 2 PIPE PLUG TORQUES SIZE INCHPOUNDS FOOT POUNDS 60 80 7 16 20 400 450 33 3 37 5 2 130 150 3 8 18 1 2 20 550 600 45 8 50 0 1 2 14 NOTE Torque loads listed are for use with 310 350 on threads as specified in chapter 3 4 Steel 60 80 6 Brass Aluminum 75 125 Hardware requiring torque not listed in Table Of Specific Torques must be torqued in accordance with Bolt Nut and Screw Torques
163. applying use short light brush strokes until an even thin coat is obtained The Permatex should be viscous enough that most of the brush marks disappear if not use a new can of Aviation Permatex Allow the Permatex to air dry to a tacky condition before threading Do not apply Permatex to crankshaft nose seal area Apply a thin translucent coat of TCM Gasket Maker P N 646942 to 1 3 5 case half Apply Gasket Maker in all areas that will mate with areas where Permatex was applied on 2 4 6 case half Apply grade D silk thread P N 641543 on 2 4 6 case half only Apply thread as shown in illustration Be sure free ends of thread are covered by gaskets except at the nose oil seal Clean crankcase crankshaft front oil seal land with Locquic Primer N and apply a thin translucent coat of gasket maker Assemble crankcase halves in accordance with the following paragraphs Install and torque all crankcase hardware in proper sequence in accordance with section 18 4 as soon as possible Stand odd numbered connecting rods straight up Have an assistant balance and guide connecting rods through 1 3 5 case half cylinder openings as crankshaft assembly is installed Back idler gear support pin partially out to clear studs Place 1 3 5 right crankcase half on 2 4 6 left case half Push idler gear support pin back onto studs See Figure 16 2 Install support pin attaching hardware 19 20 but do not torque at this time Take care to prevent di
164. ard the crankcase while lifting the cylinder end to remove Remove all pushrod housings 35 Remove springs 38 washers 36 and packings 37 Discard all packings 37 and springs 38 Rotate the engine stand placing the engine in the upright position Make sure piston in cylinder being removed is at the top dead center position Using the specified wrenches remove flange nuts 40 41 44 from cylinder base flange and seventh stud locations Cradle cylinder in arm and withdraw it straight outward Catch the piston with free hand as it clears the cylinder to prevent damage to the crankcase Remove the cylinder base packing 25 Remove piston pin 53 and piston 48 from connecting rod Install the cylinder base packing in a figure 8 pattern around the cylinder deck studs and connecting rod for support See Figure 15 1A1 Connecting Rod Support Remove all of the cylinders and pistons using the above instructions Place cylinders upright on a workbench Remove rocker shafts 18 from cylinders and discard Discard thrust washers 27 Discard all piston pins 53 pistons 48 and piston rings 49 through 52 Using a retrieval magnet remove all of the hydraulic tappets 45 46 from the crankcase tappet bores Discard hydraulic tappets 45 46 Nomenclature for Figure 15 1A 1 Cylinder Assembly 15 Seal 29 Cover Valve Rocker 43 Bracket 7th Stud 2 Cylinder 16 Roto Coil 30 Washer 44 Nut Flanged 3 Insert Spark Plug 17
165. ardware Route wiring bundle clear of engine i Miscellaneous airframe accessories Disconnect the throttle and mixture control accordance with the airframe manufacturer s instructions Remove manifold pressure gauge line and airframe fuel supply hoses in accordance with the airframe manufacturer s instructions Properly cap off lines and connections to prevent fuel spillage and the admittance of debris Removal of the exhaust system may be necessary prior to engine removal See the applicable airframe manufacturer s instructions CAUTION Place a suitable stand under the aircraft tail at the proper load bearing area before removing the engine to prevent airframe damage due to the aircraft tail dropping 10 Attach an engine hoist to the engine The engine hoist must be attached to the engine lifting eyes only Extend the hoist relieving engine weight from the engine mounts OCTOBER 2000 6 3 11 Remove engine mount to airframe attaching hardware in accordance with the airframe manufacturer s instructions NOTE Hoist the engine slowly making sure all wiring lines hoses and connections have been properly disconnected Do not bump or drop engine 6 4 6 6 12 Install the engine on an engine stand transportation dolly or engine shipping container base as applicable Install protective covers over all open lines and fittings Do not use tape or plugs inside the lines or fittings PRELIMINARY CLEANIN
166. are 4 5 6 Torque bolts 6 to 90 110 inch pounds Push new hoses 9 and clamps 8 on front of risers 3 Install balance tube assembly 14 into hoses Torque clamps 8 to 40 50 inch pounds Secure balance tube to oil sump flange bracket using clamp 13 Install new hoses 9 and clamps 7 on rear of risers 2 Install elbows 10 11 into hoses 9 Torque clamps 7 to 40 50 inch pounds Install new hoses 9 and clamps 7 on ends of elbows 10 amp 11 Install throttle assembly into hoses See Figure 9 1C Install bracket 42 on accessory drive adapter studs using existing hardware Torque adapter nuts to 180 220 inch pounds Install brackets 47 48 on bracket 42 using new bushings 45 sleeve 46 and attaching hardware 49 50 Torque nut and bolt 49 50 to 90 110 inch pounds Install spacer 52 and lower bracket 51 on throttle Secure using attaching hardware 22 Torque nut 22 to 90 110 inch pounds Connect lower bracket 51 to tach drive assembly using nut 22 Torque nut 22 to 90 110 inch pounds 18 160 INDUCTION SYSTEM IO 550 G P amp 1 See Figure 10 10 Install plugs 4 5 into intake manifold 2 Torque plugs 4 5 to the specified torque in Table 6 2 Pipe Plug Torques Attach new bumper 3 below manifold where it will contact crankcase backbone Using new gasket 1 assemble throttle and metering assembly to intake manifold 2 Secure with attaching hardware 14 15 19
167. area the cylinder has reached its limit of cooling fin repair and must be replaced CYLINDER BARREL FINS Repairs can be accomplished only on fin tips which are outside of the power stroke stress area of the cylinder barrel Reference Figure 15 2 Pitting sharp indentations or chafing damage in the fin tip LESS than 050 inch deep Remove only enough material to eliminate the damage with a small hand held grinder and fine grit disk or stone or by turning the cylinder on a lathe Precautions must be taken to prevent damage to adjacent fins and localized fin heating during the material removal process Blend the area smooth so that no sharp edges remain and insure that original fin profile and contours are retained Inspect the area for cracks WARNING Do not weld cylinder barrel or barrel fins CYLINDER BARREL Any cylinder or cylinder associated parts worn beyond new parts limits or failing to meet the inspection criteria in sections 15 2 through 15 5 must be replaced unless repair is possible with the following instructions Cylinder machining may be accomplished by a repair facility certified for specialized cylinder repairs The cylinder bore may be ground and honed to but must not exceed the maximum allowable oversize dimension specified in Figures 15 4A1 15 4B1 as applicable Grind the cylinder bore with a cam controlled grinder Use grinding stones that will produce an R finish of 50 micro inches or less Magnetic particle insp
168. arter shaftgear roller bearing hole Governor drive shaft in crankcase Crankcase each half idth Crankcase cylinder deck to cylinder deck idth Accessory drive adapter pilot in crankcase NEW PARTS DIMENSIONS Crankcase Crankshaft Journal Bore diameter 2 5625 2 5635 Camshaft Journal Bore Diameter 1 0000 1 0010 Tappet Guides Diameter 1 0005 1 0015 Governor Driven Gear Bearing Diameter 0 8750 0 8760 Starter Shaft Needle Bearing Hole Diameter 0 9995 1 0005 Idler Gear Support Pin Crankcase Support Diameter front 0 9990 1 0000 Crankcase Support Diameter rear 1 0620 1 0630 Camshaft Journal Diameter 4 0 9980 0 9990 Hydraulic Valve Tappets Outside Diameter 0 9990 0 9995 16 24 OCTOBER 2000 g OVAN Vo EN TENE NY oo SECTION B B SECTION C C FIGURE 16 10 CRANKCASE FITS AND LIMITS OCTOBER 2000 16 25 16 7 CRANKCASE AND ASSOCIATED PARTS REPAIR AND REPLACEMENT Any crankcase or associated parts worn beyond new parts limits or failing to meet inspection criteria in section 16 6 must be replaced 100 unless repair is possible with the following instructions 1 Crankcases with cracks must be replaced or repaired Teledyne Continental Motors has established that welding of crankcases is an acceptable repair process Weld repairs in the crankcase non critical areas shown in Figures 16 6 may be accomplished by a repair facility certified for specialized crankcase repai
169. ashers 26 down and remove screws 27 tab washers 26 and retainers 25 Remove rocker arms 20 shafts 24 and thrust washers 23 from cylinder studs Discard tab washers 26 rocker shafts 24 thrust washers 23 and retainers 25 Withdraw pushrods 40 from housings Repeat for all six cylinders 4 Rotate the engine stand placing the engine in the inverted position Remove all pushrod housings 35 by pushing in toward the crankcase while lifting the cylinder end Remove springs 39 washers 36 seals 37 and packings 38 Discard all seals 37 packings 38 and springs 39 5 Rotate the engine stand placing the engine in the upright position Make sure piston in cylinder being removed is at the top dead center position Using the specified wrenches remove flange nuts 41 42 49 from cylinder base flange and seventh stud locations Remove brackets 47 48 Cradle cylinder in arm and withdraw it straight outward Catch the piston with free hand as it clears the cylinder to prevent damage to the crankcase Remove the cylinder base packing 52 6 Remove piston pin 60 and piston 55 from connecting rod Install the cylinder base packing in a figure 8 pattern around the cylinder deck studs and connecting rod for support See Figure 15 1A1 Connecting Rod Support Remove all of the cylinders and pistons using the above instructions 7 Place cylinders upright on a workbench Discard all piston pins 60 pistons 55 and
170. asket 14 3A OIL SUMP AND SUCTION TUBE REMOVAL See Figure 14 3A 1 2 Remove attaching hardware 11 12 13 Lightly bump oil sump 10 using a soft mallet and remove from crankcase Remove gasket 9 from crankcase oil sump and discard Remove nut 5 washers 2 4 and bolt 3 Remove oil suction tube assembly from crankcase Remove gasket 6 from oil suction tube and discard FIGURE 14 3A OIL SUMP FOR 10 550 amp 1 Oil Suction Tube 8 Plug 2 Washer 9 Gasket 3 Bolt 10 Oil Sump 4 Washer 11 Washer 5 Nut 12 Washer Lock 6 Gasket Copper 13 Screw 7 Gasket Copper 14 Gasket Copper MAY 1998 14 11 14 3B OIL SUMP AND SUCTION TUBE REMOVAL See Figure 14 3B Remove attaching hardware 10 11 12 Lightly bump oil sump 7 using a soft mallet and remove from crankcase Remove gasket 6 from crankcase oil sump and discard Cut and remove lock wire from bolts 2 Remove bolts 2 Qr d oom c Remove oil suction tube assembly from crankcase Remove gasket 3 from oil suction tube and discard FIGURE 14 3B OIL SUMP FOR 10 550 B 10 550 R 1 Oil Suction Tube 10 Washer 2 Bolt 11 Washer Lock 3 Gasket Copper 12 Screw 4 Plug 13 Felt 5 Gasket Copper 14 Bracket 6 Gasket 15 Washer 7 Oil Sump 16 Nut 8 Stud 17 Wire Lock 9 Gasket Copper 14 12 2000 14 3C OIL SUMP AND SUCTION TUBE REMOVAL See Figure 14 3C gv de poc Ne Remove attachi
171. asket 21 Remove attaching hardware 18 20 and cover 16 Remove shaftgear 15 and driven gear assembly 4 5 from oil pump housing Remove oil pressure relief valve 6 through 14 from oil pump housing 2 Discard spring 7 gasket 10 and self locking nut 14 Remove plug 28 and gasket 27 Discard gasket 27 Remove remaining attaching parts 18 19 20 and remove oil pump housing 2 from crankcase studs Remove and discard gasket 17 Place the oil pump components in a clean protected area until they are to be overhauled Nomenclature for Figure 14 1C 1 Oil Pump Assembly 12 Helical Coil 23 Adapter Oil Filter 2 Housing Oil Pump 13 Washer Copper 24 Washer 3 Stud 14 Nut Self Locking 25 Washer Lock 4 Gear 15 Gear 26 Nut 5 Bushing 16 Cover 27 Gasket 6 Plunger 17 Gasket 28 Plug 7T Spring 18 Washer 29 Stud 8 Seat 19 Washer Lock 30 Thread Silk 9 Screw 20 Nut 31 Wire Lock 10 Gasket 21 Gasket 11 Housing 22 Filter Oil 14 6 MAY 1998 10550 2 FIGURE 14 1C OIL PUMP ASSEMBLY FOR 10 550 G5B G6B 14 7 MAY 1998 14 2 OIL COOLER REMOVAL See Figure 14 2A 1 Remove attaching hardware 5 through 11 Remove cooler 3 from crankcase studs Remove and discard gaskets 1 2 2 Place the oil cooler in a clean protected area until it is to be overhauled FIGURE 14 2A OIL COOLER ASSEMBLY FOR 10 550 A 10 550 10 550 G1B G2B G4B 1 Gasket 9 Wa
172. assistance contact your local TCM distributor or TCM field representative Requests for copies of Teledyne Continental Aircraft Engine service publications should be made through your distributor or Teledyne Continental Motors P 0 Box 90 Mobile AL 36601 ATTN Publications Sales Department ENGINE DESIGN FEATURES For a complete description of the engine systems components and maintenance of the engine prior to engine overhaul see the 10 550 Permold Series Maintenance Manual Form X30634A MAY 1998 1 5 1 6 INTENTIONALLY LEFT BLANK 2 TOOLS AND EQUIPMENT Section 2 2 General Information Possible Special Tool Procurement Sources 2 1 2 2 2 3 Special a e e 2 1 2 1 GENERAL INFORMATION The mechanic should be equipped with a complete set of the necessary tools that include the following 1 ceo qe o 10 11 12 13 14 15 Wrenches 1 4 through 1 1 4 Common and Philips Head Screwdrivers Pliers Common Diagonal Cutters Needle Nose Duck Bill Snap Ring Safety Wire Ratchets 1 4 3 8 1 2 Drive Sockets 1 4 Drive 5 32 through 1 2 3 8 Drive 3 8 through 1 1 2 Drive 7 16 through 1 1 4 Sockets Deepwell 1 2 Drive 7 6 through 1 Feeler Gauges Leather or Soft Plastic Mallet Torque Wrenches 0 500 In Lbs and 0 100 Ft Lbs Micrometers Slide Hammer Pullers Thickness Gauges Vernier Calipers Small Hole Ga
173. at a given pressure altitude 7 As an example looking at Figure 19 11 IO 550 B engine at a pressure altitude of 4000 feet the recorded fuel flow was 140 PPH point A The fuel flow specified for this pressure altitude is 142 PPH to 152 PPH The recorded fuel flow of 140 PPH would be correct if we were between 5000 feet and 7000 feet To achieve the specified fuel flow verses pressure altitude we must adjust the variable orifice out Adjustment of the variable orifice aneroid two complete revolutions will move point A two thousand feet to the right to 6000 feet MAY 1998 19 39 19 21 19 40 8 After making any adjustment to the variable orifice torque the lock nut to 25 30 inch pounds 9 Perform a complete ground run up and verify that unmetered and metered pressures and fuel flows are within the limits specified in appropriate table for the pressure altitude these parameters are not within the limits specified make adjustments in accordance with Fuel System Adjustment of this chapter to achieve the specified values NOTE The adjustable orifice tapered needle may be damaged if forced against it s seat The adjustment should move freely Do not continue adjustments if rotational resistance increases suddenly 10 Once the adjustments are completed remove the test equipment in accordance with Fuel System Adjustment Post Setup Procedures of this chapter 11 Perform a flight test in accordance with Test Fligh
174. ate oil transfer collar assembly 18 through 21 from crankshaft Remove and discard o ring 21 Cut safety wire and remove six bolts 22 and gears 23 24 Tap circumference on gear using a rawhide mallet and remove Remove four bolts 25 lockplates 26 and alternator drive gear 27 Discard lockplates 26 Twist and remove split reinforcing ring 29 from oil seal 30 Work oil seal spring 28 from oil seal groove and detach from seal Twist and remove oil seal from crankshaft Discard reinforcing ring 29 oil seal 30 and spring 28 WARNING The counterweights and crankshaft must not be punch marked or scribed for location identification Use tagging or ink methods to identify 8 Discard connecting rod bearings 8 retaining rings 10 retaining plates 11 and counterweight pins 12 13 14 1 Washer Thrust 12 Pin Cwt 6th Order 23 Gear Cluster Large 2 Bearing Crankshaft Main 13 Pin Cwt 4th Order 24 Gear Cluster Small 3 Gear Idler 14 Pin Cwt 5th Order 25 Bolt 4 Nut Spiral Lock 15 Counterweight Assembly 26 Plate Tab Lock 5 Bolt Connecting Rod 16 Bushing Counterweight 27 Gear Alternator Drive 6 Cap Connecting Rod 17 Nut Marsden 28 Spring 7 Rod Connecting 18 Pin Dowel 29 Ring Reinforcing 8 Bearing Connecting Rod 19 Collar 1 3 5 Side 30 Seal Oil 9 Bushing Piston Pin 20 Collar 2 4 6 Side 31 Bushing Damper 10 Ring Retaining 21 O Ring 32 Dowel Crankshaft
175. ble ties 12 b On each magneto remove three screws from cable outlet plate Remove plates from magnetos 1 c Remove ignition harness assembly from engine and discard 2 Remove nuts 4 lock washers 5 and magneto holding washers 6 from each magneto 3 Remove both magnetos 1 from the engine Discard cable ties 12 and lock washers 5 CAUTION Use care to avoid dropping magneto drive bushings and retainers the engine See Figure 8 2A 4 Magneto assemblies must be overhauled in accordance with the magneto manufacturer s instructions see Slick Ignition Systems Master Service Manual Index and Order Form Number F 1100 See Section 1 5 Related Publications for ordering information Nomenclature for Figure 8 1D 1 Magneto 7 Sparkplug 2 Harness Ignition 8 Clamp 3 Gasket 9 Bracket 4 Nut 10 Screw 5 Washer Lock 11 Nut Speed 6 Washer Holding 12 Tie Cable 8 8 MAY 1998 FIGURE 8 10 IGNITION SYSTEM FOR 10 550 B6A B6F B11B 12 B13B B14B B23B 24 28 B29B B35B 10 550 C6A C6F C8B C9B C11B C17B C19B C21B C25B MAY 1998 8 9 8 1E IGNITION SYSTEM REMOVAL AND DISASSEMBLY See Figure 8 1E 1 Remove ignition harness assembly a Remove ignition lead from each spark plug 6 Remove all cable ties 27 b On each magneto remove four screws 20 and lock washers 19 from cable outlet plate Remove plates from magnetos 2 c Remove ignition harness assembly f
176. bushings 19 Apply Molyshield grease to the rubber drive bushings Install two magneto drive bushings into each retainer with the radius rounded edges facing outward Install a retainer and bushing assembly firmly into each magneto drive gear assembly MAY 1998 18 35 3 Install both of the magneto drive gear assemblies in their accessory drive adapters WARNING Any debris that falls into the engine interior must be removed prior to engine operation WARNING Incorrect magneto to engine timing will cause detonation engine failure injury or death 4 Insure that the crankshaft is positioned in accordance with section 18 18 Magneto To Engine Timing FIGURE 18 19 POSITION OF MAGNETO COUPLINGS 5 Without turning the magneto coupling hold the magneto in the position it will occupy when installed Check the alignment of the gear coupling slot and impulse coupling lugs If not aligned pull the magneto drive gear out of mesh and turn to position needed Push gear back into mesh 6 Place a new gasket on the magneto flange and install magneto carefully so that the drive coupling lugs mate with the slots of the drive bushings 7 Install holding clamps lock washers and nuts Snug nuts but do not torque This will allow turning of the magnetos for final timing Remove the T118 timing pins from Slick magnetos 8 Using the above procedure install the remaining magneto 18 36 MAY 1998 9 10 The magneto timing light breaker
177. case and Associated Parts Repair and Replacement 16 26 Crankcase 5 2 4444 4 16 28 Crankcase Attaching Parts IO 550 A B amp C 16 3 Crankcase Attaching Parts 0 550 16 5 Oil Filler Idler Support Pin amp Camshaft Cover 16 6 Engine Mounts Crankshaft Seal Retainer amp Governor Cover 10 550 A B amp 16 7 Engine Mounts Crankshaft Seal Retainer amp Governor Gover 10 550 G NB Rs iota e bene Re kae 16 8 Crankcase Studding Assembly sese 16 9 Inspection of Crankcase Non Critical Area 16 11 Inspection of Crankcase Critical White and Non Critical Shaded lt done 16 12 Crankcase Stud Setting Heights 0 550 16 15 Crankcase Stud Setting Heights 0 550 16 17 Crankcase Stud Setting Heights 0 550 16 19 Crankcase Stud Setting Heights IO 550 G N P R and 550 B14B B19B B3B cinta i 16 21 Crankcase Main Bearing Oil Feed Hole Chamfer 16 22 Dimensional Inspection Torquing Sequence 16 23 Crankcase Fits And Limit
178. ccessory Drive Adapter Assembly Repair 8 20 8 7 SW 8 21 FIGURE PAGE 8 1 Ignition System for 10 550 Specifications 8 3 8 1B Ignition System for 10 550 amp C Specifications 8 5 8 1C Ignition System for 10 550 amp C Specifications 8 7 8 1D Ignition System for 10 550 B amp C Specifications 8 9 8 1E Ignition System for 10 550 P amp Specifications 8 11 8 1F Ignition System for 10 550 G amp Specifications 8 13 8 2A Magneto and Accessory Drive Adapter for 10 550 B G1B G2B G4B N1B P1B 1 8 14 8 2A Magneto and Accessory Drive Adapter for 10 550 8 15 8 3 Gear Tooth 8 17 8 4 Accessory Drive Adapter Stud Setting Heights 8 18 8 5 Magneto Drive Adapter Fits And Limits 8 19 OCTOBER 2000 8 1 8 1A IGNITION SYSTEM REMOVAL AND DISASSEMBLY See Figure 8 1A 1 Remove ignition harness assembly a Remove ignition lead from each spark plug 6 Remove all cable ties 27 b On each magneto remove four screws 20 and lock washers 19 from cable outlet plate Remove plates from magnetos 2 c Remove ignition harness assembly from engine and discard 2 Disconnect ground terminal and retard terminal kits 28 29 from magnetos 2 i
179. ch through bolt 25 in position 46R L and 7 16 inch through bolt 21 in position 45R L Install one 5 16 X 1 12 screw in position 54 and one 5 16 X 1 38 screw in position 53 Tap the through bolt in to a position that will allow installation of hardware Install one 3 8 x 10 44 through bolt 10 two o rings 11 two washers 13 and two nuts 14 in position 64 10 550 A crankcase Install one 3 8 x 11 67 through bolt 10 two o rings 11 one spacer 12 two washers 13 and two nuts 14 in position 64 on 10 550 B crankcase Install one 3 8 x 12 14 through bolt 10 two o rings 11 two washers 13 and two nuts 14 in position 64 on 10 550 crankcase 18 6 OCTOBER 2000 1 16 RADIUS M D MATERIAL COLD ROLLED STEEL POLISH OUTSIDE DIAMETER 10 38 BOLTS moO taer 4 Degrees 116 BOLTS meow 8 Degrees 1 2 BOLTS 1 2 Dla 4 Degrees 4 5 FIGURE 18 4 O RING INSTALLATION TOOL Snug tie bolts 15 install and snug attaching hardware 22 through 24 on through bolts 21 25 This hardware will hold crankcase halves and internal mechanism together during assembly and torquing sequence Rotate engine stand to place engine in upright position as shown in Figure 18 6 with connecting rods supported by old clean cylinder o rings Secure 1 3 5 side engine mounts to engine stand Place fuel manifold valve bracket 7 lifting eye 8 and ignition brac
180. ching hardware 14 15 16 from all cylinders Lift entire induction and throttle assembly from engine as a unit Discard lock washers 15 Loosen clamps 18 and remove induction tubes 6 through 11 hoses 17 and clamps 18 from balanced manifold 2 Discard all hoses 17 Remove gaskets 12 from all cylinders and discard See Figure 9 1D Remove crankcase backbone hardware that secures the air manifold support bracket to the engine and remove support bracket 13A Remove and discard 13B rubber bumpers FIGURE 10 1D INDUCTION SYSTEM FOR 10 550 P amp R 1 2 3 4 5 6 7 8 9 1 Gasket Manifold Bumper Rubber Plug Plug Tube Intake Tube Intake Tube Intake Tube Intake 0 Tube Intake Tube Intake Gasket Flange Washer Washer Lock Nut Plain Hose Clamp Screw OCTOBER 2000 10 5 10 2 INDUCTION SYSTEM COMPONENT DISASSEMBLY Throttle Assembly 10 550 amp 1 Document lever orientation for reinstallation 2 Drive pins 3 out using a 1 8 inch pin punch Remove nut 13 and lever 12 as applicable Remove collar 2 and washers 4 5 Loosen nut 10 and remove lever 6 Remove screws 16 and plate 15 Slide throttle shaft 14 from throttle body Discard pins 3 spring 8 screw 16 wave washer 4 and nut 13 if applicable NOTE Airframe supplied parts such as switch actuating cams must be removed inspected repaired or replace
181. cordance with the instructions in TCM Fuel Injection Systems Overhaul and Parts Catalog Form X30593A FLUORESCENT PENETRANT INSPECTION Fluorescent penetrant inspection must be performed on applicable aluminum alloy fuel injection system components by a certified technician in accordance with the instructions in section 6 12 Fluorescent Penetrant Inspection During overhaul of fuel injection system components in accordance with Form X30593A all aluminum alloy parts such as fuel pump body vapor separator manifold valve body air throttle adapter body covers and flanges must be fluorescent penetrant inspected by a certified technician in accordance with section 6 12 Fluorescent Penetrant Inspection of this manual Any components exhibiting cracks must be discarded MAGNETIC PARTICLE INSPECTION The fuel pump drive shaft must be magnetic particle inspected by a certified technician in accordance with the instructions in section 6 9 Magnetic Particle Inspection Any components exhibiting cracks must be discarded 9 20 MAY 1998 DIMENSIONAL INSPECTION The following new parts limits must be used for dimensional inspection Components that do not meet the following specifications must be discarded All components must be thoroughly cleaned and air dried prior to dimensional inspection FUEL PUMP COUPLING LENGTH 1 37 INCHES 1 Lm FIGURE 9 7 FUEL PUMP DRIVE COUPLING FITS AND LIMITS FITS amp LIMITS FUEL PUMP NEW PART
182. counterweight order is controlled by the pin diameter it is imperative only the correct pin properly identified be used The 4th order 643626 103 pin has an O D of 474 475 The 5th order 643626 104 pin has an O D of 527 528 The 6th order 643626 105 pin has an O D of 0 565 0 566 WARNING Do not exceed ten minutes at 350 F during crankshaft gear heating process Do not use a torch to heat the crankshaft gear The heating process must be performed using uniform heating methods only 2 Heat crankshaft gear 24 to 300 F for 5 to 10 minutes Use thick gloves to handle gear Align gear dowel hole with crankshaft dowel and install gear on crankshaft Attach crankshaft large gear 23 to crankshaft small gear and to crankshaft using four new bolts 22 Torque bolts to 380 420 inch pounds in a criss cross pattern Install lock wire on bolts 22 in accordance with section 5 2 Lockwire Procedure 3 Install alternator gear 27 over propeller flange With holes aligned install tab lock plates 26 and four bolts 25 Torque bolts 25 to 140 150 inch pounds Using a brass drift bend tabs of lock plates up against bolt head flats to safety 17 26 MAY 1998 WARNING Do not over torque bolt s in an attempt to line up head flat with lock tab If head flat will not line up replace the bolt s 4 Lubricate oil transfer collar 19 20 with clean 50 weight aviation engine oil and install on crankshaft Use new pins 18 and secure wi
183. crew 12 to position throttle plate 16 full open when set screw is contacting stop pin 18 Hold set screw 14 in position using a screw driver and torque nut 13 to 17 5 22 5 inch pounds Install lever 6 on throttle shaft and secure using new nut 8 Adjust lever 6 as required Torque nut 8 to 100 120 inch pounds See Figure 10 2C Throttle Assembly 10 550 G N P R Install new o rings 4 and new washer 5 on shaft assembly 3 Coat o rings 4 with a small amount of grade 50 MHS 27 oil Slide throttle shaft assembly 3 into throttle body Using a few drops of clean 50 wt aviation engine oil lubricate shaft at both throttle shaft bosses Install plate 6 into shaft Secure using new screws 7 Snug screws 7 hand tight using a screw driver The throttle plate screws are designed with a hollow end that must be expanded to safety the plate screw in place Using a staking tool conforming with the specifications in Figure 10 6 stake both throttle plate screws in accordance with the instructions in Figure 10 5 Install adjusting screw and spring 13 14 in lever 8 Install lever 8 on shaft Secure lever with new pin 12 Spread both ends of pin 12 using a pin punch and a ball peen hammer Adjust set screw 10 to position throttle plate 6 full open when set screw is contacting stop pin 2 Hold set screw 10 in position using a screwdriver and tighten nut 11 with a wrench Coat o rings 17 with Parker O Lube Install o rin
184. ction system repair facility The air throttle fuel control unit must be assembled and calibrated after overhaul in accordance with the following instructions and the instructions specifications and calibration data contained in the Teledyne Continental Fuel Injection System Overhaul Manual and Parts Catalog Form X30593A WARNING The improper installation of fuel control to throttle linkage and attaching hardware will cause excessive wear and eventual failure See Figure 9 1A Fuel Injection System 10 550 as used Install fuel control unit 5 on throttle assembly 4 Secure using new tab lock washers 8 and bolts 9 Torque bolts 9 to 75 85 inch pounds Bend tab of washer 8 up against bolt hex flat to safety See section 5 3 Tab Washer Procedure Using SHELL 5 grease or LUBRIPLATE 630M or equivalent lubricate all lever and link rod pivot points prior to assembly Using new wave washers and plain washers 15 16 install link rod assembly between throttle and fuel control See Figure 10 7 Secure rod ends using new cotter pins 17 See section 5 4 Cotter Pin Procedure See Figure 9 1B Fuel Injection System 10 550 as used Install fuel control unit 5 on throttle assembly 4A Secure using new tab lock washers 10 and stand off bolts 11 Torque bolts 11 to 75 85 inch pounds torque Bend tab of washers 10 up against bolt hex flat to safety See section 5 3 Tab Washer Procedures Using SHELL 5 grease or LUBR
185. cylinder assembly against the crankcase cylinder deck with the stud holes aligned Install the cylinder deck and through bolt nuts but do not torque at this time Carefully rotate the crankshaft placing the number 3 and number 4 connecting rods in their outer most position Using the same procedure that was used to install the number 1 and number 2 cylinder and piston assemblies install the number 3 and number 4 cylinder and piston assemblies Carefully rotate the crankshaft placing the number 5 and number 6 connecting rods in their outer most position Using the same procedure that was used to install the number 1 and number 2 cylinder and piston assemblies install the number 5 and number 6 cylinder and piston assemblies Install the 7th stud brackets and nuts but do not torque at this time NOTE The 7th stud nuts have a conical seat m See Figure 16 1B on 2 4 6 side of crankcase install baffle support 19 on through bolts n 0 at positions 43L 441 Install attaching hardware 17 18 do not torque at this time On 1 3 5 side of crankcase install attaching hardware 17 18 on through bolts at positions 41R amp 42R do not torque at this time Apply Champion thread lubricant to spark plugs in accordance with the manufacturer s instructions Install gaskets and spark plugs in bottom cylinder spark plug holes Do not Torque at this time Proceed to TORQUING OCTOBER 2000 18 11 TORQUING CAUTION Before torq
186. d High Speed Borer of the correct size Borrough s 8042C Adapter Kit or equivalent f Vertical Mill or equivalent capable of maintaining 1750 RPM g Federal Dimension Air Gauge with a 1 1268 Setting Ring and 1 1268 Air Plug or equivalent h Profilometer WARNING Removing and replacing the connecting rod piston pin bushings with makeshift tools and methods may result in irreparable damage to the connecting rods and connecting rod crankshaft malfunction CONNECTING ROD BUSHING REMOVAL Press out old bushing using connecting rod bushing removal installation set and an arbor press No nicks gouges or other damage is permissible on the bore after bushing removal Connecting rods exhibiting any of the above must be discarded CONNECTING ROD BUSHING INSTALLATION Make sure that the rod bore is smooth Dip the new bushing in clean 50 wt aviation engine oil before placing it in position Verify bushing part number The bushing may be chilled slightly to aid installation Install as follqws a Position connecting rod over the pilot so the mate marks and piston pin bore chamfer are facing up b Place the bushing on the pilot so that the bushing split is located 45 degrees from the center line of the connecting rod facing the crankpin end See Figure 17 5 Connecting Rod Dimensions c Position the ram onto the pilot d Using the arbor press carefully press the bushing flush with the piston pin bore CONNECTING ROD BUSHING FINISH
187. d toward the top center mark NOTE DIAL INDICATOR POSITIONS SHOWN ARE EXAM PLES ONLY POSITIONS ON THE PROTRACTOR TIMING INDICATOR DISC WILL DIFFER FROM ENGINE TO ENGINE POSITIVE DEAD CENTER LOCATOR INSTALLED NUMBER ONE CYLINDER PISTON LIGHTLY TOUCHING OPPOSITE NORMAL DIRECTION OF ROTA TION NOTE THE PROTRACTOR TIMING INDICATOR SHOWN IS USED WITH THE PROPELLER AND SPINNER INSTALLED FIGURE 18 18B TIMING PROCEDURE STEP 2 8 This will be approximately one half the number of degrees remaining of 360 degrees of crankshaft rotation You have now positioned the timing disc to locate top dead center 9 Remove the TDC locator from the cylinder and find the compression stroke on No 1 NOTE DIAL INDICATOR POSITIONS SHOWN ARE EXAM PLES ONLY POSITIONS ON THE PROTRACTOR TIMING INDICATOR DISC WILL DIFFER FROM ENGINE TO ENGINE POSITIVE DEAD CENTER LOCATOR INSTALLED ia NUMBER ONE CYLINDER NORMAL DIRECTION OF ROTATION PISTON LIGHTLY TOUCHING LH OF NOTE THE PROTRACTOR TIMING INDICATOR SHOWN IS USED WITH THE PROPELLER AND SPINNER INSTALLED FIGURE 18 18C TIMING PROCEDURE STEP 3 cylinder by placing a finger over the spark plug hole or any other adequate method As you come up on compression stop the pointer at the TDC location OCTOBER 2000 18 33 POSITIVE DEAD CENTER LOCATOR REMOVED NUMBER ONE CYLINDER NORMAL DIRECTION OF ROTAT
188. d and re installed in accordance with the applicable airframe manufacturer s instructions 4 6 SS amp 5 14 S sj 867 18 ex FIGURE 10 2A THROTTLE ASSEMBLY 10 550 A amp B 1 Bushing 7T Bushing 13 Nut 2 Collar 8 Spring 14 Shaft Throttle 3 Pin 9 Screw Adjusting 15 Plate Throttle 4 Washer Wave 10 Nut 16 Screw 5 Washer Plain 11 Screw Set 17 Pin Stop 6 Lever 12 Lever 18 Bushing Lever 10 6 OCTOBER 2000 Throttle Assembly 10 550 1 Document lever orientation for reinstallation 2 Drive pins 3 out using a 1 8 inch pin punch Remove nut 8 and lever 6 Remove collar 2 plain washer 5 and wave washer 4 Remove nut 13 and set screw 14 Remove lever 9 and plain washer 5 Remove screws 17 and plate 16 Slide throttle shaft 15 from throttle body Discard pins 3 spring 11 screws 17 and wave washer 4 NOTE Airframe supplied parts such as switch actuating cams must be removed inspected repaired or replaced and re installed in accordance with the applicable airframe manufacturer s instructions FIGURE 10 2B THROTTLE ASSEMBLY 10 550 1 Bushing 8 Nut 15 Shaft Throttle 2 Collar 9 Lever 16 Plate throttle 3 Pin 10 Bushing 17 Screw 4 Washer Wave 11 Spring 18 Pin Throttle Stop 5 Washer Plain 12 Screw Adjusting 19 Stud 6 Lever 13 Nut 20 Stud 7 Bushing 14 Screw Set 21 Plug MAY 1998 10 7 Throttle Assembly 10 550 P
189. d bolts 16 In a counterclockwise sequence starting with the through bolt nut torque nut and two bolts to 220 260 inch pounds See Figure 11 1 Optional Compressor Mounting Bracket Install customer supplied air conditioning compressor using kit supplied bolts 15 washer 14 and nuts 13 Torque nuts 13 and bolts 15 to 275 325 inch pounds Further installation must be accomplished using the airframe manufacturer s instructions With all components installed the alignment of compressor starter adapter and idler sheaves must be checked using a calibrated alignment tool Borroughs Tool No 8082 or equivalent see Chapter 2 Tools Check tool flatness calibration by laying it on a surface table Place the alignment tool around the drive sheave with the extended end overlaying the upper portion of the compressor sheave When the alignment is correct the alignment tools extended end bar center will fall within 0 020 inch of the center of the sheave Use this same procedure to check the idler sheave except the extended end of alignment tool will overlay the lower portion of the compressor sheave See Figure 18 11 Checking Sheave Alignment BAR SHEAVE CENTER COHBEESESE IDLER SHEAVE BORROUGHS TOOL 8082 FIGURE 18 11 CHECKING SHEAVE ALIGNMENT MAY 1998 18 19 5 If drive or idler sheaves are not in alignment remove sheaves and install up to but not to exceed five 0 020 shims P N 643956 20 to achieve the corr
190. d ends must be under idler pin and cam cover gaskets 1 Oil Filler Idler Support Pin amp Camshaft Cover See Figure 16 2 torque idler gear support pin nuts 20 to 90 110 inch pounds Using a new gasket 11 install camshaft cover 12 and secure with attaching hardware 13 14 15 Torque nuts 15 to 90 110 inch pounds WARNING Oil pressure is applied to the face of the governor drive pad If gasket accessory or cover is not properly installed and hardware is not properly torqued oil leakage 18 6A will occur 2 Oil Seal Retainer and Governor Cover 550 See Figure 16 3A install crankshaft oil seal retainer 18 and secure with bolts 19 Torque bolts 19 to 21 0 25 0 inch pounds Using new gasket 12 install cover 13 and secure with attaching hardware 14 through 17 or install propeller governor using the correct gasket in accordance with the airframe manufacturer s Instructions Torque nuts 17 to 180 220 inch pounds Oil Seal Retainer and Governor Cover 550 P amp See Figure 16 3B install crankshaft oil seal retainer 13 and secure with bolts 14 Torque bolts 14 to 21 0 25 0 inch pounds Using new gasket 7 install cover 8 and secure with attaching hardware 9 through 12 or install propeller governor using the correct gasket in accordance with the airframe manufacturer s Instructions Torque nuts 12 to 180 220 inch pounds 1 3 7 9 15 1793 25 3 1 NJ 30
191. d insure that it conforms to the dimensions specified in Figure 15 7B or 15 7C as applicable 4 Insure that the bushing oil passages are positioned as illustrated in Figure 15 7B or 15 7C as applicable WARNING Incorrectly positioned bushing oil passages will result in a loss of lubrication to the rocker arm shaft severe rocker arm bushing shaft and valve guide wear and possible engine failure 5 Thoroughly lubricate the bushing with clean 50 weight aviation engine oil 6 Using Borroughs Tools P N 8118 Rocker Arm Bushing Remover Installer Set or equivalent and an arbor press carefully press the bushing into the rocker arm bushing bore Bushing must be installed flush to 020 below surface See Figure 15 7B or 15 7C as applicable 7 Prior to reaming bushing to size fill the two bushing oil holes with beeswax to prevent debris from entering the oil passages 8 Ream bushing 1 0 to 7505 7515 with a surface finish of 32 RMS Refer to Figure 15 7B or 15 7C as applicable 9 After reaming clean and flush the oil passages with clean solvent removing beeswax and making certain that all passages are clear of any debris CAUTION After reaming clean and flush the oil passages using clean solvent Insure that the oil passages are clear of any debris or contamination 10 Perform a visual and magnetic particle inspection of rocker arm assembly in accordance with section 15 5 11 Any rocker arms or pushrods with obstructed oil
192. d lubricants may cause engine malfunction or failure 1 Insure the piston and piston rings are the correct size for the cylinder bore size Inspect the piston to cylinder clearance of each matching piston and cylinder in accordance with Figure s 15 4A1 or 15 4B1 as applicable Each piston ring must be inspected for proper gap in the cylinder bore in which it will be assembled Insert one ring at the time into the cylinder bore and push it to the position specified in the table of limits using the piston Remove the piston and inspect the ring gap using a leaf type feeler gauge If the ring gap is smaller than specified record actual gap size and remove the ring from the cylinder bore Mount a fine toothed flat file in a vise Holding the ring ends firmly and squarely against the file remove the desired amount of material Deburr the ring gap ends using crocus cloth Thoroughly clean the ring with mineral spirits and air dry Install the ring in the cylinder bore to the correct position and inspect the ring gap Repeat the above procedure until all ring gaps meet the required specification Do not use rings that are not within the specified ring gap dimensions NOTE Gap for second ring must be at least 006 larger than gap for top ring 2 Thoroughly clean the cylinder baffles cylinder valves valve springs retainers rotocoils valve spring retainer keys pistons piston rings piston pins pushrod housings springs and washers with mineral
193. d monitor the fuel flow RPM oil pressure cylinder head temperatures and oil temperatures Reduce to climb power in accordance with the Airplane Flight Manual The manual mixture control should be set in the full rich position for all operations except leaning for field elevation to maintain smoothness unless engine is equipped with altitude compensating fuel pump Leaning operations must be performed in accordance with the Airplane Flight Manual NOTE New rebuilt and overhauled engines or engines that have had new or repaired cylinders installed must be flown in accordance with the following procedure for the first two hours of operation Level flight cruise should be at 75 power with best power or richer mixture for the first hour of operation The second hour power settings should alternate between 65 and 75 power with the appropriate best power mixture settings The best power mixture setting is 100 to 125 rich of peak exhaust gas temperature Engine controls or aircraft attitude should be adjusted as required to maintain engine temperatures and pressures within specifications Descent from high altitude should be accomplished at low cruise power settings During descent engine pressures and temperatures must be carefully monitored Avoid long descents with cruise RPM and manifold pressure below 18 Hg CAUTION Rapid descents at high RPM and low manifold pressure are to be avoided During descent monitor cylinder head and oil
194. d service to correct capacity See the 10 550 Permold Series Maintenance Manual Form X306344A for oil sump capacity Engine is now ready for initial run up and test after overhaul TEST STAND After each major overhaul engine performance must be tested The engine stand must be constructed in a way to permit accessibility to all engine line and instrument connections and to permit frequent inspection of all points of possible leakage All tubes wires rods and cables used to connect instruments and controls should be well supported and of sufficient flexibility to permit them to be moved out of the way during installation and removal of the engine NOTE When necessary the airframe can be considered a suitable test stand for running in overhauled engines with the use of a test propeller and equipped with a suitable shroud or scoop to gather and direct cooling air over the cylinders Engine must be equipped with all the calibrated instruments listed in Instruments of this section TEST CLUB It will be necessary to install a test club such as those supplied by the Hartzell Propeller Fan Co Piqua Ohio or the flight propeller if the engine is installed in the aircraft Test clubs are customarily supplied in standard diameters so that the blade length is reduced by the cut and try method The club will absorb the BHP at the RPM specified in Table 19 1 Use the test club in combination with the cell test stand and operating limits for which
195. discrepancies noted MAY 1998 19 7 8 Inspect all engine control rod ends for wear freedom of movement proper installation and security in accordance with the test stand or aircraft manufacturer s instructions Correct any discrepancies noted 9 Insure all engine controls operate freely throughout their full range of travel and are properly adjusted in accordance with the test stand or aircraft manufacturer s instructions 10 Lubricate all control rod ends and fuel system components in accordance with the latest revision of the 10 550 Permold Maintenance Manual Form X30634A and the test stand or aircraft manufacturer s instructions WARNING Failure to correctly install and maintain engine controls can result in loss of system control and engine power 11 Inspect the exhaust and induction systems for proper installation security and leaks Correct any discrepancies noted 12 Inspect all lines hoses and wire bundles for chafing loose connections leaks and stains Correct any discrepancies noted INLET SCREEN FUEL INLET FITTING IDLE MIXTURE UNMETERED ADJUSTMENT PRESSURE CW ENRICH f e LEVER THROTTLE FUEL OUTLET METERED PRESSURE SCREW FUEL RETURN CW INCREASE TO FUEL PUMP 10 550 A B amp C IDLE SPEED STOP IDLE MIXTURE ADJUSTMENT CW LEAN CCW ENRICH IDLE RPM ADJUSTMENT CW INCREASE CCW DECREASE FUEL OUTLET FUEL INLET ME
196. dle 24 Bearing Ball 37 Washer Lock 50 Nut 12 Gear Worm 25 Ring Retaining 38 Nut 51 Clip Seal Retainer 13 Spring 26 O Ring 39 Plug 13 4 MAY 1998 FIGURE 13 1B STARTER AND STARTER ADAPTER 10 550 B1F B2F B3F B4F BSF B6F B11F B12B B13B B15B B16B 17 B18B B20B 21 B22B B23B B24B B25B B26B B27B B28B B29B B31B B32B B33B B34B B37B MAY 1998 43 5 13 2 STARTER AND STARTER ADAPTER DISASSEMBLY See Figure 13 1A 1 Place the starter adapter shaftgear a shielded vise Remove retaining ring 24 using snap ring pliers Insert worm shaft tool into the worm shaft slot and rotate the shaft counterclockwise to break bearing 23 loose from the housing Remove bearing 23 and shaft assembly 19 through 23 Separate worm gear 22 spring 20 woodruff key 21 and shaft 19 It may be necessary to use an arbor press to remove ball bearing 23 from shaft 19 Discard retaining ring 24 bearing 23 spring 20 and woodruff key 21 Remove attaching parts 27 28 and remove starter adapter cover 26 Clamp starter shaftgear teeth in shielded vise jaws Remove and discard retaining ring 18 Use a starter adapter disassembly tool as shown in Figure 13 2 Rotate the worm wheel gear in counterclockwise direction at the same time pull axially on the worm wheel and spring to separate it from the starter shaft gear Remove starter shaft gear 13 from vise Clamp worm wheel in shield
197. dures in section 15 6 Visually inspect the valve seats for any indication of burning pitting erosion or cracks Determine if the valve seat dimensions exceed the specifications in Figures 15 5 and 15 6 Any valve seats that are burned pitted eroded cracked or that do not conform with the specifications in Figures 15 5 and 15 6 must be replaced INTAKE VALVE DIMENSIONAL INSPECTION 1 2 Inspect the entire length of the valve stem outside diameter with a micrometer Discard valves with stems less than 0 4335 diameter Using a micrometer inspect the valve head outside diameter Intake valves with heads smaller than 2 339 diameter must be discarded ROCKER ARM DIMENSIONAL INSPECTION 1 2 Dimensionally inspect the rocker arm bushing bore The bushing bore must be 8725 to 8755 inch diameter Dimensionally inspect the rocker arm thrust width The rocker arm width must be 937 to 940 15 20 OCTOBER 2000 Y Y NOLLO3S 2a ce te oc ez bp ILE I 2 r DD 5540 4 ee w mm Ct nn SELLE LS e WY TESK AS 27 gt g atl N ao M n m s d 86 2 5 NOLLOAS 80 15 9 gz 2000 15 21 FIGURE 15 4B CYLINDER FITS AND LIMITS 10 550 G N P R 2 276 COL ih aue me gae DIAMETER FIGURE 15 4B1 CYLINDER DIMENS
198. e 5224 Valve Seat Straight Side Insert Cutters available from Kent Moore 5225 Valve Seat Straight Side Insert Cutters available from Kent Moore 8135 Valve Seat Step Side Insert Cutters available from Kent Moore 8136 Valve Seat Step Side Insert Cutters available from Kent Moore 8138 Valve Seat Step Side Insert Cutters available from Kent Moore Borrough s 8122A Common Drive Handle or equivalent 122 Valve Guide Cleaner available from Kent Moore 4981 Valve Guide Remover available from Kent Moore 2842 Valve Guide Replacer available from Kent Moore Borrough s 3170 Floating Holder or equivalent 4981 Valve Guide Remover available from Kent Moore Borrough s 8116 24 through 29 Valve Stem Hole Reamers or equivalent 2847 2CP Reamer Carbide Tipped available from Kent Moore 2847 1CP Reamer Carbide Tipped available from Kent Moore 2847 1HP Reamer High Speed Steel available from Kent Moore 2847 2HP Reamer High Speed Steel available from Kent Moore 2848 1 Plug Gauge for valve guide inspection available from Kent Moore 4943 1 HS through 5HS Reamers Valve Guide Boss available from Kent Moore Borrough s 4918 Spark Plug Insert Replacer or equivalent Borrough s 4919 Spark Plug Insert Remover or equivalent Borrough s 445 18mm Spark Plug Tap or equivalent for straightening out damaged 2769A13 Rosan Stud Remover available from McMASTER CARR Supply Co RosanG is a registered trademark of Fairchild
199. e Do not exceed sheave Do not exceed five 5 shims five 5 shims FIGURE 18 12 SHEAVE ALIGNMENT 8 Confirm that belt tension is 50 70 Ibs by one of the following methods a Use direct reading belt tension gage such as Borroughs Tool BT 33 73F b Measure belt deflection under a five pound load at the center of the longest belt span Correct deflection is 0 30 0 40 inch If belt tension is not within the above tolerance loosen jam nut and slide nut and readjust belt tension One full turn of adjusting screw will give approximately ten pounds change in belt tension CAUTION Do not over torque drive belt 18 20 OCTOBER 2000 After approximately five hours of operation recheck belt tension and adjust as required to maintain 50 70 pounds belt tension COMPRESSOR BRACKET ASSEMBLY JAM NUT ADJUSTING BOLT CHECK MIDSPAN DEFLECTION HERE SEE PARAGRAPH 8b COMPRESSOR AIRFRAME SUPPLIED DRIVER SHEAVE FIGURE 18 13 BELT TENSIONING 18 10 ALTERNATOR ASSEMBLY See Figure 12 1 1 Install new gasket 1 on crankcase alternator flange 2 Insure that the alternator slips onto the crankcase without binding and that the mounting flange is properly seated against the crankcase Do not force the alternator into position 3 If there is stud interference with the mounting lug holes while mounting the alternator do not force the alternator over the studs Installation of the alternator in a binding config
200. e Drive the new stud with a tee handle stud driver Turn it slowly and compare the torque values listed in the Table 6 1A General Use Torques Drive the stud in until it projects a distance equal to the specified setting height See stud setting heights in the applicable component or system section 6 23 CYLINDER EXHAUST PORT ROSAN STUD REPLACEMENT Rosan ring locked studs are installed in the cylinder exhaust ports These studs are either size on size or step type Certain precautions must be taken during the removal of these studs to prevent damage to the cylinder REMOVAL OF SIZE ON SIZE STUDS The size on size captive lock ring studs utilize a small external diameter lock ring for usage in locations where edge distance is of concern The lock ring is so small in diameter that the use of a typical amp Rosan SM or BT series milling tool is impractical and could cause unwanted removal of cylinder head material in the lock ring area Therefore the following removal method must be used 1 Using caution cut the stud off as close as possible to flush with the cylinder head Do not come in contact with or mark the cylinder head 2 Center punch the remaining portion of the stud 3 Locate the proper size primary removal drill directly over the center of the stud and drill to the specified depth NOTE The primary removal drill size and specified depths are noted below 4 Center the secondary removal drill over the small ho
201. e Figure 5 3 General Tab Washer Installation Procedure COTTER PIN PROCEDURE Cotter pins are installed by inserting the cotter pin through a hole in one part slots in the other part and spreading the exposed ends Cotter pins are not reusable and must be replaced with a new cotter pin after removal 1 Torque the nut to the lower limit of the torque specification If the slots in the nut do not line up with one of the holes in the bolt continue torquing until one does Do not exceed the upper limit of the torque specification Change the nut if necessary 2 Insert the cotter pin with the head seated firmly in the slot of the nut Bend the ends over the flat on the nut and the end of the bolt Trim the prong lengths as necessary 3 Seat the prongs firmly against the bolt and nut See Figure 5 4 General Cotter Pin Installation CAUTION Do not use side cutting type pliers to bend the ends over since the resulting nick could weaken the pin and allow a portion to become detached 5 5 5 6 5 7 FIGURE 5 4 GENERAL COTTER PIN INSTALLATION APPLICATION OF ADHESIVES Adhesives and sealants will be used only in specific applications outlined in Chapter 3 Table Of Sealants and Lubricants WARNING The improper use of sealants and lubricants will cause engine malfunction or failure Gasket Maker P N 646942 Surfaces must be clean and free of nicks burrs oil and grit Apply a thin translucent coat of Gasket Maker not t
202. e WARNIBIG Notice 1956 MM Notes Cautions and 068 Publication Table Of Contents i e eret d eene CHAPTER INDEX CHAPTER 1 2 Tools cates te oes a 3 Sealants And Lubricants 2 4 4 Airworthiness Limitations ios sa sessed Eoo 5 Standard PractiGgs purge aS 6 Reciprocating Engine 7 EXMAUSE OVSIEI 8 Ignition System 9 Med paria tds 10 INGUCHON SystelTi 11 Air Conditioning System reete ettet rn 12 Electrical GhargingissysltelTr co ie ote tbt tet pe P 13 Starter amp Starter 14 t bricati n System 15 Cylinder Assembly 16 c H 17 Engine Drive Reto e ades 18 Final Assembly 19 Post Overhaul Adjustment And Test MAY 1998 vii INTENTIONALLY LEFT BLANK viii 1 INTRODUCTION SECTION PAGE 1 1
203. e conducted on all ferrous parts Where magnetic particle inspection is required use fluorescent method wet continuous procedure Refer to the latest revision of ASTM E 1444 for specific methods and procedures based on the type of inspection being performed ACCEPT REJECT CRITERIA Rejectable discontinuities are any of the following fatigue cracks forming cracks grinding and heat treat cracks embrittlement cracks seams laps burst Parts which contain linear indications which cannot be reworked or indications which break into comers edges holes thread roots fillets gear tooth roots or keyways must be rejected The particular magnetic particle manufacturer s information regarding use safety data and disposal must be followed carefully OCTOBER 2000 6 7 6 10 6 11 6 12 6 13 6 14 6 15 CRANKSHAFT ULTRASONIC INSPECTION PROCEDURE The crankshaft must be ultrasonic inspected by individuals certificated to perform this detailed inspection For approved inspection locations contact TCM at 334 438 3411 CYLINDER BARREL ULTRASONIC INSPECTION PROCEDURE Cylinders must be ultrasonic inspected by individuals certificated to perform this detailed inspection For approved inspection locations contact TCM at 334 438 3411 FLUORESCENT PENETRANT INSPECTION Inspection by the fluorescent penetrant method must be conducted on all non ferrous metal parts Where fluorescent penetrant inspection is required it must be perfo
204. e else to stand in the propeller arc area 3 Increase the pressure slowly to a maximum value of 80 PSI Saturate the entire cylinder assembly with a soap and water solution 4 Inspect the complete cylinder for leakage Leakage will be indicated by an accumulation of bubbles 5 After complete cylinder inspection relieve cylinder pressure and remove compression tester 6 Perform this inspection on each cylinder Optional airframe manufacturer accessories and various engine components that obstruct engine removal must be removed from the engine and airframe For airframe manufacturer supplied accessory removal and airframe to engine disconnection consult the appropriate airframe manufacturer s instructions Chapters 7 through 17 contain overhaul information for each of the engine systems Chapter 18 contains final engine assembly procedures Chapter 19 contains post overhaul adjustment and test procedures As the aircraft engine is being overhauled all engine parts and accessories must be overhauled All engine parts and accessories must conform with the engine and accessory manufacturer s specifications after overhaul prior to re installation on the engine See the accessory manufacturer s overhaul instructions for accessories supplied by manufacturers other than Teledyne Continental Motors During Major Overhaul of Teledyne Continental Motors aircraft engines all parts and components must conform with the manufacturer s new specifica
205. e fatigue failure Blasting techniques can be employed to remove hard carbon deposits if suitable equipment is available Suitable types of grit for dry blasting are plastic pellets and processed natural materials such as wheat grains and crushed fruit pits or shells Air pressure must be adjusted to the lowest setting that will produce the desired cleaning action Small holes and machine finished surfaces must be protected from the blast by seals and covers 6 6 MAY 1998 6 8 6 9 WARNING All cleaning material must be removed from parts and components after cleaning CAUTION Do not use sand metal grit or glass beads for any type of cleaning If water mixed degreasing solutions containing caustic compounds or soap are used to clean aluminum alloy components they must be thoroughly and completely rinsed with clear boiling water or steam to prevent corrosion CASTINGS Gasket surfaces must be thoroughly cleaned with a suitable hydrocarbon solvent such as acetone naphtha or methyl ethyl keytone MEK to remove dirt oil and grease Surfaces must be clean dry and free of all old gasket material before applying new gaskets SMALL STEEL PARTS Degrease steel parts by spraying or brushing with mineral spirit solvent Heavy grease or dirt deposits can be cleaned effectively by allowing the part to soak in this solvent for a short period of time NOTE See Chapters 7 through 17 for specific individual system component and part cleaning i
206. e following special instructions All oil pressure springs gaskets packings o rings seals lock washers and self locking nuts removed from the lubrication system components must be replaced 100 at overhaul Cleaning these parts is not required Internal cleaning flushing and pressure testing of the oil cooler requires special adapters gauges tanks and circulating pump Oil cooler overhaul must be accomplished by adequately equipped and qualified cooler repair facilities Clean the oil sump assembly using mineral spirit solvent If the oil sump is immersed in an alkaline bath when removed it must be sprayed with steam removing all traces of alkaline After the sump dries inspect it for any alkaline residue and if necessary re spray with steam to remove The sump exterior cavities and all oil passages must be thoroughly flushed with mineral spirit solvent after any alkaline cleaning process has been used CAUTION Alkaline cleaning solutions will cause corrosion to metals if not completely removed 6 Clean the oil pump housing oil filter adapter or tach drive adapter using mineral spirit solvent All oil passages must be clear and free flowing If the oil pump housing oil filter adapter or tach drive adapter are immersed in an alkaline bath when removed they must be sprayed with steam removing all traces of alkaline After the parts dry inspect them for any alkaline residues and if necessary re spray with steam to remove
207. e ignition harness assembly from engine and discard 2 Remove nuts 5 lock washers 4 and magneto holding washers 3 from each magneto 3 Remove both magnetos 2 from the engine Discard cable ties 27 and lock washers 4 6 CAUTION Use care to avoid dropping magneto drive bushings and retainers into the engine See Figure 8 2A 4 Magneto assemblies must be overhauled in accordance with the magneto manufacturer s instructions see TCM ignition systems Master Service Manual Form No X40000 See Section 1 5 Related Publications for ordering information Nomenclature for Figure 8 1B 1 Gasket 11 Lead 2B 21 Clamp 2 Magneto 12 Lead 2T 22 Clamp 3 Washer Holding 13 Lead 3B 23 Nut Speed 4 Washer Lock 14 Lead 3T 24 Clamp 5 Nut 15 Lead 4B 25 Screw 6 Washer Lock 16 Lead 4T 26 Bracket 7 Nut 17 Lead 5B 27 Tie Cable 8 Sparkplug 18 Lead 5T 9 Lead 1B 19 Lead 6B 10 Lead 1T 20 Lead 6T 8 4 OCTOBER 2000 FIGURE 8 1B IGNITION SYSTEM FOR 10 550 A7B 10 550 B1F B2F B3F B4F B9B B20B B21B B22B B26B B30B B31B B33B B34B B36B 10 550 C3F C16B 18 C26B 28 C27B C29B MAY 1998 8 5 8 1C IGNITION SYSTEM REMOVAL AND DISASSEMBLY See Figure 8 1C 1 Remove ignition harness assembly a Remove ignition lead from each spark plug 6 Remove all cable ties 26 b On each magneto remove three screws 19 from cable outlet plate Remove plat
208. e special lubricants are required See Chapter 3 Sealants and Lubricants During assembly the mechanic must measure clearances of running parts as they are installed and compare with clearances listed in Fits and Limits of the applicable system or component section During engine overhaul use only NEW PARTS LIMITS See section 6 16 Parts Limits Also TCM requires certain parts be replaced 100 at overhaul See section 6 6 100 Replacement Parts Engine assembly must be performed in a clean dust free environment All engine openings must be covered as soon as possible to prevent admittance of debris or small parts CRANKCASE See Figures as indicated in paragraphs 1 Uncover crankcase halves Using clean 50 wt aviation engine oil thoroughly coat all crankcase camshaft bearing surfaces prop governor gear bearing surface starter shaft gear bushing and idler gear bushing The crankcase crankshaft bearing saddles must be dry prior to installing the crankshafts bearings do not coat them with oil 2 Install left crankcase half on engine stand open side up Place right crankcase half on bench open side up Using clean 50 weight aviation engine oil thoroughly lubricate all surfaces that were lubricated on the right crankcase half Do not lubricate the crankshaft bearing saddles 3 See Figure 17 2 Crankshaft Assembly Install crankshaft bearings 2 in crankcase crankshaft bearing saddles Apply clean 50 wt aviation engine oil to thr
209. e starter motor assembly must be overhauled in accordance with the manufacturer s instructions See TCM Form X30592 for TCM starters See section 1 5 Related Publications for ordering information 13 4 STARTER ADAPTER CLEANING 1 All starter adapter components and associated hardware must be cleaned in accordance with the instructions in section 6 7 General Cleaning and the following special instructions All bushings bearings sleeves spacers springs gaskets o rings oil seals lock washers tab lock washers retainers self locking nuts and starter clutch spring removed from the starter adapter must be replaced 100 at overhaul Cleaning of these parts is not required The starter adapter housing and covers 27 35 cavities and oil passages must be flushed with mineral spirit solvent OCTOBER 2000 13 7 13 5 13 8 4 If the starter adapter housing or covers are immersed in an alkaline bath when removed they must be sprayed with steam removing all traces of alkaline After the housing dries inspect for any alkaline residues and if necessary re spray with steam The housing exterior cavities and all oil passages must be thoroughly flushed with mineral spirit solvent after any alkaline cleaning process has been used CAUTION Alkaline cleaning solutions will cause corrosion to metals if not completely removed 5 6 Clean the worm shaft using mineral spirit solvent Clean gears that have bushings using m
210. e valve seat rework information and crankcase studding assembly additions OCTOBER 1998 59 4 2 48 2 26 40 30 45 INTAKE SEAT GRINDING PROCEDURE NOTE USE STONES THAT WILL PRODUCE 40 R FINISH 1 GRIND SEAT WITH 30 STONE TO SPECIFIED FINISH 2 NARROW SEAT OUTSIDE DIAMETER WITH 15 STONE TO ESTABLISH OUTSIDE DIAMETER 3 NARROW SEAT INSIDE DIAMETER WITH 45 STONE TO ESTABLISH 60 010 FIGURE 20 1 10 550 B39B AND 10 550 C31B INTAKE VALVE SEAT REFACING 20 2 OCTOBER 1998 THE 10 550 39 654130 6 STUDDING ASSEMBLY IS THE SAME AS FIGURE 16 7B AND THE 10 550 C31B 654130 5 STUDDING ASSEMBLY IS THE SAME AS FIGURE 16 7C EXCEPT FOR THE FOLLOWING ADDITIONS 1 654638 DOWEL 8 EACH SETTING HEIGHT 47 2 MS9021 016 O RING 8 EACH FIGURE 20 2 10 550 B39B AND 10 550 C31B CRANKCASE STUDDING ASSEMBLY ADDITIONS OCTOBER 1998 20 3 INTENTIONALLY LEFT BLANK 20 4 OCTOBER 1998
211. eamers warning sign Glenwood MN 56334 e preservative oils exterior aluminum parts US amp CAN 1 800 4432136 MN 1 800 862 2443 3 6 OCTOBER 2000 4 AIRWORTHINESS LIMITATIONS This Airworthiness Limitations section has been FAA approved and specifies maintenance required under 43 16 and 91 403 of the Federal Aviation Regulations unless an alternative program has been FAA approved Federal Aviation Regulations 43 16 and 91 403 require owner operator compliance with all maintenance limitations in this section concerning mandatory replacement times inspection intervals and other related procedures that are specific to this engine Any such limitations listed below are part of the design limits of the engine and the engine was type certificated based upon required owner operator compliance with the limitations 1 Mandatory Replacement Times Subject to additional information contained in FAA Airworthiness Directives AD issued after the date of certification the engines covered in this manual do not contain any components having mandatory replacement times required by type certification 2 Mandatory Inspection Intervals Subject to additional information contained in FAA Airworthiness Directives AD issued after the date of certification the engine does not require specific intervals of inspection pursuant to type certification 3 Other Related Procedures Subject to additional information conta
212. eating operation always inspect the cylinder assembly and insure that the head has not turned in relation to the barrel Movement of the head in relation to the barrel will destroy the assembly preload Discard any cylinder with indications of head to barrel movement VALVE SEAT REMOVAL Heat the cylinder assembly to 450 F maximum Heat soak one hour Using the correct remover from the list above remove the worn valve seat or seats Allow cylinder to cool to room temperature Inspect the seat bore for cracks and erosion Discard any cylinder with a cracked valve seat bore or a valve seat bore that has eroded beyond the allowable valve seat oversize bore repair VALVE SEAT BORE MACHINING Measure the new valve seat insert outside diameter and select the proper size valve seat bore cutter Install the cylinder in the holding fixture Using the specified tools machine the valve seat bore s to the correct diameter Do not exceed the tolerances specified in Figures 15 4A1 or 15 4B1 as applicable Deburr the valve seat bore and clean the cylinder removing all debris from machining procedure Inspect and record the valve seat bore inside diameter and new valve seat outside diameter On 10 550 amp engine cylinders an interference fit of 0 007T to 0 010T is required for exhaust valve seats An interference fit of 0 009T to 0 012T is required for intake valve seats 10 550 G N P R engine cylinders an interference fit of 0 007T to 0 010T is
213. ecific hardware On castellated nuts unless otherwise specified the cotter pin head must fit into a recess of the nut with the other end bent such that one leg is back over the stud and the other is down flat against the nut in accordance with Section 5 4 Use only manufacturer specified corrosion resistant steel cotter pins All lockwire utilized on TCM engines must conform to MS20995 Condition A When replacing gaskets packings or rubber parts use the type or composition specified by the manufacturer Make sure replacement nonmetallic and metallic parts show no sign of storage deterioration Parts exceeding specified shelf life limitations must not be used When a hammer is required to come in direct contact with an engine part during assembly or disassembly use a mallet made of plastic or rawhide material only Parts removed from the engine must be cleaned and inspected in accordance with the specified instructions located in the applicable system chapter 5 2 MAY 1998 5 2 LOCKWIRE PROCEDURE Lockwiring is the securing together of two or more parts with lockwire installed in such a manner that any tendency for a part to loosen will be counteracted by additional tightening of the lockwire All lockwire utilized on TCM engines must conform to MS20995 Condition A Most bolts utilized in TCM engines that require lockwiring will use 032 lockwire and require twisting at a rate of 7 to 10 twists per inch Smaller lockwire when specified or
214. ecks Check fuel flow Do not run engine above 1800 RPM until oil temperature has reached 160 F and cylinder head temperatures have reached 200 F Do not shut engine down until oil temperature is below 200 F and cylinder head temperatures are below 300 F Fuel and oil leaks not acceptable Engines failing to pass acceptance test for high oil consumption major oil leaks low power damaged components excessive noise excessive roughness low oil pressure excessive oil filter contamination require further investigation correction of all discrepancies and complete re test See next page for oil consumption determination test run 19 34 OCTOBER 2000 19 18 OIL CONSUMPTION DETERMINATION PERIOD TIME MINUTES RPM 5 Warm up to 2000 25 RPM 0 2100 25 RPM 5 5 7596 Power RPM Check Fuel and Oil Pressures Check Temperatures BEEN MEAE 2 Rated Power RPM EUN NEN INN d ee ee Stop engine drain and weigh oil in for consumption determination 6 215 YO O7TE PowerRPM NOTES Make one check on performance of each magneto alone at 2100 RPM Clear spark plugs by operating with both magnetos on for a few seconds between checks Check fuel flow Do not run engine above 1800 RPM until oil temperature has reached 160 F and cylinder head temperatures have reached 200 F Do not shut engine down until oil temperature is below 200 F and cylinder head temperatures are bel
215. ect alignment See Figure 18 12 Sheave Alignment When idler sheave is properly adjusted torque sheave screw to 800 850 inch pounds When drive sheave is properly adjusted torque sheave 12 point self locking nut to 450 500 inch pounds Nuts must be lubricated with clean 50 wt aviation engine oil All threads of the sheave nut must be engaged CAUTION Prevent engine from turning when torquing nut 6 See Figure 18 13 Belt Tensioning on next page Loosen the jam nut adjusting bolt and slide nut The slide nut should be loosened only enough to allow the slide to move freely and the adjusting bolt should be turned out far enough to allow Installation of the belt 7 Install the drive belt Slide the idler sheave snugly against the belt and torque the adjusting bolt finger tight into its socket In this position the idler sheave should rotate by hand under the belt Torque the adjusting bolt two full turns Torque the adjusting bolt jam nut to 275 375 inch pounds Torque the idler sheave bracket slide nut to 300 350 inch pounds DRIVER SHEAVE IDLER SHEAVE ASSY ed MT ANTA p mm D SL Wy 22081 2225 777 d 224 QE i KER 2 Add 643956 20 shims as Add 646064 20 shims as required between sheave required between bearing and spacer for proper and spacer for proper allgnment with compressor allgnment with compressor sheav
216. ect cylinder bore after grinding in accordance with section 6 9 Identify the cylinder with the correct bore size by steel stamping the cylinder barrel flange with the appropriate oversize designation in accordance with Figure 15 11 15 24 MAY 1998 VALVE SEAT REPLACEMENT Valve seats that are damaged or have worn beyond acceptable specifications must be replaced using the following special tools and procedures Special Tools Required 1 Borrough s valve seat remover and replacer 8086 or equivalent Borrough s 5221B holding fixture and 5221 13A adapter or equivalent Borrough s 8122A common drive handle or equivalent Valve stem or valve guide hole pilot of correct size Valve seat boss cutter of correct size Use the cutter size required for new valve seat outside diameter Universal drive from Borrough s 8116 common parts kit or equivalent 7 Heavy duty drill press Qi Pe eS WARNING Do not use a torch to heat the cylinder assembly The heating process must be performed using uniform heating methods only After cylinder has been heated do not bump the head or barrel To establish an inspection point for head to barrel movement mask off a 1 4 wide x 1 high area across the cylinder head to barrel junction on the intake port side of the cylinder Apply a heavy coat of high temperature paint and allow the paint to dry thoroughly Remove the masking material After a cylinder assembly has been subjected to a h
217. ed vise Remove clutch spring retaining screw 16 and tab washer 15 Place a straight slot screw driver through a hole in the worm wheel 11 to catch the end of spring 14 Rotate spring 14 clockwise to release it from the land in the worm wheel gear Separate spring 14 from worm wheel gear 11 Remove roller bearing 12 from worm wheel gear 11 Use a slide hammer and Borrough s 8093C or equivalent to remove needle bearing 10 from adapter housing 5 WORM SHAFT TOOL 2 13 16 3 4 BARSTOCK STARTER ADAPTER GEAR AND SPRING REMOVER 3 8 BARSTOCK FIGURE 13 2 STARTER ADAPTER DISASSEMBLY TOOL 13 6 OCTOBER 2000 13 2B STARTER AND STARTER DRIVE ADAPTER See Figure 13 1B 1 Place the starter adapter shaftgear in a shielded vise Remove retaining ring 17 using snap ring pliers Insert worm shaft tool into the worm shaft slot and rotate the shaft counterclockwise to break bearing 16 loose from the housing Remove bearing 16 and shaft assembly 12 through 16 Separate worm gear 12 spring 13 woodruff key 15 and shaft 14 It may be necessary to use an arbor press to remove ball bearing 16 from shaft 14 Discard retaining ring 17 bearing 16 spring 13 and woodruff key 15 Clamp shaft gear 18 in shielded vise jaws and remove 12 point self locking nut 46 Remove sleeve 44 and spacer 45 or airframe supplied sheave as used from shaft Remove four sets of attaching parts 36 37
218. eft hand threads When installing apply antiseize lubricant Must be reworked to through bolt rocker shaft configuration in accordance with Service Bulletin M92 6 or current revision as applicable 6 Point nuts used at cylinder through bolt positions must be torqued to 690 710 inch pounds torque WARNING Failure to lubricate threads apply the specific torque and follow the specific torquing procedure may result in damage and subsequent engine malfunction or failure OCTOBER 2000 6 19 INTENTIONALLY LEFT BLANK 6 20 MAY 1998 7 1 7 EXHAUST SYSTEM EXHAUST SYSTEM This chapter is reserved for engines utilizing an exhaust system and components supplied on some engine models by Teledyne Continental Motors For 10 550 A B C G N P amp R exhaust system overhaul information see the airframe manufacturer s instructions OCTOBER 2000 7 1 7 2 INTENTIONALLY LEFT BLANK 8 IGNITION SYSTEM AND MAGNETO ACCESSORY DRIVES SECTION PAGE 8 1A Through 8 1G Ignition System 8 2 8 2A and 8 2B Magneto Accessory Drive 8 14 8 3 Magneto Accessory Drive Disassembly 8 16 8 4 sd pant dt eee net At e reir 8 16 8 5 Magneto Drive Gear Inspection 8 16 8 6 Magneto and A
219. el pressure gauge Connect fuel supply line to upper elbow projecting from left side of fuel pump Connect fuel pump to supply tank return line to upper elbow projecting from right side of fuel pump Connect fuel pressure gauge line to the fitting projecting from the center rear of fuel manifold valve GOVERNOR PAD COVER A removable oil transfer tube conducts oil under pressure from the front main bearing through the crankshaft to the propeller hub Crankshafts are equipped with an oil transfer collar to supply the governor controlled oil to the crankshaft for use with an oil controlled propeller When a test club or fixed pitch propeller is used for testing purposes the governor pad cover must have an internal grooved surface to allow the circulating oil to lubricate the oil transfer collar The governor pad cover is not needed if a propeller governor is installed WARNING Oil pressure is applied to the face of the governor drive pad If gasket accessory or cover is not properly installed and hardware is not properly torqued oil leakage will occur 19 4 MAY 1998 19 14 19 15 ENGINE TEST WARNING Over priming can cause hydrostatic lock and subsequent engine failure CAUTION Insure propeller area is clear before initiating starting sequence NOTE Before starting engine insure that fuel tanks contain proper type of fuel 100LL blue or 100 green Check engine oil sump for proper servicing See chapter 3 for oil type and specification
220. ence 20 Note this data is approximate with Fuel pressure gauge at same elevation of differential fuel head in gauge line FIGURE 19 18 FUEL FLOW VS METERED PRESSURE 10 550 MAY 1998 19 29 FULL THROTTLE HORSEPOWER AT ZERO RAM BRAKE HORSEPOWER BRAKE HORSEPOWER 2 LIII 17 18 19 20 21 2 UA 4 25 26 27 28 29 30 ABSOLUTE DRY MANIFOLD PRESSURE IN HG AM M MN MEZ l2 Au AA SA ape Tt 112 FIGURE 19 19 CONSTANT SPEED SEA LEVEL PERFORMANCE 10 550 P R 19 30 OCTOBER 2000 YAMOdASHOH 3 V3ga 015 062 0 2 0Sc 055 0 2 061 011 0S ilii E E ONE EINEN M NIE uos pr A Nez AT E GL F ZNNENENE m LII T E 550 19 31 2000 FUEL FLOW LBS HR 00 H 25 oz E 051 ELA LL LL LL LLL LL LLLI 7 09i 3MV 8 SA 1913 N 0SS Ol 20 FUEL FLOW VS OBSERVED BRAKE HORSEPOWER FIGURE 19 METERED FUEL PRESSURE PSI x N e lt N e N N v psi re Q o c i 6 550 METERED FUEL PRESSURE VS FUEL FLOW
221. er Diameter Magneto coupling retainer on magneto and accessory drive gear sleeve Diameter 0 0250L 0 040L End Clearance 0 0110L 0 0770L Magneto coupling retainer in magneto drive gear slot Side Clearance 0 0020 0 0280L Magneto coupling rubber bushings on magneto drive lugs Side Clearance 0 014L 0 052T Diameter 0 001L 0 005L FIGURE 8 5 MAGNETO DRIVE ADAPTER FITS AND LIMITS MAY 1998 8 19 8 6 MAGNETO AND ACCESSORY DRIVE ADAPTER ASSEMBLY REPAIR 1 Remove the drive adapter bushings for inspection and replacement Turn down the bushing flange to the body diameter of 0 939 of an inch and bore out the bushing to a thin shell that can be collapsed and removed All boring operations must be on center Take care to prevent cutting into the end of the adapter boss or marking the adapter bore The old magneto adapter oil seals must be removed by driving out with a 1 8 inch diameter pin punch inserted through the four oblique oil holes in the bushing boss alternately if the seal is too tight for that method drill and tap two opposite machine screw holes in the exposed flange of the seal case that will match two screw clearance holes in a pressure plate Do not allow drill to pass through the seal case into the adapter Lay pressure plate on the adapter studs Run nuts on two long machine screws then insert the screws through the pressure plate holes and screw them into the holes tapped in the seal To avoid unnecessary s
222. er Form Number F 1100 See Section 1 5 Related Publications for ordering information 2 The magneto drive gear and adapter assemblies and magnetos will be installed on the engine during final engine assembly Store all components in a clean protected area until final engine assembly OCTOBER 2000 8 21 INTENTIONALLY LEFT BLANK 8 22 MAY 1998 9 FUEL INJECTION SYSTEM SECTION PAGE 9 1A Fuel Injection System Disassembly 10 550 9 2 9 1B Fuel Injection System Disassembly 10 550 9 4 9 1C Fuel Injection System Disassembly 10 550 9 6 9 1D Fuel Injection System Disassembly 10 550 G P R 9 8 9 2 Fuel Injection System Component Disassembly 9 10 Fuel Manifold Valve deiectis mc mei 9 10 tee Lh rider 9 13 a Ren Be 9 17 Throttle and Fuel Metering 9 18 9 3 Fuel Injection System 9 20 9 4 Fuel Injection System 9 20 9 5 Fuel Injection System Repair and Replacement 9 21 9 6 Fuel Injection System 9 22 FIGURE PAGE 9 1A Fuel Inject
223. eral 18 3 18 2 18 3 18 3 Crankcase Sealant Threading 18 5 18 4 Crankcase Through Bolt Installation and Torquing 18 6 18 5 Idler Gear Support Pin Camshaft Cover Crankshaft Oil Seal Retainer And Oil Filler Tube 18 15 18 6A Oil Sump 10 550 A amp C dere uada do eina 18 15 18 6B Oil Sump 550 0 550 18 16 18 6C Oil Sump 1 550 3 amp 18 16 18 7 Oil Pump 10 550 A2B 10 550 B1F B2F B3F B4F B5F B6F B9B B11B B14B B15B B16B B19B B21B B23B B29B B30B B32B B35B B37B 10 550 C2F C2U C3F C6F C8B C11B C12B C13B C15B C18B C19B C25B C26B C27B C28B C29B C30B nec ced ced tee e edes 18 16 18 7B Oil Pump 10 550 A4B A5B A6B A7B 10 550 B5F B12F B13F B17B B18B B20B B22B B24B B25B B26B B27B B28B B31B B34B B36B 10 550 C16B C17B C21B C22B 10 550 G1B G2B G4B 10550 N1B 550 IO 550 R eee 18 17 18 7C Oil Pump 10 550 G5B G6B 10550 N2B 18 17 18 8A Starter And Starter Adapter 10 550 10 550 B9A B9B B9F B14B B19B B30B B35B B36B 10 550 10
224. erhauled 6 Remove the crankcase backbone hardware that secures the fuel manifold valve to the engine and remove fuel manifold valve 18 Place the fuel manifold valve in a clean protected area until it is to be overhauled 7 Remove nuts 34 lock washers 33 and hold down washers 32 Remove fuel pump assembly 3 and gasket 2A Reach into crankcase fuel pump cavity and remove drive coupling 2 Discard fuel pump gasket 2A and lock washers 33 Place the fuel pump in a clean protected area until it is to be overhauled Nomenclature for Figure 9 1A 1 Fuel Injection System 12 Spring 25 Nozzle Fuel 2 Coupling 13 Rod End 26 Shield 2A Gasket 14 Nut Self Locking 27 Screen 3 Fuel Pump 14A Pin 28 Jet 4 Throttle Assembly 15 Washer Wave 29 Nozzle 4A Throttle And Control Unit 16 Washer 30 Clamp 5 Fuel Control Unit 17 Pin Cotter 31 Bracket 6 Lever 18 Fuel Manifold Valve 32 Washer Hold Down 7 Bushing 19 Tube Fuel Cyl 6 33 Washer Lock 8 Washer Tab 20 Tube Fuel Cyl 4 34 Nut 9 Screw 21 Tube Fuel Cyl 2 35 Hose 10 Rod And Link 22 Tube Fuel Cyl 5 36 Hose 10 Rod And Link Assembly 23 Tube Fuel Cyl 3 11 Nut Plain 24 Tube Fuel Cyl 1 9 2 MAY 1998 FIGURE 9 1A FUEL INJECTION SYSTEM FOR 10 550 OCTOBER 2000 9 3 9 1B FUEL INJECTION SYSTEM REMOVAL AND DISASSEMBLY See Figure 9 1B gt oa NO 9 4 Mark each fuel injection line 30 45 46 47 with i
225. es from magnetos 2 c Remove ignition harness assembly from engine and discard 2 Disconnect ground terminal kit from magnetos 2 in accordance with airframe manufacturer s instructions 3 Remove nuts 5 lock washers 4 and magneto holding washers 3 from each magneto 4 Remove both magnetos 2 from the engine Discard cable ties 26 and lock washers 4 CAUTION Use care to avoid dropping magneto drive bushings and retainers into the engine See Figure 8 2A 5 Magneto assemblies must be overhauled in accordance with the magneto manufacturer s instructions see Slick Ignition Systems Master Service Manual Index and Order Form Number F 1100 See Section 1 5 Related Publications for ordering information Nomenclature for Figure 8 1C 8 6 MAY 1998 1 Gasket 14 Lead 4T 2 Magneto 15 Lead 5B 3 Washer Holding 16 Lead 5T 4 Washer Lock 17 Lead 6B 5 Nut 18 Lead 6T 6 Sparkplug 19 Screw 7 Lead 1B 20 Clamp 8 Lead 1T 21 Clamp 9 Lead 2B 22 Nut Speed 10 Lead 2T 23 Clamp 11 Lead 3B 24 Screw 12 Lead 3T 25 Bracket 13 Lead 4B 26 Tie Cable FIGURE 8 1 IGNITION SYSTEM FOR 10 550 15 B16B B17B 18 B19B 25 B32B B37B 10 550 12 C13B C15B C22B C27B C30B MAY 1998 8 7 8 10 IGNITION SYSTEM REMOVAL AND DISASSEMBLY See Figure 8 10 1 Remove ignition harness assembly a Remove ignition lead from each spark plug 7 Remove all ca
226. eter of the guide to reduce the chance of binding during installation Heat the cylinder assembly to 450 F maximum Heat soak for one hour Using the specified installation tool install the new valve guides Allow the cylinder to stabilize to room temperature and inspect the valve guide inside diameter If necessary ream the valve guide inside diameter to the required specifications CYLINDER HEAD FLUORESCENT PENETRANT INSPECTION After valve guide installation the cylinder head must be fluorescent penetrant inspected in accordance with section 6 12 Fluorescent Penetrant Inspection Structural cracks in the cylinder head are not acceptable or repairable Cylinder heads exhibiting cracks in the structure must be discarded REAMING VALVE GUIDES The intake and exhaust valve guide bore inside diameters are prefinished and will conform to the required specifications when installed under controlled production procedures However field repair conditions may vary and some valve guide bores may require a finish reaming operation in accordance with the following procedures WARNING Do not attempt this procedure with a hand held power tool Install the holding fixture into drill press Index fixture to proper angle and install cylinder into fixture Zero in guide with dial indicator Using the proper size reamer ream the valve guides Ream at 400 RPM for high speed steel reamers and 700 RPM for Carbide tip reamers using plenty of lubricant Ins
227. ety wire self locking fasteners including exhaust manifold nuts and lock washers with new parts 6 4 MAY 1998 Engine mounted accessories not manufactured by TCM must be overhauled at engine overhaul and maintained in accordance with the instructions provided by the manufacturer Do not re use any fasteners that are worn deformed or are designed to be used only once Do not replate any cadmium plated fasteners or washers If the cadmium plating has been removed discard the item and replace it with a new part At engine overhaul in addition to the previously listed items the parts listed below must be discarded and replaced with new parts NOTE If for any reasons hydraulic valve tappets are removed for inspection before the overhaul period has been reached they must be placed back in the same location from which they were removed Hydraulic valve lifters tappets Bearings connecting rod crankshaft main and thrust needle ball and roller Bushings rocker arm connecting rod counter weight and crankshaft counter weight blade Counterweight pins retaining plates and snap rings Camshaft gear bolts Crankshaft gear bolts Woodruff keys Crankshaft alternator face gear bolts and lock plates Connecting rod bolts and nuts Magneto drive rubber bushings Exhaust valves Roto coils exhaust valves Intake and exhaust valve keepers Inner and outer valve springs Piston pins Piston rings Pistons Rocke
228. exceed 1 2 ounce or 14 175 grams g Lubricate the piston pin and piston and ring assemblies with clean 50 weight aviation engine oil Place the new piston and ring assembly with the cylinder assembly for which it was previously sized and gapped Place a new piston pin with each piston and ring assembly Install the piston pins in the piston pin bores The piston pins must slide freely in the piston pin bores h Position the rings so the ring gaps are 180 apart with the first or top ring gap toward top of the piston Using a ring compressor install each piston into it s cylinder so that the top three rings are in the cylinder barrel and the piston pin is accessible for installation on the connecting rod Install the piston and ring assemblies into the cylinder bore with the piston position number toward the propeller flange when the cylinder is installed on the engine i Place the cylinders on a clean protected work bench in position order and cover until final engine assembly j Install washers 36 new packing 37 and second washer 36 on cylinder end of pushrod housings 35 Place two each pushrod housings 35 new springs 38 washers 36 new packings 37 and second washer 36 with each cylinder 7 Cylinder Subassembly For the IO 550 G N P R model engines a See Figure 15 1B Cylinder and Piston Assembly for 1O 550 G N P R Using the following instructions assemble each of the six cylinders If the valves have been lap
229. ey are not exposed to temperatures in excess of 400 F To prevent sticking of sleeves and to minimize twisting of ferrule coat insulating sleeves use MS 122DF Spray Miller Stephenson Chemical Co Inc 16 Sugar Hollow Road Danbury Connecticut 06810 See Figure 18 20 Coating Insulating Sleeve NOTE Hold ferrules while torquing or loosening spark plug coupling nuts to protect against twisting conduit or cable d Clamp harness leads as required IGNITION HARNESS INSTALLATION 1 The cable outlet plates be attached to either magneto only one position The shortest ignition cable is for No 1 upper spark plug The ignition lead to spark plug positions are stamped on the ignition lead to spark plug nuts Apply Champion thread lubricant to spark plug threads in accordance with the manufacturer s instructions see Chapter 3 Install all spark plugs and torque to 300 360 inch pounds Secure the ignition leads to the cylinder rocker covers using the ignition lead clamps and rocker cover screws Use caution routing and attaching leads Keep leads away from high heat sources such as the exhaust manifold Keep the leads away from any engine component that may cause chafing Connect the right magneto switch ground wire to the right magneto and the left magneto switch ground wire to the left magneto in accordance with the magneto manufacturer s instructions Install the ignition leads on the proper spark plugs and screw on
230. f Disassembly 2 6 4 6 5 Parts to be Discarded 6 4 6 6 100 Replacement Parts 6 4 6 7 General Cleaning 6 6 6 8 Visual Inspection 6 7 6 9 Magnetic Particle Inspection 6 7 6 10 Crankshaft Ultrasonic Inspection Procedure 6 8 6 11 Cylinder Barrel Ultrasonic Inspection Procedure 6 8 6 12 Fluorescent Penetrant Inspection 6 8 6 13 Dimensional Inspection sss 6 8 6 14 Dimensional Limits sse 6 8 6 15 Original Dimensions conoci ar htc Ee teret 6 9 6 16 Parts Limits e 6 9 6 17 Authorized Oversize and Authorized Undersize Parts 6 9 6 18 Protective Coating ne tribe RR Cer 6 9 6 19 Application Of Accelagold 6 9 6 20 6 9 6 21 Helical Coil Insert Replacement 6 10 6 22 Stud Replacement 6 11 6 23 Cylinder Exhaust Port Stud Replacement 6 12 6 24 New Parts ce eene tu ten Id rbi rea tee do re ree aee esed 6 14 6 25 TORQUES i 6 14 6 1 Installation Of Typical Helica
231. f TELEDYNE 7 Permold Series Overhaul Manual MODELS 10 550 ACTZOAR Courtesy of Bomar Flying Service www bomar biz FORM NO X30568A FAA APPROVED 2000 OCTOBER 2000 CURRENT STATUS OF PAGES AS OF OCTOBER 2000 See Manual Revisions in the introduction section for distribution procedure THE ORIGINAL DATE OF THIS PUBLICATION IS SEPTEMBER 1994 INSERT LATEST PAGES DESTROY SUPERSEDED PAGES WARNING the user of this manual is uncertain whether all current revisions have been incorporated into the manual contact Teledyne Continental Motors Do not perform any operation maintenance installation or other operation until the manual is confirmed current MODEL 10 550 A B C G N P amp R FORM X30568A PAGE STATUS PAGE STATUS PAGE STATUS PAGE STATUS COV OCTOBER 2000 6 12 OCTOBER 2000 9 12 through 13 7 MAY 1998 ii OCTOBER 2000 6 13 MAY 1998 9 16 OCTOBER 2000 13 8 MAY 1998 iii OCTOBER 2000 OCTOBER 2000 9 17 MAY 1998 13 9 OCTOBER 2000 iv through 6 15 MAY 1998 9 18 OCTOBER 2000 13 10 through iiv MAY 1998 6 16 MAY 1998 9 19 OCTOBER 2000 13 12 MAY 1998 MAY 1998 6 17 through MAY 1998 13 13 OCTOBER 2000 ORIGINAL 6 19 OCTOBER 2000 MAY 1998 13 14 through 1 3 OCTOBER 2000 MAY 1998 9 22 through 13 20 MAY 1998 1 4 OCTOBER 2000 OCTOBER 2000 9 24 OCTOBER 2000 13 21 OCTOBER 2000 1 5 OCTOBER 2000 ORIGINAL OCTOBER 2000 13 22 OCTOBER 2000 1 6 ORIGINAL OCTOBER 2000 10 2 MAY 1998 14
232. f makeshift tools not conforming with the specifications in Figure 17 8 Control Plug Installation Tool may cause damage to oil control plug or crankshaft during installation The 2 375 inch diameter collar at the rear of installation tool prevents driving oil control plug beyond the specified depth of 4 69 4 75 inches OIL CONTROL PLUG INSPECTION Using the special leak test fixture shown on previous page and a C clamp that has its spindle and foot protected by neoprene rubber pads pressure test the crankshaft See Figure 17 10 Crankshaft Leak Test The oil control plug must maintain 60 PSI minimum air pressure 7 After all crankshaft repairs have been completed use a strip of 180 grit emery cloth approximately 1 2 inch wide and apply a helix to the crankshaft as shown in Figure 17 11 Helix Pattern Application Apply helix to approximately 1 4 of the surface indicated at a time The pattern is applied by stroking the cloth outward toward the propeller flange in the direction of rotation CCW towards you using maximum hand pressure which will result in a 30 pattern as shown After doing the first portion rotate the crankshaft so that the next portion is visible Apply the same pattern again and continue completely around crankshaft in this manner The helix is applied to insure proper seating of the crankshaft oil seal After helix application the crankshaft must be re cleaned After the helix has been applied the helix area mu
233. form magnetic particle inspection on the valves Discard any valve with cracks or indications of cracks Clean the valves using mineral spirits and air dry Coat all surfaces thoroughly with clean 50 weight aviation engine oil MAY 1998 15 41 135 130 32812 R 005 CORNER BREAK LL 001 A MIN U CUT 1250 R 02 0005 1 00 1 9995 1 9990 VALVE GAUGE TOOL ADAPTER FIGURE 15 10 VALVE GAUGE LINE INSPECTION FIXTURE 15 42 MAY 1998 15 7 CYLINDER AND PISTON SUBASSEMBLY Original cylinders have a position number stamped on the edge of the base flange New cylinders must have a position number 1 through 6 as used stamped in the location shown in Figure 15 11 New pistons must have a position number 1 through 6 stamped in the location shown in Figure 15 11 Cylinder And Piston Position Number 100 MIN EDGE DISTANCE ALL METAL STAMPING NUMBERS MUST BE STAMPED IN POSITIONS SHOWN USING A METAL STAMP AND BALLPEEN HAMMER STAMP CORRECT CYLINDER BORE OVERSIZE DIAMETER HERE NUMBERS MUST BE 1 2 INCH FROM EDGE OF PISTON ABOVE PISTON PIN BORE FIGURE 15 11 CYLINDER AND PISTON POSITION NUMBER INNER VALVE SPRING NOTE INNER AND OUTER SPRINGS MUST OUTER VALVE SPRING BE INSTALLED AS SHOWN WITH CLOSED COILS TOWARD CYLINDER HEAD VALVE SEAT INSERT CYLINDER ASSEMBLY FIGURE 15 12 VALVE AND SPRING INSTALLATION OCTOBER 2000 15 43 WARNING Improper use of sealants an
234. formation and instructions for aircraft and engines that have been modified CAUTION Engine performance service life and reliability will be compromised if the engine s fuel injection system is neglected The following adjustment procedures are presented in a sequential format that must be followed to insure proper fuel system adjustment Reference the applicable Aircraft Maintenance Manual for detailed fuel system adjustment and maintenance procedures Any fuel system that can not be adjusted to meet the specified values will require repair or replacement of the affected components prior to further engine operation CAUTION Refer to chapter 6 Tables 6 4 and 6 5 for specified values when torquing all hose connections and fittings Adjustment Tools And Equipment Required A complete set of tools and test equipment is essential for correct setup of TCM fuel injection systems Various combinations of these tools and equipment will be used depending on the engine model A proper inventory of tools and equipment for fuel system adjustment will include the following 1 TCM recommends the Model 20 ATM C Porta Test Unit P N 630045 20 ATM C or equivalent to insure the fuel injection system meets all pressure and flow specifications An alternative procedure would be to use calibrated gauges You may acquire a Model 20 ATM C Porta Test Unit by contacting the following company AERO TEST Inc 29300 Goddard Road Romulus Michigan 48174 734
235. g procedures have been completed the crankcase halves must be fluorescent penetrant inspected by a certified technician as specified in section 16 6 in accordance with section 6 12 Fluorescent Penetrant Inspection 7 Section 6 19 Application Of Accelagold applies to all aluminum alloy castings sheet metal and tubing MAY 1998 16 27 16 8 CRANKCASE SUB ASSEMBLY NOTE All crankcase components must be clean and completely free of debris before assembly 1 See Figures 16 7A through 16 7D as applicable Crankcase Stud Setting Heights Install all pipe plugs that were removed in accordance with the specifications in Figures 16 7A through 16 7D as applicable Before installation apply Loctite Pipe Sealant with Teflon PS T sparingly on the pipe plug male threads Install and torque plugs to the specified values in Table 6 2 Pipe Plug Torques WARNING Use the proper installation tool when installing bearing See Figure 16 4 Using an arbor press and a TCM crankcase roller bearing installer or equivalent as shown in Figure 16 12 stand the 1 3 5 crankcase on it s nose end and press a new roller bearing 2 with P N facing outward into the bearing bore Press the bearing into case until it bottoms out See Figure 16 2 Oil Filler Idler Support Pin amp Camshaft Cover Install new o ring 2 on oil filler adapter 3 Install new o ring 1 in oil filler adapter 3 Lightly coat o rings 1 2 with clean 50 wt aviation eng
236. gine malfunction or failure a b Verify that all cylinder valve keepers have been properly installed Insure that each cylinder has a new cylinder base packing properly installed as described in section 15 7 Carefully rotate the crankshaft placing the number 1 and number 2 connecting rods in their outer most position Lubricate all cylinder through bolt and deck stud threads using clean 50 weight aviation engine oil Back the number 1 piston pin far enough out to allow the piston to be installed on the number 1 connecting rod Place the number 1 cylinder and piston assembly on the number 1 connecting rod and slide the piston pin into the connecting rod and piston Using a ring compressor compress the number 4 piston ring and push the cylinder until the number 4 ring is positioned inside the cylinder barrel Remove the ring compressor and push the cylinder assembly against the crankcase cylinder deck with the stud holes aligned Install the cylinder deck and through bolt nuts but do not torque at this time Back the number 2 piston pin far enough out to allow the piston to be installed on the number 2 connecting rod Place the number 2 cylinder and piston assembly on the number 2 connecting rod and slide the piston pin into the connecting rod and piston Using a ring compressor compress the number 4 piston ring and push the cylinder until the number 4 ring is positioned inside the cylinder barrel Remove the ring compressor and push the
237. gs 17 on throttle shaft fuel metering disc and on fuel metering cover boss Install spring 24 and bushing 23 in bottom most position of cover 15 Hold cover 15 with opening upright and install spring 18 into recess at the bottom of cover Place o ring 19 in metering plug 20 Install metering plug 20 into cover 15 with metering plug pin aligned with mixture adjustment pin opening in cover Depress plug assembly in cover to determine proper alignment of plug pin in mixture adjustment recess When assembly is complete the pin on the metering plug must be positioned between bushing 23 and mixture adjustment screw 21 Holding parts 15 through 20 10 12 OCTOBER 2000 together carefully mate them to the air throttle assembly 1 Install screws 16 securing fuel metering assembly to throttle body Tighten screws 16 to 21 25 inch pounds torque Lock wire screws 16 in accordance with Chapter 5 Lockwire Procedure Install mixture adjustment screw 21 with a new o ring 22 After calibration the mixture adjustment screw must be secured using a new retaining ring 25 After overhaul this unit must be calibrated in accordance with the data in Table 10 1 and the Fuel Metering Unit Calibration Instructions in the TCM Fuel Injection Parts And Overhaul Manual Form X30593A TABLE 10 1 THROTTLE AND FUEL METERING UNIT CALIBRATION SETTINGS LIMITS PART THROTTLE INLET PRESSURE FUEL FLOW METERED PRESSU
238. he system Take necessary precautions to prevent a fire hazard If contamination is present locate and correct the source and repeat this step prior to proceeding Prior to any checks or adjustments verify the accuracy of the tachometer manifold pressure gauge and fuel flow gauge Any gauge found to be inaccurate must be repaired or replaced prior to adjusting the fuel system WARNING Use of inaccurate gauges will result in incorrect adjustment of the engine fuel system possible cylinder wear due to lean operation pre ignition detonation overheating loss of power and severe engine damage 3 Insure that all fuel system components are of the correct part number and installed properly Correct any discrepancies noted Remove inspect clean and reinstall the engine test stand or aircraft and engine fuel screens in accordance with the manufacturer s instructions If the engine is installed in the airframe for testing inspect the aircraft induction air filter and alternate air system for condition operation and cleanliness Repair or replace any component that is not operating properly in accordance with the airframe manufacturer s instructions Inspect the test stand or aircraft vapor return system for proper operation in accordance with the manufacturers instructions Correct any discrepancies noted Insure the fuel manifold valve vent and fuel pump drain lines are properly installed open and free of obstruction Correct any
239. he two measurements must not exceed 0015 Connecting rods and caps not meeting these specifications must be scrapped Inspect the rod channel rails for damage such as nicks gouges or mechanical damage Scrap rods with any of these indications 17 8 OCTOBER 2000 Visually inspect oil transfer collar assembly for cracks and scoring Discard cracked or scored oil control collars Visually inspect oil control collar inside diameter area to insure tin plating is intact If tin plating has worn away discard oil control collar Inspect studs for distorted or stripped threads Inspect studs for corrosion pitting incomplete threads and looseness Replace studs with any of these indications Studs and dowels must be checked for security and proper setting height See the following for oil transfer collar stud setting heights ITEM SETTING QTY LOCATION THREAD SIZE HEIGHT poss 1 1 _ Stud Control Collar 1 4x1 1 4 Lg 15 16 1 8x7 16 Lg 5 32 ITEM 1 e FIGURE 17 3 OIL CONTROL COLLAR STUD AND DOWEL SETTING HEIGHTS MAY 1998 17 9 MAGNETIC PARTICLE INSPECTION NOTE The standard magnetic particle inspection procedure found in the latest revision of ASTM Standards on nondestructive testing describes the method of magnetization inspection and demagnetization The crankshaft counterweights camshaft crankshaft gears camshaft gear idler gear and governor drive gear must be magnetic particle inspected by a certified technician
240. her is a special thrust washer and must be installed with the bearing surface copper color toward the alternator Install nut 4 Place the toothed portion of drive hub gear in shielded vise jaws and tighten vise only enough to prevent rotation during torquing of nut Using a currently calibrated torque wrench torque nut 4 to 300 inch pounds torque If slots of nut do not align with cotter pin hole in alternator shaft the nut may be torqued further but must not exceed 450 inch pounds Do not back off nut to align holes Install cotter pin as shown in Figure 12 2 Cotter Pin Installation to insure clearance when alternator is installed on engine If assembling a new TCM alternator remove shipping spacer and washer from the alternator shaft and discard Follow the applicable manufacturer s instructions on alternators other than TCM WARNING Installation of the drive coupling assembly on TCM alternators with the shipping washer in place will cause interference with the face gear on the crankshaft and will result in damage to the engine and alternator 3 Store the alternator and attaching hardware in a clean protected area until final engine assembly MAY 1998 12 5 INTENTIONALLY LEFT BLANK 12 6 13 STARTING SYSTEM SECTION PAGE 13 1A Starter and Adapter 13 2 13 1B Starter and Adapter 13 4
241. honing Cylinder bore out of round not to exceed new 002 service 003 OCTOBER 2000 1 2 317 207 2 297 5 17 DIMENSIONAL INSPECTION The following new parts limits must be used for dimensional inspection Components that do not meet the following specifications must be discarded All components must be thoroughly cleaned and air dried prior to dimensional inspection CYLINDER AND ASSOCIATED PARTS FITS AND LIMITS 10 550 G N P R Description NEW PARTS MIN MAX CYLINDERS Cylinder bore lower 4 1 4 inch of barrel See Figure 15 4B1 Cylinder bore choke Taper See Figure 15 4B1 Cylinder bore surface Nitrided Barrels Cross hatch 22 32 30 50 0 0040L 0 0100L 0 006T 0 012T 0 0010T 0 0025T 0 0010T 0 0025T 0 0070T 0 0100T See Figure 15 5A See Figure 15 5B 4500 Rocker arm bushing bore Diameter Rocker arm bushing inside Finish Bore Diameter 0 7505 0 7515 Intake valve guide Inside Diameter 4350 4377 Intake valve in guide Diameter 0 0010L 0 0042L Exhaust valve guide Inside Diameter 4375 4395 Exhaust valve in guide Diameter 0 0035L 0 0062L 59945 60 15 45 00 45 30 See Figure 15 9 Replace 100 0 0000 0 0015 0 060 0 200 Piston moly coated bottom of skirt in cylinder Diameter 0 006L 0 010L Piston non moly coated bottom of skirt in cylinder Diameter 0 008L 0 011L 0 0015 0 0040 0 0015 0 0040 0 0035 0 0055 15 18 Description NE
242. housing Using a new pin 16 install bevel gear 17 on oil pump drive gear 15 2 Assemble pressure relief valve housing 11 and adjusting screw 9 Turn adjusting screw into housing about halfway Secure adjusting screw using new copper washer 13 and new nut 14 Assemble plunger 6 new spring 7 new washer 8 and slide into relief valve opening in oil pump housing Install new gasket 10 on pressure relief valve housing 11 Coat housing threads with TCM P N 646943 Anti Seize Lubricant Insure that adjusting screw aligns with plunger spring and washer Screw relief valve housing into oil pump housing Torque housing to 240 260 inch pounds Safety wire housing 11 in accordance with section 5 2 Lockwire Procedure 3 To assemble the mechanical tach drive housing to the oil pump housing lightly coat new oil seal 19 outside diameter with TCM Gasket maker P N 646942 and install using an arbor press and correct size driving tool Press seal in flush Make sure new oil seal is squarely seated before pressing Coat the inside diameter of oil seal 19 with with clean Molyshield grease 4 Coat oil pump gear cavity flange with 3 aviation permatex Apply silk thread to oil pump housing flange as shown in Figure 14 9 Apply TCM gasket maker to the portion of the tach drive housing that will mate with the oil pump housing where the Permatex and silk thread is applied Coat tach drive shaft gear 24 with with clean Molyshield grease Pl
243. ibility of serious bodily injury or death before moving the propeller accomplish the following 2 a Disconnect all spark plug leads b Verify magneto switches are connected to magnetos that they are in the OFF Position and P leads are grounded Throttle position CLOSED Mixture control IDLE CUT OFF Set brakes and block aircraft wheels Insure that aircraft tie downs are installed and verify that the cabin door latch is open Do not stand within the arc of the propeller blades while turning the propeller MAGNETOS TCM magnetos Remove the inspection hole plug from the magneto Turn the impulse coupling backward so that the latches will not engage Turn until timing pointer inside inspection hole is aligned with the marked distributor gear tooth Slick Magnetos Insert the T118 timing pin going L or hole depending on magneto rotation in the distributor block Turn rotor in the opposite rotation of magneto until pin engages the gear ACCESSORY DRIVE ASSEMBLIES See Figure 8 2A for all 10 550 permold engines except IO 550 G5B Clean and dry the retainers 14 and bushings 15 Apply Molyshield grease to the rubber drive bushings Install two magneto drive bushings into each retainer with the radius rounded edges facing outward Install a retainer and bushing assembly firmly into each magneto drive gear assembly See Figure 8 2B for 550 Clean and dry the retainers 18 and
244. icated on the gauge Slowly move the mixture control toward the IDLE CUT OFF position and record the maximum RPM rise Return the mixture control to FULL RICH 16 Monitoring all engine gauges slowly advance the throttle control to full rated power for the engine and allow the engine to stabilize for 15 seconds Record all engine and test gauge indications DO NOT ALLOW ENGINE TEMPERATURES TO EXCEED 420 F CYLINDER HEAD TEMPERATURE AND 210 F OIL TEMP Retard throttle control to 800 to 1000 RPM NOTE Engine driven fuel pump output pressures vary with engine RPM If the engine will not achieve full power rpm during static ground operational test run use Table 19 2 to correct the metered fuel pressure specification for the actual rom achieved NOTE Insure that all engine and aircraft systems are adjusted and functioning properly before making any adjustment to the fuel system 17 Compare the recorded IDLE fuel pressure IDLE RPM fuel air mixture rise and full power RPM manifold pressure as applicable unmetered fuel pressure metered fuel pressure and fuel flow indications with the specified values recorded on the operational test form If all recorded values are within specifications proceed to paragraph 23 19 10 MAY 1998 FUEL PUMP REAR VIEWS 10 550 amp 10 550 10 550 N P amp R 1 IDLE UNMETERED PRESSURE ADJUSTMENT SCREW CENTERLINE 2 ADJUSTABLE ORIFICE ADJUSTING SCREW FIGURE 19 3 FUEL PUMP ADJUSTMEN
245. il passages for free flow Rocker arms with blocked oil passages that cannot be cleared by solvent action must be discarded MAY 1998 15 9 POWER STROKE STRESS AREA ON THE 1 3 5 CYLINDERS TOP 12 O CLOCK POSITION as mounted on crankcase CYLINDER BARREL FIN TIP REPAIR NO FIN TIP REPAIR IS ALLOWED IN THE POWER STROKE AREA REMOVE ONLY ENOUGH MATERIAL THE ORIGINAL FIN TO ELIMINATE DAMAGE TIP PROFILE AND CONTOUR MUST BE RETAINED BLEND AREA SMOOTH NO SHARP EDGES ARE ALLOWED BOTTOM 6 O CLOCK POSITION as mounted on crankcase POWER STROKE STRESS AREA ON THE 2 4 6 CYLINDERS MUST BE NO GREATER THAN 050 DEEP FROM HEAD TO BARREL JUNCTION ORIGINAL EDGE MAGNETIC PARTICLE INSPECT REPAIRED AREA FOR CRACKS AND IF NONE ARE PRESENT APPLY PROTECTIVE COATING OF TCM ENAMEL OR EQUIVALENT POWER STROKE STRESS AREA TOP AND BOTTOM OF CYLINDER BARREL FIGURE 15 2 CYLINDER INSPECTION 15 10 MAY 1998 INSTALL SPARK PLUG HELICAL COIL TO A DEPTH OF 109 TO 129 L OF INCH BELOW GASKET SEAT eae RUST PITTING IN THIS INSPECT FOR aca Sema AREA ON ANY CYLING FLATNESS aaa DER IS NOT ACCEPT ABLE INSTALL SPARK PLUG HELICAL COIL 01 TO 03 OF AN INCH FROM BOTTOM OF SPARK PLUG HOLE uxo o fl Ee VEHI DERE INSPECT FOR AREA ON ANY CYLIN FLATNESS DER IS NOT ACCEPT ABLE 10 550
246. ilable sides Gasket governor pad both sides 3 3 SUGGESTED SOURCES APPLICATION LUBRIPLATE 930 AA For Distributor information Call Apply to the outside diameter of P N L0096 035 LUBRIPLATE valve guides at installation Phone 1 800 733 4755 TCM P N 654514 CRC 3 36 May be purchased through Spray exhaust end of turbocharger Rust Preventative Compound your local TCM Distributor for engine preservation Permatex Aviation Grade 3D For Distributor information call Crankcase parting face oil pump Permatex Customer Service covers scavenge pump covers Phone 1 800 641 7376 and 641543 Silk Thread May be purchased through and your local TCM Distributor 646942 Gasket Maker May be purchased through or your local TCM Distributor Loctite Gasket Eliminator For Distributor information call 515 Sealant Loctite Customer Service Phone 1 800 243 4874 653692 Primer May be purchased through Crankcase crankshaft nose oil seal your local TCM Distributor area or Loctite LocQuic Primer 7649 For Distributor information Loctite Customer Service Phone 1 800 243 4874 646942 Gasket Maker May be purchased through your Endine nose outside di t local TCM Distributor 9 of all uncoated seals except fuel pump adapter seal between oil sump and oil sump gaskets or Loctite Gasket Eliminator For Distributor information 515 Sealant Loctite Customer Service Phone 1 800 243 4874 TYPE SUGGESTED SOURCES
247. ill tend to follow the drilled hole For drilling and tapping aluminum alloy castings use a commercial grade cutting lubrication oil to prevent overheating of the metal and tearing of the thread FIGURE 6 1 INSTALLATION TYPICAL HELICAL COIL INSERT 6 10 MAY 1998 6 21 6 22 HELICAL COIL INSERT REPLACEMENT cont d To remove a damaged helical coil insert use the proper size of extracting tool for the nominal thread size Tap it into the insert so the sharp edges get a good bite then turn the tool to the left and back out the helical coil until it is free To install new insert in a properly tapped hole after blowing out all liquid and chips slide it over the slotted end of the driving mandrel of the proper size installing tool and engage the driving tang bent end of the helical coil in the mandrel slot then wind the insert slowly into the tapped hole See Figure 6 1 Installing Typical Helical Insert The outer end of the insert must lie within the first full thread of the hole Break off the driving tang of a notched helical coil by bending back and forth across the hole with long nose pliers or with a special tang break off tool After helical coil replacement the remaining wall thickness edge distance must not be less than one half the helical coil diameter or 08 minimum whichever is greater WARNING The 2 and 4 o clock cylinder deck stud positions must not be repaired by helical coil insert installation STUD REPLA
248. induction system and properly disposed of prior to attempting engine start Failure to do so could cause hydraulic lock and subsequent engine failure 11 Install the engine cowling or cooling shroud during ground operation 12 The Operational Test Form on page 19 33 may be reproduced for use in recording adjustments and test indications Record the applicable IDLE and FULL POWER adjustment points RPM fuel pressure fuel flows manifold pressure and fuel air mixture rise from Test Operating Specifications on page 19 13 on the operational test form See pages 19 15 through 19 32 of this chapter for Constant Speed Sea Level Performance Curves a b Fuel Flow Vs Brake Horsepower Performance Curves c Fuel Flow Vs Metered Pressure Performance Curves d Auto Leaning Schedule Performance Curves WARNING Before starting the engine insure that the aircraft wheels are chocked and brakes are set 13 Prepare the engine test stand or aircraft for ground run and start the engine in accordance with the aircraft manufacturer s instructions 14 Advance the throttle to 1500 to 1800 RPM While monitoring all engine gauges operate the engine at this speed until the engine temperatures and pressures have stabilized in the operational range Use the operational test form to record the gauge indications 15 With the mixture control in the FULL RICH position reduce the throttle to the specified IDLE RPM Record the unmetered pressure ind
249. ine oil Install adapter into left crankcase half Make sure o rings are not pinched or twisted Insert oil filler tube 5 into adapter 3 Do not displace o ring 1 Using a new gasket 4 attach oil filler assembly to left case half and secure with attaching hardware 6 7 8 Torque bolts 8 to 155 175 inch pounds See Figure 16 3A Engine Mounts Crankshaft Seal Retainer amp Governor Cover 550 amp On 550 crankcase install engine mounts 6 7 and secure using attaching hardware 8 9 Torque nuts 9 to 275 325 inch pounds 10 550 use right lower engine mount bracket P N 653306 which replaces P N 630695 550 crankcase install engine mounts 2 4 amp 5 and secure using attaching hardware 8 9 amp 10 Torque nuts 9 to 275 325 inch pounds torque Engine mount 3 will be installed with the oil cooler during final engine assembly 550 and 550 engine mounts are installed in section 14 7 Oil Sump See Figure 16 3B Engine Mounts Crankshaft Seal Retainer amp Governor Cover 550 G N P amp R Install engine mounts 1 2 on crankcase halves and secure using attaching hardware 4 5 amp 6 Torque bolts 5 6 to 220 260 inch pounds Cover and store crankcase halves and associated parts in a clean protected area until final engine assembly 16 28 OCTOBER 2000 DRAW BLUE COLOR Ro WA ONE INCH MATERIAL SAE
250. ined in the Airworthiness Directives AD issued after the date of certification there are no other related procedures required pursuant to the type certification for this engine 4 Distribution of Changes to Airworthiness Limitations Changes to the Airworthiness Limitations section constitute changes to the type design of this engine and require FAA approval Such changes will be published in FAA Airworthiness Directives AD NOTE The limitations in this section apply only to specific limitations which are part of the engine design Under the Federal Aviation Regulations numerous other additional limitations are applicable to this engine and it s accessories For example Federal Aviation Regulation Parts 91 and 43 among other parts define inspection criteria maintenance requirements and procedures that are applicable to this engine It is the responsibility of the owner operator to maintain the engine in an airworthy condition by complying with all applicable Federal Aviation Regulations and by performing maintenance in accordance with TCM Instructions for Continued Airworthiness which consist of TCM publications and service documents 1998 44 4 2 INTENTIONALLY LEFT BLANK SECTION 5 1 5 2 5 3 5 4 5 5 5 6 FIGURE 5 1 5 2 5 3 5 4 5 STANDARD PRACTICES PAGE General fc aes bee 5 2 Lockwire 5 3 Tab Washer
251. ineral spirit solvent and a brass wire brush Gears with bushings must not be cleaned using alkaline solutions Gears that do not have bushings can be cleaned using mineral spirit solvent or by immersion in a alkaline stripping bath if mineral spirit solvent is not effective After cleaning with alkaline solution the gears must be sprayed with steam removing all traces of alkaline After steam rinsing the gears must be thoroughly flushed with mineral spirit solvent CAUTION Alkaline cleaning solutions will cause corrosion to metals if not completely removed WARNING Do not pressure blast gears with an abrasive media Blasting will remove surface hardening STARTER AND STARTER ADAPTER INSPECTION VISUAL INSPECTION 1 The starter adapter components must be visually inspected in accordance with instructions in section 6 8 Visual Inspection Special attention must be given to the following components and areas The starter motor assembly must be overhauled in accordance with the starter manufacturer s instructions See TCM Form X30592 for TCM starters See section 1 5 Related Publications for ordering information Using a flashlight and a 10X magnifying glass visually inspect the exterior and the cavity of the starter adapter housing for cracks Housings exhibiting cracks must be discarded Inspect the starter adapter covers for cracks Adapter covers exhibiting cracks must be discarded Inspect all oil passages for restrictions S
252. ing Install new gasket 10 on pressure relief valve housing 11 Coat housing threads with TCM P N 646943 Anti Seize Lubricant Insure that adjusting screw aligns with plunger spring and washer Screw relief valve housing into oil pump housing Torque housing to 240 260 inch pounds Safety wire housing 11 in accordance with section 5 2 Lockwire Procedure 3 Coat oil pump gear cavity flange with 3 aviation permatex Apply silk thread to oil pump housing flange as shown in Figure 14 9 Apply TCM gasket maker to the portion of the tach drive housing that will mate with the oil pump housing where the Permatex and silk thread is applied As the oil pump cover is being installed make sure silk thread is not displaced Secure with two sets of attaching hardware 18 20 Torque nuts 20 to 90 110 inch pounds 4 Oil pump filter adapter and oil filter assembly will be installed during final engine assembly Cover components and store in a clean protected area until final assembly CROSS THREAD FIGURE 14 9 OIL PUMP HOUSING THREADING DIAGRAM MAY 1998 14 25 Oil Cooler 10 550 10 550 10 550 G1B G2B amp G4B See Figure 14 2 NOTE Before installing fittings in oil cooler insure they are free of any debris by thoroughly flushing them with an approved solvent WARNING Never use teflon tape on lubrication system fittings 1 Install fitting 12 plugs 13 amp 14 new gasket 16 and new oil temperature control valve
253. ing 1 1267 to 1 1269 tolerance available from Federal Tool Supply Inc 5209 Propeller Shaft Oil Seal Installer available from Kent Moore OPERATIONAL INSPECTION 85328 Alcor Portable Digital EGT Unit available from Alcor Inc 85329 Alcor Portable Digital CHT available from Alcor Inc Model 20 ATM C Porta Test Unit available from Aero Test Inc See possible sources on page 2 3 for tool procurement NOTE The rights to manufacture Borrough s Tools has been acquired by Kent Moore OCTOBER 2000 2 6 OCTOBER 2000 3 SEALANTS AND LUBRICANTS Aviation Engine Oil Ashless Dispersant Recommended Grade Above 40 F ambient air sea level Below 40 F ambient air sea level SAE 50 or Multi Viscosity SAE 30 or Multi Viscosity BP Oil Corporation Castrol Castrol Limited Australia Chevron U S A Inc Continental Oil Delta Petroleum Company Exxon Company U S A Gulf Oil Company Mobil Oil Company NYCO S A Pennzoil Company Phillips Petroleum Company Phillips Petroleum Company Quaker State Oil amp Refining Company Red Ram Limited Canada Shell Australia Shell Canada Limited Shell Oil Company Sinclair Oil Company Texaco Inc Total France Union Oil Company of California BP Aero Oil Castrol Aero AD Oil Castrol Aero AD Oil Chevron Aero Oil Conco Aero S Delta Avoil Oil Exxon Aviation Oil EE Gulfpride Aviation AD Mobil Aero Oil TURBONYCOIL 3570 Pennzoil Aircraft
254. install ring 56 into the first ring groove and install ring 59 into the fourth ring groove f Inspect all ring side clearances with the ring edge flush with the piston outside diameter All ring side clearances must conform with the dimensions in Cylinder And Associated Parts Fits And Limits NOTE Weight differences of piston pairs in opposing bays must not exceed 1 2 ounce or 14 175 grams g Lubricate the piston pin and piston and ring assemblies with clean 50 weight aviation engine oil Place the new piston and ring assembly with the cylinder assembly for which it was previously sized and gapped Place a new piston pin with each piston and ring assembly Install the piston pins in the piston pin bores The piston pins must slide freely in the piston pin bores MAY 1998 15 47 h Position the rings so the ring gaps are 180 apart with the first top ring toward top of the piston Using a ring compressor install each piston into it s cylinder so that the top three rings are in the cylinder barrel and the piston pin is accessible for installation on the connecting rod Install the piston and ring assemblies into the cylinder bore with the piston position number toward the propeller flange when the cylinder is installed on the engine i Place the cylinders on a clean protected work bench in position order and cover until final engine assembly j Install new gasket 37 on cylinder end of pushrod housings 35 Place two e
255. ion System 10 550 9 3 9 1B Fuel Injection System 10 550 9 5 9 1C Fuel Injection System 10 550 9 7 9 1D Fuel Injection System 10 550 G amp 9 9 9 2A Fuel Manifold Valve Fitting Orientation 10 550 A 9 10 9 2B Fuel Manifold Valve Fitting Orientation 10 550 B amp C 9 11 9 2C Fuel Manifold Valve Fitting Orientation 10 550 G N R 9 12 9 3A Fuel Pump Fitting Orientation 10 550 A amp C except 10 550 531 Bandi 328 cnt ie i bu yee 9 13 9 3B Fuel Pump Fitting Orientation 10 550 B except 10 550 B37B B39B B38B B40B B41B B42B B43B B45B B46B B48B B49B B51B 2 reet nepote e rel x RARI Qus Pl nie rt 9 13 9 3C Fuel Pump Fitting Orientation 10 550 B37B B39B B38B B40B B41B B42B B43B B45B B46B B48B B49B B51B B52B 10 550 C30B C31B and C32B 9 14 9 3D Fuel Pump Fitting Orientation 10 550 G G1B G2B G4B 10 550 N N1B N2B 10 550 amp 10 550 R 9 15 9 3E Fuel Pump Fitting Orientation 10 550 5 G6B 9 16 9 4 Fuel Control Fitting Orientation 9 17 9 5 Fuel Metering Unit Fitting Orientation
256. irs Lp SS 7 11 4B 4A 4B 147 19 17 12 OCTOBER 1998 7 Mi KA 16 FIGURE 17 4A CRANKSHAFT CAMSHAFT AND CONNECTING ROD FITS AND LIMITS 22 21 12 18 During dimensional inspection the camshaft must mounted on matched vee blocks supporting the front and rear main journals The crankshaft must be mounted on matched vee blocks supporting the 3 and rear main journals The vee blocks must be mounted on a surface plate Rotate the shafts under a dial indicator placed on the center main journal to detect bending runout Rotate the crankshaft prop flange under a dial indicator to detect bending runout See items 2 3 17 of Figure 17A Crankshaft and Camshaft Fits and Limits for camshaft and crankshaft runout tolerances R Description GEAR BACKLASH Crankshaft gear and camshaft gear Backlash 0 0080 0 0120 Crankshaft gear and idler gear Backlash 0 0080 0 0120 Idler gear and magneto drive gear right and left Backlash 0 0080 0 0120 Starter shaftgear and crankshaft gear Backlash 0 0080 0 0120 FIGURE 17 4B CRANKSHAFT CAMSHAFT AND IDLER GEAR BACKLASH OCTOBER 1998 17 13 DIMENSIONAL INSPECTION continued The connecting rod piston pin bushing alignment must be checked with the crank pin end bearing bore Make alignment measurements using a push fit arbor for the bushing bore piston pin end and another for the bearing seat crank pi
257. it was calibrated 19 2 OCTOBER 2000 19 5 19 6 19 7 19 8 19 9 19 10 COOLING AIR SCOOP An air scoop must be designed to fit over the tops of all cylinders with padded seals for rear cylinders and valve rocker covers to direct an adequate flow of air downward through the cylinder fins Vanes are necessary to direct cooling air to the center cylinder and the oil cooler CHT should not vary more than 50 F between coolest and hottest cylinders Provide an air duct to the alternator vent tube INDUCTION AIR INTAKE An air filter and housing must be attached to the intake flange The filter area must be sufficient to avoid restriction of air flow Always clean filter before each test calculations of filter area should be based on approximately 389 c f m of air required by the engine at full throttle and on the filter capacity per unit of area The calculated area of a clean filter should be increased by at least 50 to allow for dirt accumulation EXHAUST The exhaust system supplied by the airframe manufacturer or STC holder as applicable must be installed for testing purposes CONTROLS The controls required are a mixture control and throttle control capable of operating the fuel mixture and throttle shafts through their complete ranges and a magneto switch connected to the magneto ground terminals If a flight propeller is used a proper governor and governor control is also required ELECTRICAL WIRING A storage batte
258. ith the specifications in Figure 17 6 Crankshaft Hanger Blade Bushing Replacement Replacement bushings are available in standard size only BUSHING LEAD IN MUST BE POSITIONED TOWARD CRANKSHAFT HANGER BLADE DURING BUSHING INSTALLATION NR BUSHINGS IN FLUSH TO BELOW SURFACE BUSHINGS MUST NOT PROTRUDE FROM HANGER BLADE EDGE ON aS SIDE DIA m AFTER ASSEMBLY ZZ 622 FIGURE 17 6 CRANKSHAFT HANGER BLADE BUSHING REPLACEMENT NOTE After installation of new bushings the crankshaft counterweight hanger blades must be magnetic particle inspected in accordance with section 6 9 Magnetic Particle inspection Discard crankshafts with cracked counterweight hanger blades Inspect the new installed bushing inside diameter using an air gauge and with correct air plug and setting ring See Figure 17 6 for correct dimension No finishing operation is required The new installed bushings are made to final dimensions 17 16 OCTOBER 2000 5 The counterweight bushings must be replaced 100 at engine overhaul regardless of condition The bushing replacement must be performed using the specified procedure and the following special tools a Borrough s 8077C Counterweight Bushing Removal Installation Fixture or equivalent b Arbor Press WARNING Removing and replacing bushings with makeshift tools and methods may result in irreparable damage to the counterweight and counterweight crankshaft malfunction COUNT
259. itting cylinder decks Using the proper fixtures and dial indicators check and record gear backlash before removing drive train See Chapter 17 Gear Backlash Fits and Limits Lift out camshaft and governor driven gear Remove idler gear hydraulic tappets and crankshaft assembly Place the camshaft and crankshaft assemblies on the proper holding fixtures to prevent damage Remove and discard crankshaft bearings and thrust washers 16 4 OCTOBER 2000 eqq o nS 28 31 3 28 31 32 21 22 23 24 29 30 31 32 FIGURE 16 1B CRANKCASE ATTACHING PARTS 550 Bolt Bolt Bolt Washer Washer Nut Eye Lifting Eye Lifting Bracket Ignition Bolt Through O Ring Washer Nut Bolt Bolt Through O Ring Washer Nut Support Baffle Bolt Through Washer Washer Nut Bolt Through Bolt Washer Nut 28 Bolt 29 Washer 30 Nut 31 Bolt 32 Bolt 33 Screw 34 Screw OCTOBER 2000 16 5 16 2 OIL FILLER AND GAUGE HOUSING REMOVAL See Figure 16 2 1 Remove attaching hardware 6 7 8 lift oil filler assembly 5 from engine remove oil filter adapter 3 and discard o rings 1 2 Remove and discard gasket 4 Separate oil gauge assembly 9 from oil filler FIGURE 16 2 OIL FILLER IDLER SUPPORT PIN amp CAMSHAFT COVER 1 O Ring 6 Washer Plain 11 Gasket 16 Bushing Idler Gear 2 O Ring 7 Washer Lock 12 Cover Cam Hole 17 Gasket Flange
260. juster or equivalent for Gen Alt Belt Tensioning BT 33 73F Belt Tension Gauge available from Kent Moore Borrough s 4973 Generator Drive Holders or equivalent Borrough s 61 5 Pulley Puller or equivalent for gen alt sheave removal Borrough s 8091 GEN ALT Output Tester or equivalent 647 Alternator Analyzer Voltage Regulator Tester available from Eastern Electronics Inc E100 Alternator Regulator Battery Tester available from Eastern Electronics Inc Model 29 Voltage amp Circuit Tester available from Eastern Electronics Inc STARTING SYSTEM Borrough s 8093C Bearing Puller or equivalent for needle bearing removal TCM Needle Bearing Installer or equivalent see 13 6 for specifications LUBRICATION SYSTEM 8048 Oil Pressure Relief Spot Facer available from Kent Moore CYLINDERS 15 1A 15 1B 68 3 Push Rod Spring Compressor available from Kent Moore 15 1A 15 1B 5203 5204 amp 8158A Cylinder Base Nut Wrenches available from Kent Moore 15 1A 15 1B Borrough s 8079 Cylinder Base Nut Wrenches or equivalent 15 1A 15 1B 3882 3882 2 Cylinder Base Nut Wrenches available from Kent Moore 18 4 3601 Ring Compressor for cylinder installation available from Kent Moore 15 1A 15 1B 8121 Piston Pin Removers available from Kent Moore 15 2 3602 Valve Spring Compressor available from Kent Moore 15 5 545 116 Dial Bore Gauges available from Federal Tool Supply Co Inc 15 6 CFL10 Cylinder Hone available from Snap On Tools No 1675 Valve
261. ket 9 at crankcase backbone position specified in Figure 16 1A Install backbone bolts 1 through 4 with washers 5 and nuts 6 Finger tighten nuts 6 Do not torque at this time Install remaining bolts washers and nuts 1 through 6 in hole positions specified in Figure 16 1A Finger tighten but do not torque at this time Install four 5 16 bolts 26 in hole positions 73 74 75 76 install and finger tighten attaching hardware 27 28 Lower crankcase hardware and suction tube installation See Figure 14 3A Oil Sump For 10 550 amp See Figure 14 3A install gasket 6 with split line toward crankcase on suction tube 1 Insert threaded end of tube through hole provided in crankcase Install gasket 7 and plug 8 on protruding threaded end of suction tube Attach suction tube bracket to crankcase with bolt 3 spacer 2 and washer 4 and nut 5 at position 78 in Figure 18 8 Install remaining 1 4 bolts 29 in hole positions specified in Figure 16 1A install and finger tighten attaching hardware 32 33 See Figure 14 3B Oil Sump For 10 550 Install gasket 3 with split line toward crankcase on suction tube 1 Insert threaded end of tube through hole provided in crankcase Install gasket 5 and plug 4 on protruding threaded end of suction tube Do not tighten plug at this time See Figure 14 3B attach suction tube bracket to crankcase with bolts 2 Torque bolts 2 to 155 175 inch pounds
262. l Coil Insert 6 10 6 2 Standard and Oversize Stud Identification 6 11 6 3 Removal TOO ini eh sete 6 12 6 4 Stud Removal osteitis a ei eres 6 13 6 5 Stud Installation 6 13 TABLE PAGE 6 1 General Use Torques sss 6 15 6 2 Pipe Plug Torques 6 15 6 3 Torques Specifications for 65 2 6 15 6 4 Torque Specifications For Hose Fittings 6 16 6 5 Specific Torques seen 6 17 OCTOBER 2000 6 1 6 2 GENERAL WARNING Use only parts meeting the engine type design Prior to engine removal using a differential pressure gauge perform the following leak check on each cylinder Record findings LEAK CHECK This check serves as an identifier for conditions which may not be detectable by visual inspection 1 Position the piston as close to bottom dead center on the compression stroke as possible insuring that the intake valve remains closed to allow the cylinder to hold pressure 2 With the compression tester connected apply 5 PSI to the cylinder WARNING It will be necessary to hold the propeller stationary while pressure is applied to the cylinder Use extreme caution to prevent injury to personnel or damage to equipment WARNING During pressurization of cylinders do not stand or allow anyon
263. lange screw holes for complete threads Inspect all helical coils for damage The spark plug helical coil outer ends must lie in the first full thread of the tapped holes in which they are installed The helical coil teeth at the outer end of the helical coil must not be visible Repair threaded bores in accordance with section 6 21 and Figure 15 3 INTAKE VALVES Visually inspect the intake valves using a 10X magnifying glass Inspect the intake valve stems for scoring damage in valve retainer grooves and spalling on stem tips Place the valve head on a one inch wide precision parallel bar and inspect for distortion with a 001 feeler stock Discard valves that are damaged distorted cracked burned pitted or rusted Valve faces may be machined to the dimensions specified in Figure 15 9 Intake Valve Refacing ROCKER ARMS Visually inspect all rocker arm foot contact areas for wear galling spalling scoring or grooves Inspect rocker arm ball seats for smoothness Discard rocker arms with any signs of wear galling spalling scoring or grooves Inspect the thrust surfaces of the rocker shaft bore for displaced metal galling and spalling Discard all rocker arms with these conditions Inspect for and discard any rocker arm that has peeling copper plating Inspect for and discard rocker arms with loose or missing oil passage rivets Inspect oil passages for obstruction Use an oil squirt bottle and clean 50 weight aviation engine oil to check o
264. le and drill to the specified depth NOTE The secondary removal drill size and specified depths are noted below This should cut the engagement between the stud serrations and the internal serrations of the lock ring 5 The remaining lock ring will have a very thin wall A sharp punch will easily break it away from the cylinder head 6 Drive an Ezy Out into the small hole in the stud and apply removal torque 7 After the stud has been removed clean the hole Cylinder Exhaust Port Stud Primar Removal Drill Secondar Removal Drill Basic Stud Number Minimum Depth 015 Depth 164 dia SFC164 1 16 062 3 16 188 190 dia SFC190 1 16 062 25 723221 2090 aman FIGURE 6 3 REMOVAL TOOL 2222 6 12 2000 REMOVAL OF STEP TYPE STUDS The step type captive lock ring studs have a larger lock ring than the size on size type and therefore can be removed any one of two ways Method 1 Using the appropriate removal tool as shown in Figure 6 3 Removal Tool mill the lock ring away to the appropriate depth See Figure 6 4 Stud Removal Using the best suitable means apply removal torque to the stud The remaining portion of the lock ring should lift out as the stud is being removed If not the remaining portion can be broken away from the cylinder head using a sharp punch FIGURE 6 4 STUD REMOVAL Method 2 Using the same
265. ll aluminum alloy castings sheet metal and tubing 9 6 FUEL INJECTION SYSTEM SUB ASSEMBLY NOTE All fuel injection system components must be overhauled or new clean and free of debris before assembly 1 The fuel pump fuel control throttle and metering unit fuel manifold valve and fuel nozzles must be new factory rebuilt or field overhauled and tested in accordance with TCM Form X30593A Fuel Injection Systems Overhaul and Parts Catalog NOTE Before re installation of fuel system component fittings insure they are free of any debris by screwing them into the proper size holes of a softwood block then thoroughly flushing them with an approved solvent WARNING Never use teflon tape on fuel injection component fittings 2 See Figures 9 2A through 9 2C Sparingly apply TCM 646940 sealant on fittings that have male tapered pipe threads in accordance with Figure 9 9 General Sealant Application Install fittings A through C into fuel manifold valve at the proper locations and correct orientations 3 See Figures 9 3A through 9 30 Sparingly apply TCM 646940 sealant on fittings that have male tapered pipe threads in accordance with Figure 9 9 General Sealant Application Install fittings A through E into fuel pump at the proper locations and correct orientation 4 See Figure 9 4 Sparingly apply TCM 646940 sealant on fittings that have male tapered pipe threads in accordance with Figure 9 9 Gene
266. lve spring retainers 14 over valve guides 4 and 5 cupped side up Coat the sealing surface of a new intake valve guide seal with clean 50 weight aviation engine oil Install new seal 15 on the intake valve guide by hand See Figure 15 14 for valve guide seal installation tool and correct installation Using the specified installation tool and a plastic mallet tap the seal on to the guide until it is firmly seated Install new inner and outer valve springs 12 13 new rotocoil 16 on the exhaust valve springs and retainer 26 on the intake valve springs The valve springs must be installed with the closed coils toward the cylinder head as shown in Figure 15 12 Valve And Spring Installation CAUTION Do not allow the valve spring compressing tool to cock the rotocoils Contact between the rotocoils and valve stems will cause damage to the valve stems b Using a valve spring compressor compress the valve springs and insert the valve stem retainer keys 17 The springs should be depressed only enough to admit the keys to seat into the valve stem grooves If keys drop too far they may become fouled This condition could cause them to damage the stem when the springs are released Make sure the keys are properly seated into the grooves of the valve stem before releasing pressure on springs Remove the cylinder from fixture and set it upright on the workbench Place a plastic mallet squarely on the end of the valve stem and strike the plastic
267. lve tip to rocker foot and compare with limits given in Figure 15 4A or 15 4B Cylinder Fits and Limits as applicable Install valve actuating parts on remaining cylinders using the above procedure Using new gaskets 28 install rocker covers 29 and secure with attaching hardware 30 31 amp 32 Do not torque screws 32 at this time The rocker covers will be removed for engine pre oiling during post overhaul adjustment and test 18 12B VALVE MECHANISM 550 P amp See Figure 15 1B 1 2 Lubricate all tappet faces using Dow Corning G N Paste or equivalent Dow Corning is a registered trademark of Dow Corning Corporation Install new exhaust tappets into exhaust side tappet guides Install new intake tappets into intake side tappet guides Install twelve pushrod housings Using a Borrough s 68 3 Rod Spring Compressor or equivalent compress spring 39 Place a new packing 38 between two steel washers 36 and install on the crankcase end of pushrod housing Place a new gasket 37 on the cylinder end of pushrod housing Insert housing into crankcase guide until other end can be aligned with cylinder head opening Move assembly outward until gasket has entered cylinder hole Release spring slowly until it is free Remove spring compressor See Figure 18 17 Installing Pushrod Housing Install the pushrod housings nearest to engine mount brackets first The spring compressor tool must lie close to horizon
268. lvent Insure that the magneto drive adapter lubrication holes are clear and unobstructed CAUTION Alkaline cleaning solutions will cause corrosion on metals if not completely removed WARNING Do not pressure blast gears with an abrasive media Blasting will remove surface hardening 8 5 MAGNETO DRIVE GEAR INSPECTION 1 Inspect the magneto drive gear teeth for signs of overheating and excessive wear Normal wear produces a fine polish on the tooth thrust faces Gears that have alteration of the tooth profiles score marks burning pitting nicks burrs or corrosion must be discarded See Figure 8 3 Gear Tooth Inspection for acceptable and unacceptable gear tooth wear Using a flashlight visually inspect the magneto adapter oil seal and bushing bores for damage resulting from bushing and oil seal removal process Inspect the adapter housing for cracks Magneto adapter housings with damaged oil seal bores bushing bores or that exhibit cracks must be discarded Inspect all oil passages for restrictions Magneto adapters with oil passages that cannot be cleared of obstructions must be discarded 8 16 OCTOBER 2000 UNACCEPTABLE UNACCEPTABLE HEAVY WEAR SPALLING AND PITTING HEAVY WEAR SPALLING AND PITTING FULL TOOTH WIDE PARTIAL TOOTH WIDTH ACCEPTABLE ACCEPTABLE LIGHT WEAR LINE MODERATE WEAR LINE FULL TOOTH WIDTH NO MORE THAN 50 TOOTH UP TO 0 01 WIDE LENGTH AND 0 05 WIDE FIGURE 8 3 GEAR TOOTH INSPECTION MAY
269. ly MAY 1998 11 3 INTENTIONALLY LEFT BLANK 12 1 12 2 12 3 12 4 12 5 12 6 FIGURE 12 1 12 2 CHAPTER 12 ELECTRICAL CHARGING SYSTEM PAGE Alternator 12 2 Alternator 0474 2 49 12 3 Electrical Charging System Component Cleaning 12 3 Electrical Charging System Component Inspection 12 3 Electrical Charging System Component Repair 12 4 Electrical Charging System Component Sub Assembly 12 5 PAGE Alternator Assembly cette eee dtes 12 2 Cotter Pin 2 2 444447 12 4 MAY 1998 12 1 12 1 ALTERNATOR REMOVAL 1 Remove four sets of attaching parts 8 9 10 Pull alternator 2 from crankcase Remove and discard gasket 1 2 Remove cotter pin 7 and nut 4 Pull hub assembly 5 from alternator shaft Remove woodruff key 3 Discard cotter pin 7 and woodruff key 3 3 Separate thrust washer 6 and gear driven hub assembly 5 NOTE Further disassembly of Alternator is not advised unless proper test equipment is available For overhaul information see Teledyne Continental Motors Alternator Service Instructions Form 30531 FIGURE 12 1 ALTERNATOR ASSEMBLY 1 Gasket 6 Washer Thrust 2 Alternator 7 Pin Cotter 3 Ke
270. mped to the fuel line support brackets Do not assemble in a binding configuration 6 Install fuel lines 19 through 24 between fuel manifold valve 12 and nozzles 28 Torque fuel line B nuts at nozzles to 40 45 inch pounds Torque fuel line B nuts at manifold valve to 55 60 inch pounds Attach clamps 27 to fuel lines 19 through 24 Insure that fuel line clamps are installed on fuel line insulators Snap clamps into brackets 25 26 Install fuel hose 37 between fuel pump and fuel metering unit Torque hose B nuts to the specified limit in Table 6 4 Torque Specifications for Hose Fittings OCTOBER 2000 18 31 18 18 MAGNETO TO ENGINE TIMING NOTE The engine is equipped with a right angle drive starter adapter If it does not freely turn in the opposite direction of normal rotation the starter motor must be removed from the starter adapter Some right angle starter drive adapters incorporate an over riding spring clutch design that restricts engine rotation in the opposite direction of normal rotation Use the following basic timing procedure to insure that timing is accomplished in accordance with the required specifications NOTE Whenever positioning the crankshaft for magneto installation always turn the crankshaft steadily in the direction of rotation to eliminate any backlash error In conducting magneto timing check use a top dead center locator protractor and pointer such as the Eastern Electronics Model E
271. mps 7 8 from riser elbows 2 3 Discard all hoses 9 Place the induction manifold and elbow risers in a clean protected area until they are ready to be overhauled FIGURE 10 1B INDUCTION SYSTEM FOR 10 550 1 Gasket 9 Hose 2 Elbow Riser 10 Manifold 3 Elbow Riser 11 Plug 4 Washer 12 Bracket 5 Washer Lock 13 Clamp 6 Screw 14 Balance Tube 7 Clamp 15 Hose 8 Clamp 16 Clamp OCTOBER 2000 10 3 10 1C INDUCTION SYSTEM REMOVAL AND DISASSEMBLY See Figure 10 1C 1 Loosen clamps 7 8 and remove elbows 10 11 Remove clamps and hoses 7 9 from elbows 10 11 2 Remove oil sump screws that attach balance tube bracket 12 to oil sump and crankcase Remove clamp 13 and bracket 12 from balance tube 14 Remove balance tube 14 from front hoses 9 3 Remove screws 6 lock washers 5 and washers 4 Discard lock washers 5 Remove risers 2 3 from cylinders Remove hoses 9 and clamps 7 8 from risers 2 3 Discard all hoses 9 4 Place the induction manifold and risers in a clean protected area until they are ready to be overhauled 12 FIGURE 10 1C INDUCTION SYSTEM FOR 10 550 1 Gasket 8 Clamp 2 Elbow Riser 9 Hose 3 Elbow Riser 10 Tube Elbow 4 Washer 11 Tube Elbow 5 Washer Lock 12 Bracket 6 Screw 13 Clamp 7 Clamp 14 Balance Tube 10 4 OCTOBER 2000 10 10 INDUCTION SYSTEM REMOVAL AND DISASSEMBLY See Figure 10 10 1 Remove atta
272. n accordance with airframe manufacturer s instructions 3 Remove nuts 5 lock washers 4 and magneto holding washers 3 from each magneto 4 Remove both magnetos 2 from the engine Discard cable ties 27 and lock washers 4 19 CAUTION Use care to avoid dropping magneto drive bushings and retainers into the engine 8 2 See Figure 8 2A 5 Magneto assemblies must be overhauled in accordance with the magneto manufacturer s instructions see TCM ignition systems Master Service Manual Form No X40000 See Section 1 5 Related Publications for ordering information Nomenclature for Figure 8 1A 1 Gasket 11 Lead 3B 21 Clamp 2 Magneto 12 Lead 3T 22 Clamp 3 Washer Holding 13 Lead 4B 23 Nut 4 Washer Lock 14 Lead 4T 24 Clamp 5 Nut 15 Lead 5B 25 Screw 6 Sparkplug 16 Lead 5T 26 Bracket 7 Lead 1B 17 Lead 6B 27 Tie Cable 8 Lead 1T 18 Lead 6T 28 Kit Ground Terminal 9 Lead 2B 19 Washer Lock 29 Kit Retard Terminal Left Magneto 10 Lead 2T 20 Screw OCTOBER 2000 FIGURE 8 1A IGNITION SYSTEM FOR 10 550 A2B A4B A5B A6B MAY 1998 8 3 8 1B IGNITION SYSTEM REMOVAL AND DISASSEMBLY See Figure 8 1B 1 Remove ignition harness assembly a Remove ignition lead from each spark plug 8 Remove all cable ties 27 b On each magneto remove four lock washers 6 and four nuts 7 from cable outlet plate Remove plates from magnetos 2 c Remov
273. n 25 indicates the mixture is too lean Any mixture conditions that are too rich or too lean will be adjusted as follows a Adjust idle mixture in accordance with Figure 19 2 Throttle and Fuel Metering Adjustments b Perform an IDLE fuel air mixture check and observe RPM rise If the RPM rise is not within specifications advance the throttle control to 1500 1800 RPM for 15 seconds after each adjustment to clear the engine Retard the throttle control to IDLE RPM and repeat mixture check Make the necessary adjustment Repeat this procedure until the specified RPM rise is achieved c Recheck IDLE RPM unmetered pump pressure If pressure in not within limits repeat Steps 18 19 20 a and 20 b before continuing 21 See Table 19 1 Test Operating Specifications Adjust the full power fuel flow to the specified value by turning the adjustable orifice screw clockwise to increase fuel flow and counterclockwise to decrease fuel flow See Figure 19 3 for fuel pump adjustments 22 When full power fuel flow has been adjusted to the specified values recheck the IDLE RPM unmetered fuel pressure and fuel air mixture If any values are not within specified limits repeat the adjustment procedures 23 With the fuel system set to the specified pressure and flow values set the IDLE RPM to the airframe manufacturers specified value by turning the Idle Speed Stop screw clockwise to increase RPM and counterclockwise to decrease RPM See Fig
274. n 48174 Ph 734 9465547 PARKER RESEARCH CORPORATION P O Box 1406 Dunedin Fla 34697 Ph 1 800 525 3935 Fax 813 797 3941 Instruments for Light Powered Aircraft Special Tools Precision Instruments Measuring Instruments Precision Tools Special Tools Spark Plugs Ignitors Oil Filters Special Tools Fuel Pressure Test Equipment Measuring Instruments Precision Tools Piston Position Indicators Precision Inspection Instruments Special Tools Precision Tools Special Tools Precision Tools Special Tools Precision Tools Special Tools Ignition Test Equipment Ultrasonic Test Equipment Special Tools Model 20 Porta Test Unit Model DA 200 Contour Probe OCTOBER 2000 2 3 2 3 SPECIAL TOOLS Specific tools listed or equivalent tools marketed by other manufacturers are necessary for overhaul and maintenance of the aircraft engine NO SECTION GENERAL ENGINE RECIPROCATING 646953 Master Orifice Tool for cylinder compression test available from Kent Moore 7251 Differential Pressure Cylinder Checker available from Kent Moore IGNITION SYSTEM Borrough s 3608A Protractor Timing Indicator Disc or equivalent for setting engine timing Model E25 Timing Indicator available from Eastern Electronics Inc 11 9110 1 Magneto Timing Light available from KELL STROM Tool Company Inc FUEL INJECTION Borrough s 8165 Injector Nozzle Remover and Installer or equivalent CHARGING SYSTEM Borrough s 7726 Tork Band Tension Ad
275. n a clean protected area until they are to be overhauled Nomenclature for Figure 14 1A 1 Oil Pump Assembly 12 Helical Coil 23 Washer Lock 34 Gasket 2 Housing Oil Pump 13 Washer Copper 24 Nut 35 Filter Oil 3 Stud 14 Nut Self Locking 25 Gear Bevel 36 Adapter Oil Filter 4 Gear Bushing 15 Gear 26 Gasket 37 Washer 5 Bushing 16 Pin 27 Cover 38 Washer Lock 6 Plunger 17 Gear Bevel 28 Washer 39 Nut 7 Spring 18 Housing Tach Drive 29 Washer Lock 40 Stud 8 Seat 19 Seal Oil 30 Screw 41 Plug 9 Screw 20 Gasket 31 Gasket 42 Gasket 10 Gasket 21 Stud 32 Cover 43 Thread Silk 11 Housing 22 Washer 33 Washer 44 Wire Lock 14 2 MAY 1998 FIGURE 14 1A OIL PUMP ASSEMBLY FOR 10 550 A A2B 10 550 B1F B2F B3F B4F B5F B6F B9B 11 B14B 15 B16B 19 21 B23B B29B B30B B32B B35B B37B 10 550 C2F C2U C3F C6F C8B C11B C12B C13B C15B C18B C19B C25B C26B C27B C28B C29B C30B MAY 1998 14 3 14 1B OIL PUMP REMOVAL See Figure 14 1B 1 Cut lockwire and remove filter 28 Remove attaching parts 30 31 32 Separate adapter 29 and gasket 27 from oil pump housing 2 Discard lock washers 31 and gasket 27 Remove attaching hardware 22 23 and tach drive assembly 18 Discard lock washers 22 Remove shaftgear 15 and bevel gear 17 Remove driven gear assembly 4 5 from oil pump housing Remove oil
276. n end The arbors must be eight inches long A surface plate two matched vee blocks and two blocks of ground flat steel stock of equal height are required To measure twist insert the arbors into the rod bores Then place the big end arbor crank pin end in the vee blocks on the surface plate Place the ground steel blocks under the ends of the bushing arbor piston pin end a measured distance apart Use a leaf type feeler gauge to detect any clearance under the arbor ends This divided by the separation of the blocks in inches will give the twist per inch of length To measure bushing and bearing convergence mount a dial indicator on a surface gauge and swing the rod around the crank pin end arbor to the vertical position against a firm stop Pass the indicator over the bushing arbor on both sides of the connecting rod at points an exact number of inches apart For exact parallelism the two measurements must be the same See Figure 17 5 Connecting Rod Dimensions WARNING FAILURE TO COMPLY WITH THESE SPECIFICATIONS AND INSTRUCTIONS MAY RESULT IN ENGINE MALFUNCTION AND STOPPAGE 0005 INCH MAXIMUM CONVERGENCE OF THESE AXIS PER INCH OF LENGH WITH NEW BUSHING EXAMPLE LONGITUDINAL AXIS CENTER TO CENTER DISTANCE OF L1 MINUS L2 MUST NOT EXCEED 0 004 OF AN INCH AFTER CONNECTING ROD BUSHING HAS BEEN FINISH MACHINED L1 M 1 LONGITUDINAL AXIS 8 Lom uf A 1 234 1 235 BREAK SHARP EDGES 015 INCH NO NICKS GO
277. n oil pump housing studs Torque nuts 39 to 275 325 inch pounds Secure with attaching hardware 37 38 39 5 Apply a thin coat of Dow Corning No 4 to the oil filter seal Fill new oil filter with clean Type corrosion preventative mineral oil conforming with MIL C6529 Install new spin on filter 35 and torque to 192 216 inch pounds Safety wire oil filter in accordance with section 5 2 Lockwire Procedure 6 Re install gasket 41 and plug 42 Torque plug 42 to 190 210 inch pounds Safety wire plug in accordance with section 5 2 Lockwire Procedure 18 16 OCTOBER 2000 18 7B OIL PUMP 550 A4B A5B A6B A7B 10 550 B5F B12F B17B B18B B20B 22 B24B B25B B26B 27 B28B B31B B34B B36B 10 550 16 C17B C21B C22B 10 550 G G1B G2B G4B 10550 N N1B 10550 P 10550 R See Figure 14 1B 1 2 Remove plug 34 gasket 33 from protruding end of oil suction tube Apply TCM gasket maker to silk thread and split line of crankcase at oil pump bore Place silk thread ends into split line of oil pump bore Place new oil pump gasket 20 and oil pump assembly 1 on crankcase studs Secure with attaching hardware 21 22 23 Torque nuts 23 to 90 110 inch pounds Install new gasket 27 and oil filter adapter 29 on oil pump housing studs Torque nuts 32 to 275 325 inch pounds Secure with attaching hardware 30 31 32 Apply a thin coat of Dow Corning No 4 to the
278. n the New Parts minimum and maximum clearance the part may be re used during overhaul provided it conforms with all other inspection requirements Oversize parts are supplied in some instances to permit conformity to this requirement See individual component or system sections as applicable for limits and fits ORIGINAL DIMENSIONS Although comparative measurements of mating parts will determine the serviceability of the fit it may be difficult to determine which part has worn In some instances e g main journals in new bearing inserts accurate dimensional measurements of fit are not always possible While no limits of wear on critical dimensions have been assigned to specific parts it is helpful in determining wear to know the original dimensions Therefore consult the 6 8 MAY 1998 6 16 6 17 6 19 6 20 manufacturing limits New Parts Dimensions in each individual system chapter when the serviceability of a specific part is in doubt PARTS LIMITS TCM provides parts dimensions and assembly clearances in its publications which are considered essential to perform an overhaul of its engines These values are termed New Parts Limits Values are taken from production drawings in effect at the time of publication TCM also provides a list of items that must be replaced at overhaul See section 6 6 100 Replacement Parts WARNING Service limits must not be used when performing major overhaul of the engine AUTHORIZED OVER
279. ne for and remove any metal that may have shaved from the bearing back onto the parting surface during installation Coat the rod bolt completely with clean 50 weight aviation engine oil Align the matching numbers on the connecting rod and cap and hand press the new bolts into the connecting rod Do not force bolts through the cap or rod bolt holes The connecting rod and cap must be completely seated and both bolt heads must be completely seated against the connecting rod cap seats Any connecting rod assembly requiring more than hand pressure to seat the connecting rod caps and bolts must be discarded Remove the connecting bolts and separate the connecting rod and cap Inspect each connecting rod assembly for correct fit 6 Insure that the new bearings are properly seated Using clean 50 wt aviation oil lubricate and install each rod cap and bearing assembly at the correct position on the crankshaft Install the connecting rod and cap with their numbers on top when odd number rods are extended to the right and even number rods are to the left viewing crankshaft from the rear gear end forward Lubricate the new connecting rod bolt and nut threads using clean 50 weight aviation engine oil Secure rods and caps using new special bolts and nuts 4 amp 5 On assemblies using the 643112 bolts and 643215 nuts torque the nuts to 550 600 inch pounds On assemblies using the 654490 bolts and 643215 nuts torque the nuts to 690 710 inch pounds WARNIN
280. ner 51 washer 37 and nut 38 Torque nuts 38 to 180 220 inch pounds torque See Figure 13 8B Oil Seal Installation 7 Install sleeve 44 spacer or sheave 45 as used and new nut 46 Torque nut 46 to 450 500 inch pounds Check shaft gear for freedom of rotation Install adapter in fixture and apply torque to starter shaft gear 8 Test adapter assembly for slippage by installing adapter in fixture and apply torque to input shaft Minimum allowable non slippage torque is 300 inch pounds 9 Store the starter and starter adapter in a clean protected area until final engine assembly FIGURE 13 8B OIL SEAL INSTALLATION 13 22 OCTOBER 2000 14 1 14 1 14 1 14 2 14 2 14 2 14 14 3B 14 3C 14 3D 14 4 14 5 14 6 14 7 FIGURE 14 1A 14 1B 14 1C 14 2A 14 2B 14 2C 14 3A 14 3B 14 36 14 3D 14 4 14 5 14 6 14 7 14 8 14 9 CHAPTER 14 LUBRICATION SYSTEM PAGE Oil Pump Remowval sss 14 2 Oil Pump 14 4 Oil Pump 14 6 Oil Cooler Removal 2 2 14 8 Oil Cooler Removal 14 9 Oil Cooler Removal 14 10 Oil Sump and Suction Tube Remowval 14 11 Oil Sump and Suction Tube 14 12 Oil Sump and Suction Tube Remowval
281. ng an approved method to remove all of the shavings and debris 8 Identify cylinder with steel stamp letter B as indicated in Figure 15 6E OCTOBER 2000 15 33 DRILL GUIDE P N 8181 1 CHAMFER 120 DIAMETER OF 34 31 TAP USING 1 4 20 HELICOIL TAP 430 DEEP DRILL GUIDE PILOT P N 8181 2 S T NS FIGURE 15 6E CYLINDER IDENTIFICATION CYLINDER PROTECTIVE COATING 1 Clean the exterior cylinder head surface and apply a protective coating of Accelagold aluminum conversion in accordance with section 6 19 WARNING Do not paint the cylinder flange nut seats skirt or flange to crankcase mating surface 2 Thoroughly clean the entire cylinder with mineral spirits and air dry Mask the cylinder flange nut seat contact surfaces cylinder skirt and flange to crankcase mating surfaces Apply a protective coating of specified TCM enamel paint or equivalent to the cylinder barrel in accordance with section 6 20 3 After the paint has dried completely remove all masking materials and coat all bare steel surfaces with clean 50 weight aviation engine oil Store the cylinder assembly in a clean protected area until cylinder subassembly 15 34 OCTOBER 2000 INTERNAL CHAMFER ONLY AS RECEIVED INSTALL AT OUTER END A THESE SURFACES MUST BE SQUARE WITHIN 002 INCH FULL INDICATOR READING TWO HOLES SECTION A A IN LINE PRESS BUSHINGS IN FLUSH TO THESE SURFACES BUSHING FINISH 32 RMS F
282. ng hardware 11 12 13 Lightly bump oil sump 10 using a soft mallet and remove from crankcase Remove gasket 9 from crankcase oil sump and discard Remove nut 5 washers 3 4 and bolt 2 Remove oil suction tube assembly from crankcase Remove gasket 6 from oil suction tube and discard TM 12 FIGURE 14 3C OIL SUMP FOR 10 550 10 550 1 Oil Suction Tube 8 Plug 2 Bolt 9 Gasket 3 Washer 10 Oil Sump 4 Washer 11 Washer 5 Nut 12 Washer Lock 6 Gasket Copper 13 Screw 7 Gasket Copper 14 Gasket Copper MAY 1998 14 13 14 30 OIL SUMP AND SUCTION TUBE REMOVAL See Figure 14 30 Remove attaching hardware 11 12 13 Lightly bump oil sump 10 using a soft mallet and remove from crankcase Remove nut 5 washers 2 4 and bolt 3 Remove oil suction tube assembly from crankcase Remove gasket 6 from oil suction tube and discard 1 2 3 Remove gasket 9 from crankcase oil sump and discard 4 5 amp 412 8 amp amp 3 FIGURE 14 3D OIL SUMP FOR 10 550 P 1 Oil Suction Tube 8 Plug 2 Washer 9 Gasket 3 Bolt 10 Oil Sump 4 Washer 11 Washer 5 Nut 12 Washer Lock 6 Gasket Copper 13 Screw 7 Gasket Copper 14 Gasket Copper 14 14 OCTOBER 2000 14 4 LUBRICATION SYSTEM COMPONENT CLEANING 1 lubrication system components and associated hardware must be cleaned accordance with the instructions in section 6 7 General Cleaning and th
283. not meeting this criteria Lubricate connecting rod bolt and nut threads with clean 50 weight aviation oil On assemblies using the 643112 bolts and 643215 nuts torque the nuts to 550 600 inch pounds On assemblies using the 654490 bolts and 643215 nuts torque the nuts to 690 710 inch pounds Inspect the inside diameter joint of the rod to cap with both bolts and nuts installed and torqued Mismatch or a step of more than 0 001 inch is not acceptable An acceptable method of checking mismatch is to use a dial indicator as follows Place the rod on a surface plate so that the splitline is at the 6 and 12 o clock position Use vee blocks to hold the rod in place Using a dial indicator mounted on a height gauge zero out on one side of the splitline Move the indicator across the splitline There must be no more than 0 001 indicator movement Remove piston pin bushing from connecting rod in accordance with section 17 4 Inspect piston pin bushing bore and surrounding area for nicks gouges and mechanical damage Scrap connecting rods with any of these indications Using precision measuring equipment such as dial bore gauge or air gauge verify that the connecting rod meets the dimensional specifications provided in Dimensional Inspection New Parts Dimensions and Figures 17 4A and 17 5 Measure the connecting rod big bore diameter 15 to 30 degrees either side of connecting rod split line and 90 from the first measurement Difference between t
284. nstall the 7th stud brackets and nuts but do not torque at this time NOTE The 7th stud nuts have a conical seat m See Figure 16 1A install baffle support 20 on through bolts at positions 43L amp 44L n 0 Install attaching hardware 18 19 do not torque at this time 1 3 5 side of crankcase install baffle support 34 on through bolts at positions 41R amp 42R Install attaching hardware 18 19 do not torque at this time Apply Champion thread lubricant to spark plugs in accordance with the manufacturer s instructions Install gaskets and spark plugs in bottom cylinder spark plug holes Do not Torque at this time Proceed to TORQUING OCTOBER 2000 18 9 10 550 G N P amp R CRANKCASE ASSEMBLY 1 See Figures 16 1B Crankcase Attaching Parts O 550 G amp and 18 8 Torquing Sequence Using an o ring installation tool conforming with the specifications in Figure 18 4 O Ring Installation Tool and new o rings 16 install eight 1 2 x 10 75 through bolts 15 with new o rings 16 into positions 37R L through 44R L Install three 5 16 x 4 00 inch tie bolts 14 washers 4 in positions 69 71 amp 72 Install one 7 16 inch through bolt 24 in position 46R L and one 7 16 inch through bolt 20 in position 45R L Install one 5 16 X 1 12 screw in position 54 and one 5 16 X 1 38 screw in position 53 Tap the through bolt in to a position that will allow installation of hardware
285. nstructions VISUAL INSPECTION All engine parts except those to be replaced 100 must be inspected visually with at least a 10 X power magnifying glass under good light for surface damage such as nicks dents deep scratches visible cracks distortion burned areas pitting transfer of metal corrosion erosion and removal of enamel coating Visual inspection should also determine the need for further cleaning of obscure areas Inspect all studs for bending looseness or partial removal Inspect all threaded parts for nicks and other damage to the screw threads After visual inspection place the engine parts in three groups apparently serviceable parts repairable parts and parts to be discarded NOTE See Chapters 7 through 17 for specific individual system components and part visual inspection instructions MAGNETIC PARTICLE INSPECTION CAUTION Before magnetic particle inspection of any part it must be completely cleaned and free of dirt carbon varnish gum and paint Plug small holes leading to obscure cavities with tight fitting wood plugs or with a hard grease which is soluble in lubricating oil This will prevent particles from lodging in places where they would be difficult to remove and places not subject to visual inspection After magnetic particle inspection remove all such plugs and clean the part thoroughly in solvent Dry the part with compressed air Check for complete demagnetization Magnetic particle inspection must b
286. nt chafed or deformed fuel injection lines 2 Fuel injection line removal a Disconnect fuel lines 26 35 36 37 from fuel nozzles 27 b Disconnect other end of fuel lines from fuel manifold valve assembly 23 and remove fuel lines from engine 3 Fuel Nozzle Removal a Remove fuel nozzles 27 from each cylinder 4 Remove fuel hoses 24 from fuel control unit and fuel pump Remove fuel hose 25 from fuel control unit and manifold valve Discard fuel hoses 24 25 5 Remove attaching hardware 20 21 22 and fuel control shroud 19 Remove cotter pins 17 and washers 15 16 Remove link rod assembly 10 through 14 and spring 18 Bend tabs of tab washers 7 down Remove bolts 9 standoff bolts 8 and tab washers 7 Separate fuel control 5 from throttle body 4 Discard tab washers 7 lock washers 21 self locking nut 14 springs 12 18 cotter pins 17 and wave washers 15 Loosen and remove nut bolt 49 50 brackets 47 48 bushings 45 sleeve 46 from bracket 42 The hardware that attaches bracket 42 to engine was removed during magneto and accessory drive adapter disassembly Remove bracket 42 Discard self locking nut 50 Remove nuts 22 and bracket 51 Remove throttle 4 from engine Discard gasket 53 Place the throttle and fuel control unit in a clean protected area until it is to be overhauled 6 Remove the crankcase backbone hardware that secures the fuel manifold valve
287. nut and washer not shown and attaching hardware 16 17 Separate bracket assembly from engine Remove tensioning hardware 10 11 12 14 from bracket Remove hardware 1 through 8 and separate idler sheave 2 and block assembly 5 from bracket Separate components 2 through 7 and 22 Discard ball bearing 3 retaining ring 4 drive belt 18 and 12 point self locking nut 20 11 2 MAY 1998 11 3 11 4 COMPRESSOR MOUNTING KIT CLEANING 1 See section 6 6 100 Replacement Parts and discard all compressor mounting kit components listed Clean all brackets and attaching hardware in accordance with the applicable instructions in section 6 7 General Cleaning COMPRESSOR MOUNTING KIT INSPECTION VISUAL INSPECTION The visual inspection must be performed in accordance with instructions in section 6 8 Visual Inspection and the following special instructions 1 Mounting Bracket Kit Visually inspect compressor mounting bracket for cracks and elongated holes Inspect idler sheave bracket for wear and cracks Check mounting bracket flange for wear Check mounting bracket on a surface plate for warpage Inspect sheave for warpage wear in belt grooves and bearing seats Inspect the idler sheave support bolt for wear on the support shank Inspect hardware for distorted or stripped threads NOTE Components exhibiting any of the above listed indications must be discarded FLUORESCENT PENETRANT INSPECTION Inspect all alumin
288. o exceed 010 inch thick to the surface specified in Chapter 3 Table Of Sealants and Lubricants Gasket Maker is an easily workable tacky gel which can be extruded onto one side of a flange surface from a tube and evenly spread Small parts can be covered adequately by pressing them into a saturated polyester urethane sponge or by roll coating them with a short nap roller Once Gasket Maker has been applied evenly torque assembly into place Excess material can be cleaned by wiping with chlorinated solvent Material on hands can be cleaned with waterless mechanics hand soap followed by soap and water NOTE TCM general purpose primer P N 653160 must be used for surface preparation before applying Gasket Maker at the engine nose seal area INSTALLATION OF GASKETS All gaskets must be new of the proper material and visually inspected prior to installation Following visual inspection if the gasket shows any indication of gouges nicks cuts or bend and fatigue marks replace with a new manufacturer specified gasket Gasket surfaces must be clean and free of nicks burrs oil and grit Apply a thin coat of TCM Gasket Sealant P N 642188 1 to both sides of gasket unless otherwise specified See Chapter 3 Table Of Sealants and Lubricants for application of gasket sealant Once TCM Gasket Sealant has been applied install gasket Install assembly and evenly torque hardware to specified value This will prevent over stressing gasket WARNING
289. oil filter seal Fill new oil filter with clean Type corrosion preventative mineral oil conforming with MIL C6529 Install new spin on filter 28 and torque to 192 216 inch pounds Safety wire oil filter in accordance with section 5 2 Lockwire Procedure Re install gasket 33 and plug 34 Torque plug 34 to 190 210 inch pounds Safety wire plug in accordance with section 5 2 Lockwire Procedure 18 7C OIL PUMP 10 550 65 G6B 10550 2 See Figure 14 1C 1 2 Remove plug 28 gasket 27 from protruding end of oil suction tube Apply TCM gasket maker to silk thread and split line of crankcase at oil pump bore Place silk thread ends into split line of oil pump bore Place new oil pump gasket 17 and oil pump assembly 1 on crankcase studs Secure with attaching hardware 18 19 20 Torque nuts 20 to 90 110 inch pounds Install new gasket 21 and oil filter adapter 23 on oil pump housing studs Torque nuts 26 to 275 325 inch pounds Secure with attaching hardware 24 25 26 Apply a thin coat of Dow Corning No 4 to the oil filter seal Fill new oil filter with clean Type corrosion preventative mineral oil conforming with MIL C6529 Install new spin on filter 22 and torque to 192 216 inch pounds Safety wire oil filter in accordance with section 5 2 Lockwire Procedure Re install gasket 27 and plug 28 Torque plug 28 to 190 210 inch pounds Safety wire plug in accordance with
290. on ring and push the cylinder until the number 4 ring is positioned inside the cylinder barrel Remove the ring compressor and push the cylinder assembly against the crankcase cylinder deck with the stud holes aligned Install the cylinder deck and through bolt nuts but do not torque at this time Back the number 2 piston pin far enough out to allow the piston to be installed on the number 2 connecting rod Place the number 2 cylinder and piston assembly on the number 2 connecting rod and slide the piston pin into the connecting rod and piston Using a ring compressor compress the number 4 piston ring and push the cylinder until the number 4 ring is positioned inside the cylinder barrel Remove the ring compressor and push the cylinder assembly against the crankcase cylinder deck with the stud holes aligned Install the cylinder deck and through bolt nuts but do not torque at this time Carefully rotate the crankshaft placing the number 3 and number 4 connecting rods in their outer most position Using the same procedure that was used to install the number 1 and number 2 cylinder and piston assemblies install the number 3 and number 4 cylinder and piston assemblies Carefully rotate the crankshaft placing the number 5 and number 6 connecting rods in their outer most position Using the same procedure that was used to install the number 1 and number 2 cylinder and piston assemblies install the number 5 and number 6 cylinder and piston assemblies I
291. or overheating or high temperature operation detonation piston scoring or piston pin damage to the cylinder bore Discard all such cylinders 15 8 OCTOBER 2000 CYLINDER HEAD 1 Inspect the external surfaces of the cylinder head including the exhaust port cylinder head fins in between the fins exhaust ports top and bottom spark plug bosses and fuel nozzle boss for cracks or indications of cracks Discard any cylinder with cracks or indications of cracks 2 Minor cooling fin cracks that do not extend into the cylinder head structure may be repaired in accordance with section 15 6 3 Heat checks in the exhaust port that are 1 8 inch in length or less may continue in service WARNING Welding of the cylinder head structure can destroy the assembly preloads and casting strength resulting in cylinder assembly failure 4 Inspect the intake flange studs for damaged distorted or stripped threads Inspect studs for corrosion rusting pitting incomplete threads and security Replace studs with any of these indications 5 Inspect the cylinder exhaust flange studs and rocker shaft hold down stud holes for distorted and stripped threads Repair damaged distorted and stripped threads accordance with section 6 21 6 Check all studs with a tool maker s square for perpendicularity Check all studs for security and correct setting height See Figure 15 3 for stud setting heights 7 Damage to threaded bores Inspect rocker cover f
292. or to dimensional inspection NOTE Prior to dimensional inspection of the case crankshaft and camshaft bores the crankcase must be assembled and torqued in accordance with the following All crankcase attaching hardware must be torqued to the sequence specified below Use 1 4 inch cadmium plated washers at cylinder 1 2 inch through bolt locations Torque 1 2 inch nuts to a preliminary torque of 350 inch pounds Torque 7 16 inch nuts to a preliminary torque of 225 inch pounds Torque 3 8 inch nuts to a preliminary torque of 190 inch pounds Torque 5 16 inch nuts to a preliminary torque of 100 inch pounds Torque 1 2 inch nuts to a final torque of 750 inch pounds Torque 7 16 inch nuts to a final torque of 450 inch pounds Torque 3 8 inch nuts to a final torque of 300 inch pounds 10 Torque 5 16 inch nuts to a final torque of 160 inch pounds NOTE See New Parts Dimensions of this section for crankcase bore diameters RIGHT CRANKCASE LEFT CRANKCASE FIGURE 16 9 DIMENSIONAL INSPECTION TORQUING SEQUENCE OCTOBER 2000 16 23 CRANKCASE FITS AND LIMITS see Figure 16 10 Min No CRANKCASE Through bolt in crankcase Idler gear support in crankcase front Idler gear support in crankcase rear Oil pump housing pilot in crankcase Idler gear 0 030 0 0770 Clearance Idler gear in support bushing front Idler gear in support bushing rear Magneto pilot in crankcase St
293. or to fluorescent penetrant inspection All oil and preservative material must be removed The cylinder heads must be fluorescent penetrant inspected by a certified technician in accordance with section 6 12 Fluorescent Penetrant Inspection Cracks in the cylinder head structure are not acceptable or repairable Cylinder heads that exhibit cracks or indications of cracks in the cylinder head structure must be discarded See section 15 6 for repair of cracked cylinder head fins MAGNETIC PARTICLE INSPECTION The cylinder assembly must be thoroughly cleaned prior to magnetic particle inspection All oil and preservative material must be removed The cylinder barrel must be magnetic particle inspected by a certified technician in accordance with section 6 9 Magnetic Particle Inspection Inspect the inner and outer surfaces of the cylinder barrel using circular and longitudinal magnetization Cylinder barrels with cracks or crack indications are not acceptable or repairable Discard all such cylinder assemblies The intake valves and rocker arms must be magnetic particle inspected by a certified technician in accordance with section 6 9 Magnetic Particle Inspection Inspect the intake valves and rocker arms using circular and longitudinal magnetization Intake valves and rocker arms with cracks or crack indications are not acceptable or repairable Discard all such valves and rocker arms ULTRASONIC INSPECTION Cylinders must be ultrasonic ins
294. ottle and fuel control assembly must be installed in accordance with the airframe manufacturer s instructions 18 16B INDUCTION SYSTEM 550 1 See Figure 10 1B Install new gaskets 1 on cylinder intake flanges Assemble left right cylinder bank intake manifolds using risers 2 3 new hoses 9 and clamps 7 8 Install left and right cylinder bank manifolds on cylinders Secure with attaching hardware 4 5 6 Torque bolts 6 to 90 110 inch pounds Push new hoses 9 and clamps 8 on front of risers 3 Install balance tube assembly 14 into hoses Torque clamps 8 to 40 50 inch pounds Secure balance tube to oil sump flange bracket using clamp 13 Insure plug 11 has been installed in manifold 10 Push new hoses 9 and clamps 7 on rear of risers 2 See Figure 9 1B Install throttle 4A on oil sump and secure with attaching hardware 12 13 Torque bolts 13 to 155 175 inch pounds Safety wire bolts 13 in accordance with section 5 2 Lockwire Procedure See Figure 10 1B Install intake manifold 10 into hoses 9 and 15 Torque clamps 7 amp 16 to 40 50 inch pounds OCTOBER 2000 18 27 18 16C INDUCTION SYSTEM 550 1 See Figure 10 1 Install new gaskets 1 on cylinder intake flanges Assemble left and right cylinder bank intake manifolds using risers 2 3 new hoses 9 and clamps 7 8 Install left and right cylinder bank manifolds on cylinders Secure with attaching hardw
295. ow 300 F Fuel and oil leaks are not acceptable Engines failing to pass acceptance test for high oil consumption major oil leaks low power damaged components excessive noise excessive roughness low oil pressure excessive oil filter contamination require further investigation correction of all discrepancies and complete re test Oil consumption of 1 Ib is considered acceptable for this test One repeat of this test run is acceptable Oil consumption in excess of 1 0 pound return engine to overhaul shop for a complete recheck of construction OCTOBER 2000 19 35 19 19 19 20 19 36 ENGINE PRESERVATION FOR STORAGE OR INSTALLATION OVERHAUL The engine must be preserved for storage or installed in the airframe in accordance with the 10 550 Permold Series Maintenance Manual Form X30634A and the airframe manufacturer s information If the engine is installed for return to service proceed to Test Flight TEST FLIGHT Refer to the aircraft manufacturer s or Supplemental Type Certificate STC holders POH AFM for specific operational information NOTE 10 550 A B amp engines that have an altitude compensating fuel pump require the auto lean operation inspection below during test flight Ambient air and engine operating temperatures are of major concern during this test flight Do a normal pre flight run up in accordance with the Airplane Flight Manual Conduct a normal take off with full power an
296. p pointed tool to pry the teeth at the outer helical coil end away from the cylinder head metal Tap a helical coil extracting tool into the insert until it has a good bite See Figure 15 6A Removing Spark Plug Hole Helical Coil Insert Using the proper size mandrel on installing tool place a new helical coil in the cutout side of the installing tool and engage the driving tang toward the threaded end Engage the tang with the slotted end of the driving mandrel and wind the insert into the sleeve thread compressing the insert Hold the sleeve so the helical coil can be seen through the slot in the threaded end Turn the mandrel crank until the insert starts into the cylinder head hole If the sleeve is not in contact with the head surface grip sleeve and mandrel and turn until the sleeve touches lightly See Figure 15 6B Installing Spark Plug Hole Helical Coil Insert Wind the helical coil into the cylinder head until its toothed end lies within the first full thread The teeth should be in position to enter the depressions made by the original insert If driven too far the insert will emerge in the combustion chamber and will have to be wound through and removed When the helical coil is in the correct position use long nose pliers to bend the driving tang back and forth across the hole until it breaks off at the notch Coat a Heli Coil Corporation Number 520 2 expanding tool threaded end with Alcoa thread lube or a mixture of white lead and oil
297. passages must be cleared by soaking in an approved solvent and blowing compressed air through them Any rocker arm or pushrod with obstructed oil passages that cannot be cleared must be discarded 15 36 MAY 1998 INSTALL BUSHING ORIENTED AS SHOWN 1 1 EXHAUST INNER ROCKER ARM 2 INNER INTAKE gt DIAMETER P N 652130 4 80 DETER inii ids pu ss P N 652131 8725 HOLES IN BUSHING MUST BE LOCATED IN MUST LOCATED IN THESE POSITIONS THESE POSITIONS HOLES IN BUSHING Bushing D must maintain 0020 0065 Press in a 8755 8725 Rocker Arm Bushing Bore 03 X 45 CHAMFER BOTH ENDS EM 002 inch 77505 IN DIA INSTALL BUSHING FLUSH TO 020 BELOW SURFACE Bushing must have a surface finish of 32 RMS after reaming 1 These surfaces must be square within the center line of the bushing bore within 002 inch full indicator reading FIGURE 15 7B NEW STYLE ROCKER ARM BUSHING REPLACEMENT 10 550 amp MAY 1998 15 37 INTAKE amp EXHAUST P N 652966 HOLES IN BUSHING MUST BE LOCATED IN THESE POSITIONS Bushing D must maintain 0020 0065 Press Fit in a 8755 8725 Rocker Arm Bushing Bore ML 002 Inch 03 X 45 CHAMFER BOTH INSTALL BUSHING FLUSH TO 020 BELOW SURFACE Bushing must have a surface finish of 32 rms after reaming L These surfaces must be square within the center line of the bushing bore within 002 inch full indicato
298. pecifications for Fittings Drain valve assemblies must be installed in accordance with the airframe manufacturer s instructions 18 26 OCTOBER 2000 18 15 EXHAUST SYSTEM 1 Exhaust system may now be installed in accordance with the airframe manufacturer s instructions 18 16A INDUCTION SYSTEM 550 1 See Figure 10 1 Install new gaskets 1 all cylinder intake flanges Assemble left and right cylinder bank intake manifolds using risers 2 3 new hoses 9 and clamps 7 8 Install left and right cylinder bank manifolds on cylinders Secure with attaching hardware 4 5 6 Torque bolts 6 to 90 110 inch pounds Insure plug 18 has been installed in balance tube 17 Push new hoses 9 and clamps 8 on front of risers 3 Install balance tube assembly 17 into hoses 9 Torque clamps 7 8 to 40 50 inch pounds Secure balance tube to oil sump flange bracket using clamp 16 Insure plugs 12 have been installed in elbows 10 11 Push new hoses 9 and clamps 8 on rear of risers 2 Install elbows 10 11 Install new hoses 9 and clamps 8 on ends of elbows and install manifold 13 Torque clamps 8 to 40 50 inch pounds Slide new flexible duct 24 on manifold 13 Install bracket 19 on oil sump using attaching hardware 21 20 Torque bolts 20 to 155 175 inch pounds Secure bracket 19 to manifold using attaching hardware 22 23 Torque nut 23 to 90 110 inch pounds The air thr
299. pect finished bore size to the required specification Refer to Figure s 15 4A1 15 4B1 as applicable for correct stem hole finished sizes The valve guide finish must be 32 RMS inspect finish with a profilometer MAY 1998 15 27 VALVE SEAT REFACING Valve seat refacing must be performed in accordance with the specifications shown in Figures 15 5A and 15 5B Intake and Exhaust Valve Seat Refacing using the following special tools 1 Sioux Brand Valve Seat Grinder Set No 1675 or equivalent 2 Valve Seat Grinder Pilot check valve guide inside dia for proper size 3 Grinding Stones K106 roughening and K46 finishing for intake valve seats 95 roughening and K25 finishing for exhaust valve seats 4 Borrough s 5221B Cylinder Holding Fixture and 5221 13A Adapter or equivalent CAUTION Valve seats and valves may be lapped after refacing if desired Lapping compounds are extremely abrasive and must be completely removed from the valves valve seats and cylinder by cleaning thoroughly using hot soapy water and a stiff bristled scrub brush All lapping compound must be removed from cylinder After washing all soap residue must be removed by thoroughly rinsing with hot water The cylinder must be dried completely and all bare steel surfaces thoroughly coated with clean 50 weight aviation engine oil 15 28 MAY 1998 2 48 DIA 2 26 DIA MAX VENTURI INSERT INTAKE SEAT GRINDING NOTE USE STONES THAT WILL
300. pected in accordance with section 6 11 15 12 OCTOBER 2000 DIMENSIONAL INSPECTION The following new parts limits must be used for dimensional inspection Components that do not meet the following specifications must be discarded All components must be thoroughly cleaned and air dried prior to dimensional inspection CYLINDER AND ASSOCIATED PARTS FITS AND LIMITS 10 550 amp C Description NEW PARTS MIN MAX CYLINDERS See Figure 15 4A1 Cylinder bore choke at 5 75 inch from open end of barrel Taper See Figure 15 4A1 Cylinder bore 0 0000 0 001 Allowable Oversize See Figure 15 4A1 Cylinder bore surface Nitrided Barrels Cross hatch 22 32 0 0040L 0 009T 0 0010T 0 0100L 0 012T 0 0025T 0 0010T 0 0025T 0 0070T 0 0100T See Figure 15 5A See Figure 15 5B 45 00 59 45 60 15 Rocker arm bushing bore Diameter Rocker arm bushing inside Finish Bore Diameter 0 7505 0 7515 Intake valve guide Inside Diameter 4350 4377 Intake valve in guide Diameter 0 0010L 0 0042L Inside Diameter 4375 4395 Diameter 0 0035L 0 0062L 59245 60215 45 00 45930 See Figure 15 9 Replace 100 0 0000 0 0015 0 060 0 200 Piston moly coated bottom of skirt in cylinder Diameter 0 006L 0 010L Piston non moly coated bottom of skirt in cylinder Diameter 0 008L 0 011L 0 0015 0 0040 0 0015 0 004 0 0035 0 0055 OCTOBER 2000 15 13 De
301. ped they must be installed into the positions for which they were lapped Spread a film of Molyshield grease on the intake valve stem 12 and the exhaust valve stem 13 Install valves into the correct location Grasp the valve stems and install the cylinder on a cylindrical block of wood anchored to a work bench Again apply Molyshield grease to valve stems Place valve spring retainers 17 over valve guides 4 and 5 cupped side up Coat the sealing surface of a new intake valve guide seal with clean 50 weight aviation engine oil Install new seal 50 on the intake valve guide by hand See Figure 15 14 for valve guide seal installation tool and correct installation Using the specified installation tool and a plastic mallet tap the seal on to the guide until it is firmly seated Install new inner and outer valve springs 14 15 new rotocoil 19 on the exhaust valve springs and retainer 51 on the intake valve springs The valve springs must be installed with the closed coils toward the cylinder head as shown in Figure 15 12 Valve And Spring Installation CAUTION Do not allow the valve spring compressing tool to cock the rotocoils Contact between the rotocoils and valve stems will cause damage to the valve stems 15 46 OCTOBER 2000 b Using a valve spring compressor compress the valve springs and insert the valve stem retainer keys 18 The springs should be depressed only enough to admit the keys to seat into the valve stem grooves
302. pine below camshaft 25 28 90 110 7 5 9 2 Idler gear support pin 25 28 90 110 7 5 9 2 OCTOBER 2000 6 17 Torque In Lbs Ft Lbs 7 5 9 2 90 110 90 110 7 5 9 2 Location and hardware Model Thread size Nut 25 28 Nut 25 28 Nut 375 24 Al 625 18 Al 2528 75 Alternator drive gear amp hub to Nut All 625 32 alternator Il Alternator to crankcase Nut Al 31 24 II Qty 2 2 3 275 325 22 9 27 1 1 15 8 17 5 1 7 5 9 2 16 18 1 300 450 25 0 37 5 4 15 0 18 3 22 9 27 1 180 220 15 0 18 3 36 7 38 3 gt gt Oil cooler to crankcase Nut upper All 375 24 Nut lower Oil temperature control valve Oil cooler bottom Accessory drive adapter to crankcase Nut All 31 24 Nut 375 24 31 24 ZI 55 gt N m O z 5 4NS3A 550 125 27 375 18 60 80 5 0 6 7 185 215 15 4 18 0 180 220 15 0 18 3 275 325 22 9 27 1 2 90 100 7 5 8 3 4 190 210 15 8 17 5 48 55 65 4 6 5 4 55 65 4 6 5 4 32 12 9 14 6 1 15 8 17 5 4 8 3 9 2 7 5 9 2 12 9 14 6 6 3 7 1 2 12 9 14 6 _ A B C G N P R A B C G N P R Bolt 31 18 Oil sump drain Plug 625 18 Exhaust pipe flange to cylinder Nut 25 28 Nut 25 28 Bolt 31 18 Bolt O 550 A 25 20 Bolt 31 18 Bolt O 550 B 25 20 Nut O 550 B 25 28 Nut 25 28 Lower throttle support bracket to tach 10 550 25 28 75 85 6 3 7 1 90 110 7 5 9 2 1 90 1
303. pressure relief valve 6 through 14 from oil pump housing 2 Discard spring 7 gasket 10 and self locking nut 14 Remove plug 34 and gasket 33 Discard gasket 33 Remove remaining attaching parts 21 22 23 and remove oil pump housing 2 from crankcase studs Remove and discard gasket 20 Place the oil pump components in a clean protected area until they are to be overhauled Nomenclature for Figure 14 1B 14 4 MAY 1998 1 Oil Pump Assembly 11 Housing 21 Washer 31 Washer Lock 2 Housing Oil Pump 12 Helical Coil 22 Washer Lock 32 Nut 3 Stud 13 Washer Copper 23 Nut 33 Gasket 4 Gear Bushing 14 Nut Self Locking 24 Shaft 34 Plug 5 Bushing 15 Gear 25 Gasket 35 Stud 6 Plunger 16 Pin 26 Housing 36 Thread Silk 7 Spring 17 Gear Bevel 27 Gasket 37 Wire Lock 8 Seat 18 Housing Tach Drive 28 Filter Oil 9 Screw 19 Seal Oil 29 Adapter Oil Filter 10 Gasket 20 Gasket 30 Washer FIGURE 14 1B OIL PUMP ASSEMBLY FOR 10 550 4 A7B 10 550 B5F B12F B13F B17B B18B B20B B22B B24B B25B B26B B27B B28B B31B B34B B36B 10 550 16 C17B 21 C22B 10 550 G G1B G2B G4B 10550 N N1B 10 550 P 10 550 R OCTOBER 2000 14 5 14 1 OIL PUMP REMOVAL See Figure 14 1 1 Cut lockwire and remove oil filter 22 Remove attaching parts 24 25 26 Separate adapter 23 and gasket 21 from oil pump housing 2 Discard lock washers 25 and g
304. procedure as the size on size type stud removal select the appropriate removal drill sizes with regard to the stud end dimension Example To remove a step type stud with a 250 inch diameter nut end and a 312 inch diameter stud end use the appropriate removal drills for a 312 inch diameter size on size stud STUD REINSTALLATION 1 With the appropriate wrench install the new stud to the depth specified in Figure 6 5 Stud Installation Dimensions NOTE Location of the flange is important in preventing the lock ring drive tool from making contact with surface A in Figure 6 5 Stud Installation Dimensions Any impact or pressure on this surface may cause damage to the threads in the cylinder head resulting in a loose fit 210 020 SPECIFY THIS DIMENSION LOCK RING SEE NU poi iun i A FIGURE 6 5 STUD INSTALLATION DIMENSIONS MAY 1998 6 13 6 24 6 25 Using the appropriate drive tool install the new lock ring to the specified depth shown Figure 6 5 Stud Installation Dimensions NOTE All special tools for installation and removal of Rosan lock ring studs including tool kits and prices can be obtained from amp Rosan Inc 3130 West Harvard Santa Ana California 92704 Telephone 714 641 8800 for distributor information NEW PARTS Parts which require protection from atmospheric dust and moisture are wrapped or boxed individually These parts must not be unpacked until they are to be inst
305. produced by a wet honing process The included angle of the cross hatch measured perpendicular to the axis of the cylinder shall be 22 to 32 degrees Hone turn around areas up to 0 5 inch from the skirt and barrel stop are exempt from cross hatch angle requirements SURFACE FINISH SPECIFICATION The surface finish of the cylinder barrel bore must meet the values listed in the table below The hone pattern as taken by fax film and viewed at 100X shall be cleanly cut and substantially free of torn and folded metal The cylinder bore must be cleaned thoroughly using hot soapy water and a stiff bristled scrub brush All honing material must be removed from cylinder After washing all soap residue must be removed by thoroughly rinsing with hot water The cylinder must be dried completely and all bare steel surfaces thoroughly coated with clean 50 weight aviation engine oil ITEM SYMBOL NAME RANGE 1 R Arihmetic average surface roughness 30 50 micro inches Skew a measure of plateau 1 to 3 5 3 R3Z Three point height distance between third 130 275 highest peak and third lowest valley micro inches RPM Rz Ratio of mean peak to total depth of pattern 15 30 MAY 1998 SPARK PLUG HELICAL COIL INSERT REPLACEMENT Spark plug helical coil inserts that require replacement as determined by the inspection procedures in section 15 5 must be replaced using the following instructions Before attempting to back out a damaged insert use a shar
306. pter flanges for warpage Adapters exhibiting warpage must be discarded 4 Visually inspect the oil sump bolt holes for cracks Inspect mounting surface for scratches warpage and cracks Warped cracked or leaking oil sumps must be discarded Inspect the oil drain plug boss and drain plug for damaged threads Inspect the drain plug for damaged wrench flats Discard oil drain plugs if damaged 5 Visually inspect the oil suction tube assembly for dents cracks and distorted or restricted openings Oil suction tubes exhibiting dents cracks or distorted openings must be discarded 6 Using an 8048 Oil Pressure Relief Spot Facer reface the pressure relief valve seat in the oil pump housing See section 2 3 Tools Do not exceed the specified limit Item 2 in Figure 14 6 14 16 OCTOBER 2000 CAUTION Reface pressure relief valve seat using light finger pressure when turning refacing tool CAUTION Thoroughly clean oil pressure relief valve cavity after refacing procedure 7 Inspect oil pump housing oil filter adapter and tach drive housing studs for distorted or stripped threads Inspect studs for corrosion pitting incomplete threads and looseness Replace studs with any of these indications Check studs with a tool makers square for alignment Oil pump housing oil filter adapters and tach drive housings must have their setting heights checked for indications of backing out See the following for stud setting heights ITEM LOCATION
307. r adjacent to the bolt boss match Scrap connecting rods and caps that do not meet this criteria Visually inspect connecting rod for corrosion pitting rust discoloration bluing galling impact damage nicks bending and twisting Scrap connecting rods with any of these indications OCTOBER 2000 17 7 Remove nuts and bolts from connecting rod and separate rod and cap Visually inspect connecting rod and cap parting surface Contact signatures resulting from assembly forces are normal and acceptable However connecting rods exhibiting fretting signatures that have resulted in the loss of metal as indicated by removal of the original machining marks either locally or over the entire surface are not acceptable for continued service NOTE Scrap connecting rods with fretting at the parting surfaces DO NOT REWORK Visually inspect nut seat area Excessive fretting signatures indicating loss of material or signatures of edge loading of the bolt under head surface contact area is cause for rejection and scrap Visually inspect dowel surfaces at rod and cap bolt holes Indications of distortion or scoring are cause for rejection and scrap Insuring that the mate marks are adjacent to each other and the position numbers match assemble the connecting rod and cap by installing one bolt through cap and rod With the cap seated firmly against the rod you must be able to install the remaining bolt using hand pressure only Scrap connecting rods
308. r gear and pin Fuel injection controls o rings springs shafts and bushings Magneto rubber drive bushings Oil pump and scavenge pump gear shafts ends and teeth Oil pump and scavenge pump housing and cover gear contact areas Starter worm gear drive teeth and bevel gear teeth Dow Corning G N Paste Dow For Distributor information call Camshaft lobes and tappet faces Corning G N Paste is a 1 800 248 2481 have state amp registered trademark of Dow city information available Corning Corporation Alvania Shell 2 Shell Product Information Apply light coat at point of contact For Distributor information Center between nut seat and ferrule on Phone 1 800 231 6950 ignition lead MIL S 3545C Grease Shell 5 Shell Product Information Fuel injection linkage pivot points Center Mixture shaft bushings Phone 1 800 231 6950 Permatex Maintain Lubricant For Distributor information call Fuel injection linkage pivot points Permatex Customer Service throttle shaft bushings lever Phone 1 800 641 7376 bushings 3 2 OCTOBER 2000 646943 Anti Seize Lubricant May be purchased through your All fuel injector nozzles at cylinder or local TCM Distributor or For head Distributor information Loctite Customer Service Phone 1 800 243 4874 Loctite Anti Seize Lubricant 76732 Exhaust studs nut end before torquing Oil temp control valve Vernatherm Courtesy of Bomar Flying Service www bomar biz
309. r reading FIGURE 15 7C NEW STYLE ROCKER ARM BUSHING REPLACEMENT 550 15 38 OCTOBER 2000 ROCKER TO ROTOCOIL CLEARANCE MACHINING 1 See Figure 15 8 A minimum clearance of 020 inch must be maintained between the rocker arm and rotocoil at the time of assembly If the minimum clearance of 020 is not present at the time of assembly it is permissible to smoothly grind across the forging flash line on the underside of the rocker arm to obtain the specified clearance Prior to grinding the rocker arm bushing bore and oil passage must be protected to prevent debris entry The grind must not exceed the width illustrated in Figure 15 8 If the required clearance cannot be obtained without exceeding this grind width the rocker arm must be replaced 2 The grind must be smooth and uniform All of the ground surface must be polished to remove all grinding marks Remove the protective coverings from the rocker arm and clean thoroughly The rocker arm must be magnetic particle inspected for cracks following the polishing operation WARNING The presence of grinding marks or cracks in the rocker arm may cause the rocker arm to fail 3 Thoroughly clean the rocker arm s before assembly on the engine MAX ALLOWABLE GRIND WIDTH TO EXCEED 34 020 MINIMUM FIGURE 15 8 ROCKER ARM TO ROTOCOIL CLEARANCE 1998 15 39 15 40 MAY 1998 60 15 FIGURE 15 9 INTAKE VALVE REFACING INTAKE VALV
310. r shafts Rockers shaft thrust washers Crankcase Through Bolts Cylinder deck stud nuts and through bolt nuts Ignition system wiring harness Spark plugs Alternator and air conditioning drive belts MAY 1998 6 5 GENERAL CLEANING NOTE Parts listed in Section 6 6 100 Replacement Parts must be replaced and therefore do not require cleaning WARNING During any cleaning process always follow the cleaning material manufacturer s instructions for use and Material Safety Data Sheets for safety precautions and disposal information Engine components must be thoroughly cleaned so they can be properly inspected All surfaces must be protected from corrosion after cleaning by rinsing with a petroleum base solvent and applying a coat of clean 50 weight aviation engine oil CAUTION Cleaning methods other than the following may be destructive to engine parts and must not be used Aluminum Alloy Parts Degrease aluminum alloy components by spraying or brushing with any fortified mineral spirit solvent Heavy grease or dirt deposits can be cleaned effectively by allowing parts to soak in this solvent for a short period of time Carbon deposits and gum oil varnish may be removed easily by immersing the part in a hot bath of an inhibited mild alkaline cleaning solution Immersion time should be only as long as necessary to remove the deposit Give special attention to cleaning studs tapped holes and drilled holes Caution mus
311. ral Sealant Application Install fittings A through E into fuel control unit 9 22 OCTOBER 2000 See Figure 9 5 Sparingly apply TCM 646940 F I sealant fittings that have male tapered pipe threads in accordance with Figure 9 9 General Sealant Application Install fittings 2 through 4 into fuel metering unit See chapter 10 for air throttle and fuel control or air throttle and fuel metering unit assembly Store all fuel injection components in a clean protected area until final engine assembly Flared End Apply sealant sparingly here Tapered End Do not apply sealant to the first two threads CAUTION Sealant 646940 must be applied to tapered end of fittings only FIGURE 9 9 GENERAL FUEL INJECTION SEALANT APPLICATION OCTOBER 2000 9 23 INTENTIONALLY LEFT BLANK 9 24 OCTOBER 2000 SECTION 10 1A 10 1B 10 1C 10 1D 10 2 10 3 10 4 10 5 10 6 FIGURE 10 1A 10 1B 10 1C 10 1D 10 2A 10 2B 10 2C 10 3 10 4 10 5 10 6 10 7 CHAPTER 10 INDUCTION SYSTEM PAGE Induction System Removal and Disassembly 10 550 10 2 Induction System Removal and Disassembly 10 550 10 3 Induction System Removal and Disassembly 10 550 10 4 Induction System Removal and Disassembly I0 550 G NECS eei 10 5 Induction System Component Disassembly 10 6 Induction System Cleaning
312. rdance with the aircraft manufacturer s instructions perform a complete pre flight inspection engine start and ground run up Set the aircraft altimeter to 29 92 inches Hg In accordance with the aircraft manufacturer s instructions make a normal take off Climb must be accomplished at full throttle FULL RICH mixture and 2700 RPM at the best rate of climb airspeed or higher for the aircraft Using the aircraft fuel flow gauge and altimeter record the fuel flows at all pressure altitudes specified Compare the recorded fuel flows with the specified fuel flows for all pressure altitudes If fuel flows are within the minimum and maximum limits at all altitudes no adjustments are required If the fuel flows are not within the specified limits at all pressure altitudes the fuel injection system auto leaning schedule will require adjustment TABLE 19 2 ALTITUDE FUEL SCHEDULE 10 550 A ENGINE FULL OPEN THROTTLE FULL RICH MIXTURE 300 BHP 2700 RPM Pressure Altitude Fuel Flow Fuel Flow Metered Fuel Set Altimeter at Ibs hr gals hr Pressure PSID 29 92 in Hg Min Max Min Max Min Max Sea Level 16 5 17 2 1000 16 3 17 1 2 000 15 9 16 6 3000 15 1 15 7 4 000 14 3 14 9 5000 13 6 14 1 6 000 13 2 13 7 8 000 12 3 12 7 10 000 11 6 12 1 12 000 11 0 11 4 14 000 98 106 10 4 10 7 Gasoline 5 87 lbs per gallon 70 OCTOBER 2000 19 37 TABLE 19 3 ALTITUDE FUEL SCHEDULE 10 550 B ENGINE FULL OPEN THROTTLE FULL R
313. re often unaware that they are not eligible for use on certificated aircraft The hazards involved in installing these types of parts on your aircraft are obvious Know Your Supplier Many original parts and components are copied and the copies are sold at discounted prices for installation on U S certified aircraft An original manufacturer s part is often used as a guide to make duplicates that appear to be as good as the original but there are many unknowns about the quality of design materials and workmanship Other factors that go into quality parts are the degree of heat treating and plating and inspections tests and calibrations Unfortunately a cheaply produced part that looked as good as the original is usually found out too late Federal Aviation Regulations FAR 43 13 and FAR 145 57 specify performance rules for replacement of parts and materials used in the maintenance and alteration of United States certificated aircraft FAR 91 403 FAR 121 363 FAR 123 45 and FAR 135 143 a holds the owner operator responsible for the continued airworthiness of the aircraft and that includes the quality of replacement parts Identifying Approved Parts Approved serviceable replacement parts are identified by 1 Federal Aviation Administration FAA Form 8130 3 Airworthiness Approval Tag An Airworthiness Approval Tag identifies a part or group of parts that have been approved by an authorized FAA representative 2 FAA Technical Standard
314. required for exhaust valve seats An interference fit of 0 006 to 0 012T is required for intake valve seats OCTOBER 2000 15 25 VALVE SEAT INSTALLATION Heat the cylinder assembly to 450 F maximum Heat soak one hour Using the specified tools install the new valve seat s The valve seat s must be installed firmly against the bottom of the valve seat bore Valve seat s that are not seated properly or that are misaligned will cause valve leakage and burning FLUORESCENT PENETRANT INSPECTION AFTER VALVE SEAT INSTALLATION After valve seat installation the cylinder head must be fluorescent penetrant inspected in accordance with section 6 12 Fluorescent Penetrant Inspection Structural cracks in the cylinder head are not acceptable or repairable Cylinder heads that exhibit cracks must be discarded NOTE If valve guides are being replaced this inspection may be delayed until the valve guides have been installed VALVE GUIDE REPLACEMENT Valve guides worn beyond specification must be replaced using the following procedure and special tools 1 Borrough s 52216 cylinder holding fixture and 5221 15a adapter or equivalent Borrough s 4981 remover or equivalent Valve guide replacer Proper size Valve guide stem hole reamer Proper size morse adapter Borrough s 3170 floating holder or equivalent NO a kw N Heavy duty drill press VALVE GUIDE REMOVAL WARNING Do not use a torch to heat the cylinder assembly The heating p
315. rk each fuel injection line 19 through 24 with its cylinder number to facilitate installation WARNING Fuel injection lines must not be bent or deformed Discard and replace bent chafed or deformed fuel injection lines Fuel injection line removal a Disconnect fuel lines 19 through 24 from fuel nozzles 28 b Disconnect other end of fuel lines from fuel manifold valve assembly 12 Compress spring legs of each clamp 27 and remove fuel lines from engine Fuel Nozzle Removal a Remove fuel nozzles 28 from each cylinder Remove fuel hose 37 from fuel metering unit and fuel pump Discard fuel hose 37 5 See Figure 10 1D Remove four bolts 19 lock washers 14 and washers 15 Remove throttle and metering unit Remove and discard gasket 1 Discard lock washers 14 Place the throttle and fuel metering unit in a clean protected area until it is to be overhauled 6 See Figure 9 1D Remove bolts 18 washers 17 spacers 16 and remove fuel manifold valve from the induction air manifold Place the fuel manifold valve in a clean protected area until it is to be overhauled 7 Remove nuts 6 lock washers 5 and hold down washers 4 Remove fuel pump assembly 3 and gasket 2A Reach into crankcase fuel pump cavity and remove drive coupling 2 Discard fuel pump gasket 2A and lock washers 5 Place the fuel pump in a clean protected area until it is to be overhauled Nomenclature for Figure
316. rmed in accordance with ASTM E 1417 Specific process procedures are referenced in ASTM E 1208 E 1209 or E 1219 The penetrant method used must be Type fluorescent Method A B C or D ACCEPT REJECT CRITERIA Rejectable discontinuities are any of the following fatigue cracks forming cracks grinding and heat treat cracks embrittlement cracks seams laps burst Parts which contain linear indications which cannot be reworked or indications which break into comers edges holes thread roots fillets gear tooth roots or keyways must be rejected NOTE See Chapters 7 through 17 for specific individual system components and part fluorescent penetrant inspection instructions The particular fluorescent penetrant manufacturer s information regarding use safety data and disposal must be followed carefully DIMENSIONAL INSPECTION Inspect for manufacturer specified fit with mating parts by comparative linear measurements and alignment measurement using standard precision measuring instruments DIMENSIONAL LIMITS After comparative measurement of mating parts and determination of running clearance refer to the limits section related to the part Limits under the column heading New Parts are manufacturing limits Clearances in the New Parts column apply to mating parts Example Check inside and outside diameters of mating part surfaces Take the recorded dimensions and subtract the smaller from the larger If the remainder falls withi
317. rocess must be performed using uniform heating methods only After cylinder has been heated do not bump the head or barrel Install proper size head on removing tool Attach to cold water supply Heat the cylinder to 450 F Heat soak one hour Install cylinder in the holding fixture Install pilot into guide Hold valve guide removal tool down firmly into guide bore with hand on water release button Use other hand to work sliding hammer Release the water and hammer out guide while water is running Both guides can be removed with one heating Allow cylinder to cool to room temperature 15 26 MAY 1998 VALVE GUIDE BORE MACHINING CAUTION Always ream guide bore to the proper oversize Never install an oversize guide in the old bore Measure valve guide bore and select proper size reamer Install cylinder in holding fixture Ream valve guide bore to required oversize Guide bore must be free of grooves Deburr the valve guide bore and clean the cylinder removing all debris from the machining procedure Inspect the valve guide bore new inside diameter and new valve guide outside diameter An interference fit of 0 001T to 0 0025T is required for exhaust valve guides and an interference fit of 0 0015T to 0 0030T is required for intake valve guides VALVE GUIDE INSTALLATION CAUTION The intake and exhaust valve guides are different and must be installed in the correct positions Apply a small amount of LUBRIPLATE 930AA to the outside diam
318. rom engine and discard 2 Disconnect ground terminal kit from magnetos 2 in accordance with airframe manufacturer s instructions 3 Remove nuts 5 lock washers 4 and magneto holding washers 3 from each magneto 4 Remove both magnetos 2 from the engine Discard cable ties 27 and lock washers 4 19 CAUTION Use care to avoid dropping magneto drive bushings and retainers into the engine See Figure 8 2A 5 Magneto assemblies must be overhauled in accordance with the magneto manufacturer s instructions see TCM ignition systems Master Service Manual Form No X40000 See Section 1 5 Related Publications for ordering information Nomenclature for Figure 8 1E 8 10 OCTOBER 2000 1 Gasket 11 Lead 3B 21 Clamp 2 Magneto 12 Lead 3T 22 Clamp 3 Washer Holding 13 Lead 4B 23 Nut 4 Washer Lock 14 Lead 4T 24 Clamp 5 Nut 15 Lead 5B 25 Screw 6 Sparkplug 16 Lead 5T 26 Bracket 7 Lead 1B 17 Lead 6B 27 Tie Cable 8 Lead 1T 18 Lead 6T 28 Kit Ground Terminal 9 Lead 2B 19 Washer Lock 10 Lead 2T 20 Screw 2 1 FIGURE 8 1E IGNITION SYSTEM FOR 10 550 G1B G2B G4B 10 550 N1B N7B 10 550 P1B 10 550 1 OCTOBER 2000 8 11 8 1F IGNITION SYSTEM REMOVAL AND DISASSEMBLY See Figure 8 1F 1 Remove ignition harness assembly a Remove ignition lead from each spark plug 6 Remove all cable ties 27 b On each magneto remove four screws 20 and lock
319. rque all connections 6 Loosen and remove the metered fuel supply hose from the manifold valve inlet fitting 7 Install and torque the second MS51523 B4 swivel tee directly to the fuel manifold valve inlet fitting 8 Attach the metered fuel supply hose to the straight end of the tee connector and torque 9 Connect the metered pressure test hose from the Porta Test Unit to this second tee connector and torque If using the alternative procedure connect the 0 30 PSI gauge to the swivel tee using a hose long enough to provide proper clearance from the engine cowling and propeller arc Torque all connections 10 Position the throttle control in the FULL OPEN position and the mixture control to FULL RICH Operate the aircraft boost pump in accordance with the aircraft manufacturer s instructions Following the instructions provided with the Porta Test Unit bleed all air from the test unit and hoses If using the alternative calibrated test gauges loosen the test connections at each gauge to bleed the lines of any air Operate the boost pump only long enough to allow purging of air from the installed test equipment Verify that all fuel lines hoses and fittings are secured and torqued and that no fuel leaks exist before proceeding Insure test hoses have been routed clear of the exhaust system and are supported their entire length to preclude inaccurate gauge readings OCTOBER 2000 19 9 WARNING Make certain all fuel has drained from the
320. rs The dimensional integrity of the crankcase must be maintained WARNING No weld repairs are allowed in the critical areas shown in Figure 16 6 2 Installation of crankcase cylinder deck stud hole helical coils must be accomplished in accordance with the specifications in Figure 16 11 and the instructions in section 6 21 Helical Coil Insert Replacement WARNING The 2 and 4 o clock crankcase cylinder deck stud positions must not be repaired by helical coil insert installation CRANKCASE CYLINDER DECK TAP THROUGH NO DAMAGE PERMISSIBLE IN THIS AREA WARNING THE TWO AND FOUR O CLOCK POSITIONS MUST NOT BE REPAIRED BY HELICAL COIL INSTALLATION NOTE DRILLING AND HELICAL INSTALLATION MUST BE ON LOCATION DEAD CENTER FIGURE 16 11 CRANKCASE CYLINDER DECK HELICAL COIL INSTALLATION 3 Any crankcase stud found to be damaged or loose must be replaced in accordance with the instructions in section 6 22 See Figure s 16 7A through 16 7D Crankcase Stud Setting 16 26 OCTOBER 2000 Heights for proper stud setting heights See the following for crankcase cylinder mount deck studs NOTE Crankcase cylinder mount deck studs requiring replacement must be replaced in accordance with the following instructions a Studs and tapped holes must be clean and dry b Apply Lockquick Primer grade N to stud and cylinder deck threads and allow to dry c Apply Loctite grade 271 to both threads d Install studs
321. rust face must be parallel to the parting surface within 0 002 inch full indicator reading Using the above procedure install new bushing in remaining magneto adapter Smooth any scores in the adapter oil seal counterbore Clean the magneto adapters removing all debris from boring process 8 20 MAY 1998 8 7 MAGNETO ADAPTER OIL SEAL INSTALLATION 1 4 Re install the magneto drive adapter the arbor press The front face of the adapter bushing must be supported on a parallel and flat block Coat the periphery of new oil seal with a thin translucent coat of TCM gasket maker P N 646942 Press the new oil seal into the magneto adapter using a flat end block of 1 3 8 inch diameter by 1 4 inch length The oil seal is pressed in until it bottoms out Do not crush the oil seal case Using the above procedure install a new oil seal in the remaining adapter STUDS HELICAL COILS AND PROTECTIVE COATING 1 Replace any damaged or loose studs in accordance with the procedure in section 6 22 Stud Replacement 2 Replace any damaged or loose helical coils in accordance with the procedure in section 6 21 Helical Coil Insert Replacement 3 Section 6 19 Application Of Accelagold applies to all aluminum alloy castings sheet metal and tubing SUB ASSEMBLY 1 Magneto assemblies must be sub assembled in accordance with the magneto manufacturer s instructions See Slick Ignition Systems Master Service Manual Index and Ord
322. ry must be connected by a No 0 stranded copper cable from its positive terminal to the power terminal of the starter through a starter solenoid The battery negative terminal must be connected to the engine or both battery terminal and engine may be grounded A small insulated wire should connect the starter solenoid coil terminal to a 5 ampere push button switch The other switch terminal must be connected to the engine or both to common ground INSTRUMENTS The control panel must be equipped with the following calibrated engine instruments An electrical or mechanical tachometer compatible with the tach drive assembly used An oil pressure gauge and tube connection An oil temperature gauge A cylinder head temperature gauge and wiring to each cylinder ar wn gt A water manometer with rubber hose connection to the vacuum pump oil return hole at the rear of the crankcase An ammeter connected in the alternator circuit Fuel flow gauge or fuel pressure gauge An exhaust gas temperature gauge Manifold pressure gauge OCTOBER 2000 19 3 19 11 19 12 19 13 BREATHER A clean substantial hose of 3 4 inch inside diameter must be installed on the crankcase breather elbow and support so it leads to a point above and to the rear of engine FUEL SYSTEM The test stand fuel system is to incorporate an auxiliary pump capable of delivering fuel to and through engine system at a pressure of 2 to 2 1 2 psi indication on fu
323. s 16 25 Crankcase Cylinder Deck Helical Coil Installation 16 26 Crankcase Needle Bearing 16 29 OCTOBER 2000 16 1 16 1A CRANKCASE DISASSEMBLY AND DRIVE TRAIN REMOVAL 550 1 See Figure 16 2 Oil Filler Idler Support Pin amp Camshaft Cover Remove attaching hardware 13 14 15 Remove cover 12 and gasket 11 Discard gasket 11 Remove attaching hardware 19 20 Remove idler gear support pin 18 gasket 17 and bushing 16 Discard gasket 17 and bushing 16 2 See Figure 16 1A Crankcase Attaching Parts 550 amp Remove crankcase backbone attaching hardware 1 through 6 Remove lifting eye 8 ignition bracket 9 and fuel manifold valve 7 Remove attaching hardware 22 23 24 Carefully tap through bolts 21 25 and remove Remove three bolts 15 and washers 5 NOTE Do not attempt to remove bolt and washer adjacent to right magneto upper stud The bolt and washer are installed before the upper magneto mounting stud and cannot be removed without causing damage to the bolt hole Rotate the engine stand placing the right crankcase half downward Support the engine with a prop under the right crankcase half A length of 2 X 4 lumber with the end supporting the crankcase padded may be used Remove remaining half inch nuts 19 and washers 18 Remove
324. s 28 in hole positions specified in Figure 16 1B install and finger tighten attaching hardware 29 30 See Figure 14 3D Oil Sump For 10 550 Install gasket 6 with split line toward crankcase on suction tube 1 Insert threaded end of tube through hole provided in crankcase Install gasket 7 and plug 8 on protruding threaded end of suction tube Attach suction tube bracket to crankcase with bolt 3 and washers 2 4 at position 78 in Figure 18 8 Install remaining 1 4 bolts 30 in hole positions specified in Figure 16 14 install and finger tighten attaching hardware 32 33 See Figure 14 3B Oil Sump For 10 550 Install gasket 3 with split line toward crankcase on suction tube 1 Insert threaded end of tube through hole provided in crankcase Install gasket 5 and plug 4 on protruding threaded end of suction tube Do not tighten plug at this time See Figure 14 3B attach suction tube bracket to crankcase with bolts 2 Torque bolts 2 to 155 175 inch pounds Lockwire bolts 2 in accordance with section 5 2 Lockwire Procedure See Figure 16 1A install and finger tighten hardware 29 through 33 10 550 G N P R Cylinder Installation Rotate engine to upright position Install the cylinder and piston assemblies in accordance with the following procedure 18 10 OCTOBER 2000 NOTE See Chapter 3 for lubricant specifications and suppliers WARNING The improper use of sealants and lubricants may cause en
325. s must use the methods techniques and practices prescribed in the Instructions for Continued Airworthiness Failure to comply with the Instructions for Continued Airworthiness may result in engine malfunction engine failure injury or death The Mechanic Prior to performing maintenance alteration overhaul or preventive maintenance the mechanic must meet requirements of FAR 65 and must follow FAR Parts 43 91 and 145 as applicable Use this manual in conjunction with Teledyne Continental Motors TCM service documents related publications accessory manufacturer s instructions FAR and FAA Advisory Circulars MAY 1998 Notes Cautions and Warnings NOTE Special interest information which may facilitate performance of a procedure or operation of equipment CAUTION Used to emphasize certain information or instructions which if disregarded may result in damage to engine or accessories WARNING Used to provide warning with respect to information and or instructions which if disregarded will endanger personnel and or severely damage the engine resulting in subsequent engine malfunction or failure Notes cautions and warnings do not impose undue restrictions They are inserted to obtain maximum safety efficiency and performance Abuse misuse or neglect of equipment can cause eventual engine malfunction or failure vi MAY 1998 PUBLICATION TABLE OF CONTENTS COVER PAGES Status eae e
326. s or property on the ground unless some specific action inspection repair replacement etc is taken by the product owner or operator Documents in this category may be incorporated in an Airworthiness Directive issued by the FAA CATEGORY 3 SERVICE BULLETIN SB Service documents not included in Categories 1 and 2 considered by the product manufacturer to constitute a substantial improvement to the inherent safety of an aircraft or component of an aircraft This Service Bulletin category also includes updates of instructions for continued airworthiness CATEGORY 4 SERVICE INFORMATION DIRECTIVE SID Service documents not included in Categories 1 2 or 3 that have been determined by the manufacturer to be of value to an owner operator in the use of a product by enhancing safety maintenance or economy CATEGORY 5 SERVICE INFORMATION LETTER SIL This category includes all information not included in Categories 1 through 4 that may be of use to the owner operator or maintainer of the aircraft CATEGORY 6 SPECIAL SERVICE NOTICE SSN TCM may issue a Special Service Notice when a product condition can be rectified by direct contact with each customer to whom the product was delivered Special service notices will be upgraded to Service Bulletins if confirmation of compliance with the Special Service Notice cannot be verified by TCM SERVICE REPORTS AND INQUIRIES If for any reason you have an inquiry or require technical
327. scription NEW PARTS MIN MAX 0 0060 0 0080 Second ring gap at 1 00 50 depth in cylinder barrel 0 034 0 050 Gap for second ring must be at least 006 larger than gap for top ring Diameter 1 1293 1 1295 0 0022 0 00261 0 0025 0 0050T 0 0000L 0 00181 0 0009 0 00341 0 0060 0 0110L Connecting rod bearing and bushing twist or convergence PEEING of cete to teat c attenta 0 0000 0 0005 0 0010 0 00254 Installed outer valve spring ight NOTES T Tight L Loose 15 14 OCTOBER 2000 CYLINDER DIMENSIONAL INSPECTION 1 Inspect cylinder bore dimensions in accordance with Figure 15 4A1 Cylinder Dimensions Cylinders bores that do not conform to the standard size dimensions after honing must be ground to the next oversize dimension 2 Inspect the cylinder base flanges for flatness If cylinder base flange exceeds 001 out of flat the cylinder must be discarded 3 Dimensionally inspect the cylinder exhaust flange stud and rocker shaft hold down stud holes using a thread gauge and determine the appropriate oversize stud for replacement 4 intake flange studs have been removed for replacement dimensionally inspect the intake flange stud hole s using a thread gauge and determine the appropriate oversize stud for replacement 5 Dimensionally inspect the valve guides inside diameter Guide dimensions must be within specifications the en
328. seal area for scoring and burning Inspect the gear bolt holes for distorted or stripped threads Check oil passages for obstructions and loose oil tubes Check the gear dowel for a tight fit Inspect the oil control plug for presence obstructed oil hole and tight fit Visually inspect the entire crankshaft for rust and pitting Crankshafts exhibiting any of the above indications must be repaired or replaced Crankshaft repairs must be performed under carefully controlled conditions using an approved procedure and process which meets the requirements of the applicable federal aviation regulations WARNING The counterweights and crankshaft must not be punch marked or scribed for location identification Use tagging or ink methods to identify 4 Using a 10X magnifying glass visually inspect counterweights for cracks nicks evidence of contact between bottom of counterweight and crankshaft Counterweights exhibiting these indications must be discarded Using a 10X magnifying glass visually inspect the crankshaft gear and idler gear drive gear teeth for signs of overheating and wear Normal wear produces a fine polish on the tooth thrust faces Gears that have alteration of the tooth profiles score marks pitting or galling must be discarded See Figure 8 3 Gear Tooth Wear for acceptable and unacceptable gear tooth wear Insure that connecting rod and cap mate marks are adjacent to each other and that the position numbers stamped on o
329. section 5 2 Lockwire Procedure OCTOBER 2000 18 17 18 8 STARTER AND STARTER ADAPTER 550 10 550 B9A B9B B9F B14B B19B B30B B35B B36B 10 550 550 550 10550 10550 R See Figure 13 1A 1 Apply a thin translucent coat of TCM Gasket Maker 646942 to the starter adapter gasket crankcase mating surface only 2 Install gasket 1 on crankcase CAUTION Sealant must be applied sparingly to prevent contamination of the engine oil system 3 Lubricate teeth on starter shaftgear with clean 50 weight aviation engine oil and mesh with crankshaft gear as starter adapter is placed in position Seat adapter against gasket Secure adapter assembly to crankcase with washers 2 27 new lock washers 3 and nuts 4 28 Torque 5 16 24 nuts to 180 220 inch pounds Torque 3 8 16 nuts to 200 220 inch pounds 4 Lubricate o ring 29 with clean 50 wt aviation engine oil and install on starter pilot Turn starter shaft until tongue aligns with worm drive shaft slot Mount starter 30 and secure with washers 31 and nuts 32 Torque nuts 32 to 200 220 inch pounds 18 8B STARTER AND STARTER ADAPTER 550 B1F B2F B3F B4F B5F B6F B11F B12B B13B B15B B16B B17B B18B B20B B21B B22B B23B B24B B25B B26B B27B B28B B29B B31B B32B B33B B34B B37B See Figure 13 1B 1 Apply a thin translucent coat of TCM Gasket Maker 646942 to the starter adapter gasket crankcase mating surface only
330. sher 2 Gasket 10 Washer Lock 3 Oil Cooler 11 Nut Plain 4 Baffle 12 Elbow 5 Washer 13 Plug 6 Washer Lock 14 Plug T Nut Plain 15 Oil Temp Control Valve Vernatherm 8 Nut Plain 16 Gasket 14 8 OCTOBER 14 2B OIL COOLER REMOVAL See Figure 14 2B 1 See Figure 16 3A Remove attaching hardware 8 9 10 11 from lower oil cooler mount flange and engine mount studs See Figure 14 2B Remove attaching hardware 5 6 7 Remove oil cooler 3 from crankcase studs Remove and discard gaskets 1 2 and lock washers 6 2 Place the oil cooler in a clean protected area until it is to be overhauled FIGURE 14 2B OIL COOLER ASSEMBLY FOR 10 550 C 1 Gasket 7T Nut Plain 2 Gasket O ring 8 Plug 3 Oil Cooler 9 Plug 4 Baffle 10 Gasket 5 Washer 11 Oil Temp Control Valve Vernatherm 6 Washer Lock MAY 1998 14 9 14 2 OIL COOLER REMOVAL See Figure 14 2 1 Remove attaching hardware 5 through 11 Remove cooler 3 from crankcase studs Remove and discard gaskets 1 2 2 Place the oil cooler in a clean protected area until it is to be overhauled FIGURE 14 2C OIL COOLER ASSEMBLY FOR 10 550 G5B G6B 10 550 N 10 550 10 550 R 14 10 OCTOBER 2000 Gasket Gasket Oil Cooler Baffle Washer Washer Lock Nut Plain Nut Plain 9 Washer 10 Washer Lock 11 Nut Plain 12 Plug 13 Plug 14 Oil Temp Control Valve Vernatherm 15 G
331. sing for cracks and indications of cracks Inspect for scratches on machined surfaces Housings exhibiting any of the above indications must be discarded Inspect the oil pump housing cover and tach drive housing flanges for warpage Oil pump housings covers or tach drive housings exhibiting warpage must be discarded Inspect all oil passages for restrictions Oil pump housings or tach drive housings with restricted oil passages that cannot be cleared by solvent action must be discarded Inspect the oil pump housing gear shaft for security and scoring Housings with loose or scored gear shafts must be discarded Inspect the oil pressure relief valve plunger for scoring nicks and the face for roughness Any oil pressure relief valve with scoring nicks or roughened face must be discarded 2 Inspect oil pump gear teeth for signs of overheating and excessive wear Normal wear produces a fine polish on the tooth thrust faces Gears that have alteration of the tooth profiles score marks burning or pitting must be discarded See Figure 8 3 Gear Tooth Wear for acceptable and unacceptable gear tooth wear Check the oil pump drive gear shaft and shaft splines for wear and damage Discard drive gears with any of these indications 3 Using a flashlight and a 10X magnifying glass inspect all areas of the oil filter adapter for cracks and indications of cracks Discard any oil filter adapter with cracks or crack indications Inspect the oil filter ada
332. sits with the lowest air pressure that will produce the desired results All machine surfaces the cylinder mount flange nut seats cylinder barrel wall small holes and finished surfaces must be protected from the blast by seals and covers Suitable types of materials for dry blasting are plastic pellets and processed natural materials such as wheat grains and crushed fruit pits or shells 4 After any blasting process blow off all dust with dry compressed air and insure that no blasting material has lodged in crevices recesses or holes Clean the cylinder with hot soapy water and a stiff bristled scrub brush to remove all blasting material from the cylinder After washing remove all soap residue by thoroughly rinsing with hot water Dry the cylinder completely and coat all bare steel surfaces thoroughly with clean 50 weight aviation engine oil Failure to clean and protect the cylinder in this manner could result in cylinder bore damage from rust and contamination 5 Degrease the intake valves with mineral spirits Remove all carbon varnish and gum from the intake valves using a carbon solvent or by dry blasting Use blasting techniques to remove hard carbon deposits with the lowest air pressure that will produce the desired results Suitable types of materials for dry blasting are plastic pellets and processed natural materials such as wheat grains and crushed fruit pits or shells After dry blasting clean with mineral spirits and air dry
333. spirits and air dry Inspect all parts for any damage that may have occurred during handling or shipment 3 See Figure 15 1B Install baffles 43 and springs 44 on all 10 550 G N P R engine FIGURE 15 13A INSTALLING BAFFLE FIGURE 15 13B SECURING BAFFLE cylinders Install baffle as shown in Figures 15 13A and 15 13B Insert the spring through cylinder Using another spring or a hook fashioned from stiff wire hook and pull the spring end over the cylinder fin 4 Immediately before cylinder subassembly thoroughly clean the cylinder bore using hot soapy water and a hard bristled scrub brush After washing all soap residue must be 15 44 OCTOBER 2000 removed thoroughly rinsing with hot water The cylinder must be dried completely and all bare steel surfaces thoroughly coated with clean 50 weight aviation engine oil 5 Cylinder Subassembly For the 550 amp model engines See Figure 15 1A Cylinder and Piston Assembly for 550 amp Using the following instructions assemble each of the six cylinders If the valves have been lapped they must be installed into the positions for which they were lapped Spread a film of Molyshield grease on the intake valve stem 10 and the exhaust valve stem 11 Install valves into the correct location Grasp the valve stems and install the cylinder on a cylindrical block of wood anchored to a work bench Again apply Molyshield grease to valve stems Place va
334. splacement or damage to the crankshaft oil seal and silk thread Insure thrust washer halves and bearing halves remain in place OCTOBER 2000 18 5 GRADE D SILK 1 3 5 CASE THREAD P N 641543 HALF AVIATION PERMATEX SRR NO 3D PO pee FRONT BOSS ONLY C7 GASKET MAKER GASKET MAKER CROSS THREAD SPACE THREAD EVENLY BETWEEN BOLT PERMATEX HOLES AND EDGE OF C C FLANGE FIGURE 18 3 CRANKCASE SEALANT AND THREADING PROCEDURE 18 4 CRANKCASE THROUGH BOLT INSTALLATION AND TORQUING SEQUENCE CAUTION All studs and through bolts must be lubricated in accordance with Chapter 3 Sealants and Lubricants NOTE See Figure s 16 1A or 16 1B Crankcase Attaching Parts as applicable and Figure 18 8 Torquing Sequence WARNING Failure to lubricate threads apply the specific torque and follow the specific torquing procedure may result in crankcase bearing bore damage crankshaft bearing damage crankshaft damage and subsequent engine malfunction or failure 10 550 A B amp C CRANKCASE ASSEMBLY 1 See Figures 16 1A Crankcase Attaching Parts 550 amp and 18 8 Torquing Sequence Using an o ring installation tool conforming with the specifications in Figure 18 4 O Ring Installation Tool install eight 1 2 x 10 75 through bolts 16 with new o rings 17 into positions 37R L through 44R L Install three 5 16 x 4 00 inch tie bolts 15 washers 5 in positions 69 71 amp 72 Install one 7 16 in
335. sses are clean and free of debris Flush the internal portion of the crankshaft using mineral spirit solvent Insure that all threads oil passages and recesses are clean and free of debris Clean the counterweights using mineral spirits WARNING Do not pressure blast counterweights with an abrasive media Blasting will remove surface hardening 8 Remove the connecting rod bolts and nuts but do not discard at this time All areas of the connecting rods must be degreased by brushing or spraying with mineral spirit solvent Insure all bolt holes oil passages and recesses are clean and free of debris All gum varnish deposits must be removed to permit reliable magnetic indications during magnetic particle inspection Clean gears that have bushings using mineral spirit solvent and a brass wire brush Gears with bushings must not be cleaned using alkaline solutions Gears that do not have bushings can be cleaned using mineral spirit solvent or by immersion in a alkaline stripping bath if mineral spirit solvent is not effective After cleaning with alkaline solution the gears must be sprayed with steam removing all traces of alkaline After steam rinsing the gears must be thoroughly flushed with mineral spirit solvent CAUTION Alkaline cleaning solutions will cause corrosion to metals if not completely removed WARNING Do not pressure blast gears with an abrasive media Blasting will remove surface hardening 17 6 MAY 1998 17
336. ssories that are used on your aircraft iv MAY 1998 Notice to all users This manual does not contain overhaul information for supplemental type certificated components or systems This manual contains information on engines components and systems designed tested and certified by TCM in accordance with the pertinent type design data The following publication contains overhaul information only All personnel involved with these functions must thoroughly read and understand the information provided these instructions inform of the procedures necessary to overhaul an engine and they must be followed carefully This manual contains no warranties either expressed or implied Publication Format This publication is formatted for practical use and ease of reference Due to the large volume of information necessary for maintenance chapters are independently numbered For example chapter 1 begins on page 1 chapter 2 begins again with page 1 etc To locate information easily use the Publication Table of Contents and the Chapter Contents provided at each division WARNING The Operator and Installation manual Maintenance manual Overhaul manual Service Documents and the Parts Catalog constitute the instructions for Continued Airworthiness prepared by TCM as approved by the FAA pursuant to FAR Part 33 As required by FAR 43 13 each person performing overhaul maintenance alteration or preventive maintenance on the engine or accessorie
337. st be tin plated See section 17 2 Engine Drive Train Cleaning DIRECTION OF PATTERN MARKS 30 THIS DISTANCE FIGURE 17 11 HELIX PATTERN APPLICATION 17 22 MAY 1998 WARNING The camshaft plugs must be installed and torqued before final engine assembly 8 CAMSHAFT Old Style Camshaft Using the correct size tool install new front plug to correct position shown in Figure 17 12 Old Style Camshaft Plug Installation Apply TCM Loctite Pipe Sealant 592 to the rear camshaft plug Install new 1 4 18 rear brass camshaft plug and torque to 130 150 inch pounds The camshaft must again be magnetic particle inspected in accordance with section 6 9 New Style Camshaft Apply TCM Loctite Pipe Sealant 592 to the front and rear camshaft plug Using the correct size tool install the new 1 4 18 brass camshaft plugs and torque to 130 150 inch pounds The camshaft must again be magnetic particle inspected in accordance with section 6 9 INCORRECT INSTALLATION FIGURE 17 12 OLD STYLE CAMSHAFT PLUG INSTALLATION OCTOBER 2000 17 23 9 All connecting rod piston pin bushings must be replaced 100 at overhaul The connecting rod piston pin bushing replacement must be performed using the specified procedure and the following special tools a Arbor press b Borrough s 8098 Connecting Rod Bushing Removal Installation Set or equivalent c Borrough s 8111A Connecting Rod Boring and Alignment Fixture or equivalent
338. stall four new bolts 5 and torque to 240 260 inch pounds Safety wire bolt heads in accordance with section 5 2 Lockwire Procedure After assembly coat camshaft with clean 50 weight aviation engine oil OCTOBER 2000 17 25 CRANKSHAFT WARNING Use only crankshafts that are manufactured from VAR forgings identified by the letters VAR forged into a crankshaft cheek 1 See Figure 17 2 Crankshaft Assembly Place the crankshaft on a bench with a notched wood block under front and rear journals Attach two sixth order counterweights 15 to crank cheek No 2 hanger blade with new pins 12 Install new plates and retaining rings 10 11 with sharp edge outboard Attach one fourth order and one fifth order counterweight to crank cheeks No 5 Install pins 13 14 Install new plates and retaining rings 10 11 with sharp edge outboard Pins with the same part number and dash number must be installed in each counterweight CAUTION The retaining rings plates and pins must be installed as shown in Figure 17 7 Counterweight Inspection Repair and Installation The counterweight plates have a small extruded point which provides an interference fit of 001 to 007 During installation check the counterweight plates for an actual interference fit in the bushing bore An interference fit is required WARNING Do not use plates that have a loose fit NOTE Counterweight pins are identified by dash numbers stamped on one end Because the
339. strands while taut until the twisted part is just short of a hole in the next unit The twisted portion should be within one eighth 1 8 inch from the hole in either unit Insert the uppermost strand through the hole in the second unit and follow the rules in Paragraph three After lockwiring the last unit continue twisting the lockwire to form a pigtail providing sufficient twists four minimum to assure that the pigtail will not unravel Cut off the excess lockwire and bend the pigtail toward the part and against the bolt head flats DO NOT ALLOW THE PIGTAIL TO EXTEND ABOVE THE BOLT HEAD FIGURE 5 2 GENERAL LOCKWIRE PATTERNS 5 3 5 4 FIGURE 5 3 GENERAL TAB WASHER INSTALLATION PROCEDURE TAB WASHER PROCEDURE Tab washers are installed by fitting a tab in a tab slot and bending the remaining tabs firmly against the bolt or nut flat Tab washers are used in various locations in TCM engines and must not be re used after removal Tabs that are provided to be bent up against the head flats must be seated firmly with no scarring of the tabs This provides proper locking of the unit and prevents tabs from breaking off 1 Make certain the holding tab is located in the tab hole or slot 2 Check the units to be secured and verify they have been correctly torqued in accordance with the specified instructions of the applicable system section 3 Bend tabs against the head flats firmly by tapping them into place with a soft drift Se
340. t Repeat these procedures until the engines fuel injection system meets all published specifications CONTINUED AIRWORTHINESS INSTRUCTIONS After engine installation test and approval for return to service the engine must be kept in an airworthy status The engine must be kept airworthy in accordance with the engine maintenance instructions in the 10 550 Maintenance Manual Form X30634A and related publications as listed in section 1 5 of this manual Special Instructions For 10 550 B39B and 10 550 C31B Overhaul Instructions for the 10 550 B39B are the same as the overhaul instructions for the 10 550 B37B and overhaul instructions for the 10 550 C31B are the same as the overhaul instructions for the 10 550 except for the following 5 6 The torque s listed in tables 6 1 through 6 5 are applicable to the 10 550 B39B and 10 550 C31B except for the crankcase flange backbone stainless steel nuts and bolts which are torqued to 240 to 280 inch pounds The cylinder valve springs are matched to within 5 pounds across all cylinders at the factory The six connecting rods are balanced to within 2 grams inch at the factory The crankshaft assembly is dynamically balanced to within 12 grams inch at the factory The six pistons are weight matched to within 2 grams inch at the factory During disassembly a Kent Moore Crankcase Splitter Part Number L 423 is required NOTE See the following pages for cylinder intak
341. t Washer 2 ea 652947 Rockershaft 2 ea 652984 Tools Required Drill 266 H Helicoil Installer 14 20 Drill Guide Kit P N 8181 includes 1 each drill guide P N 8181 1 and 1 each drill guide pilot P N 8181 2 Tap 4 20 Helicoil Chamfer Tool 339 Drill and T Handle Drive Prior to performing the modification clean the rocker shaft bosses and inspect for cracks using an approved method of dye penetrant inspection 1 Remove the existing rocker shafts and attaching hardware and inspect shaft bores for proper size 7495 7510 2 Install drill guide kit P N 8181 into rocker boss using the existing screw bore as shown in Figure 15 6D 3 Using a 266 drill drill to a depth of 1 820 1 850 as measured from the top of the drill guide as illustrated in Figure 15 6D in two places 4 Remove the drill guide and chamfer each bore 120 34 31 diameter by hand using 339 drill and T handle drive Deburr as necessary 5 Turn drill guide pilot 90 from original position and tap hole using 74 20 helicoil tap 430 deep 6 Remove helicoil installation tool body and use its threaded portion only Install P N 521209 4 15 20 self locking helicoil per MS33537 using the helicoil installation tool Insure that the helicoil is installed below the surface of the rocker shaft bore Break and remove the helicoil tang 7 Insure that the rocker shaft bore is clean and free of any burrs Clean the entire cylinder assembly usi
342. t be exercised when cleaning aluminum alloy parts using any alkaline cleaning solutions Immediately after removing soaked parts from inhibited mild alkaline bath or hot soapy water remove all traces of the alkaline by spraying the parts with a jet of steam or brushing vigorously with a mineral spirit solvent Cleaned parts may be dried by a jet of dry compressed air to remove all solvent liquids CAUTION When using alkaline cleaning solutions the cleaning solution manufacturer s usage safety data and disposal information must be strictly followed Alkaline etching solutions must not be used CAUTION All alkaline residues must be removed from crevices recesses and holes to prevent the formation of a foaming emulsion in the engine lubrication oil after reassembly If Accelagold surface was removed by the cleaning process it must be re applied in accordance with the procedure in section 6 19 Application Of Accelagold Accelagold is manufactured by Turco Products Inc CAUTION Alkaline cleaning solutions will cause corrosion to metals if not completely removed Carbon solvent should be employed only when carbon deposits are too hard or thick for removal by other solvents No polishing compound abrasive paste or powder is needed for cleaning engine parts Do not scrape parts or use wire brushes sandpaper abrasive cloth or abrasive wheels Scratches resulting from such methods allow concentrated stress at the scratch and may caus
343. tal in order to clear the crankcase flange Place engine in upright position Lubricate pushrods 40 with clean 50 wt aviation engine oil and install through cylinder openings into housings 35 18 24 OCTOBER 2000 FEELER GAUGE 0 002 TO 0 015 FIGURE 18 15B CHECKING ROCKER ARM SIDE CLEARANCE 5 Before installing valve actuating parts on each cylinder turn the crankshaft until pushrods are at their lowest position Lubricate rocker assemblies new thrust washers and new rocker shafts using clean 50 wt aviation engine oil Install rocker assemblies 20 and thrust washers 23 on rocker shafts 24 Install rocker and shaft assemblies on cylinder in correct positions Install retainers 25 new tab washers 26 and bolts 27 Check side clearance between retainers and rocker arms See Figure 18 15B Checking Rocker Arm Side Clearance Torque bolts 27 to 190 210 inch pounds 6 Measure exhaust rocker arm to rotocoil clearance See Figure 18 16 Rocker Arm To Rotocoil Clearance Measure dry valve gear lash at valve tip to rocker foot it must be 0 060 to 0 200 Bend tab washers 26 flat up against head of bolts 27 to safety See section 5 3 Tab Washer Procedure 9 NOTE Do not realign bolt head to suit tab washer 10 Install valve actuating parts on remaining cylinders using the above procedure ALLOWABLE GRIND WIDTH NOT TO EXCEED ir FIGURE 18 16 ROCKER ARM TO ROTOCOIL CLEARANCE OCTOBER 2000 18 2
344. tarter adapter housing oil passages must be clear and free flowing Housings with clogged oil passages that cannot be opened must be discarded Inspect the shaft gear worm wheel gear worm gear and bevel gear teeth for signs of overheating and excessive wear Normal wear produces a fine polish on the tooth thrust faces Gears that have alteration of the tooth profiles score marks burning or pitting must be discarded See Figure 8 3 Gear Tooth Wear for acceptable and unacceptable gear tooth wear MAY 1998 5 Inspect the starter adapter housing and accessory drive adapter housing studs for distorted or stripped threads Inspect studs for corrosion pitting incomplete threads and looseness Replace studs with any of these indications Check studs with a tool makers square for alignment The starter adapter housing studs must have their setting heights checked for indications of backing out See the following for stud setting heights ITEM LOCATION THREAD SIZE NO 1 5 1 Stud Starter Adapter toCrankcase 5 16 18 5 1624 2 Stud Starter Adapter to Crankcase 5 1618 5 16 24 3 Stud Cover to Adapter 5 1648X5 1624 4 Stud CovertoAdapter 516 18 X5 16 24 5 Stud Starter Motor to Adapter 3 846 38 4 2 3 4 STARTER ADAPTER HOUSING FIGURE 13 3A STARTER AND ACCESSORY DRIVE ADAPTER STUD SETTING HEIGHTS FOR 10 550 10 550 B9A B9B B9F B14B B19B B30B B35B B36B 10 5
345. th new nuts 17 Torque nuts 17 alternately in 20 inch pound increments to 75 85 inch pounds Care must be taken in assembling the collar to the crankshaft because of the close running clearance involved The collar must rotate freely to prevent frictional heating Check for a running clearance of 0005L to 0018L between the collar and crankshaft this will insure good oil pressure to the propeller 5 Original connecting rods have a position number stamped on the end cap and rod bolt boss New connecting rods must have a position number 1 through 6 as applicable vibro etched in the location shown in Figure 17 13 Connecting Rod Position Number Remove the bolts and nuts from the connecting rods and discard Place a sheet of crocus cloth on a flat surface plate and dampen with solvent Lightly rub the parting surface of the rod cap and rod across the crocus cloth to remove any burrs or nicks Inspect the parting surfaces bolt holes and bolt hole edges to insure there are no nicks burrs or sharp edges Clean rods caps bolts and nuts thoroughly blow dry and place on a clean cloth Clean the new bearing inserts in solvent and blow dry Inspect the bearings for damage and insure each bearing is the correct size and part number for the connecting rod crankshaft to be used Install a new bearing in each rod cap and rod Insure that the bearing ends project the same distance even with the parting surface and that they are properly seated Closely exami
346. tions or be replaced See Section 6 16 New Parts for further information OCTOBER 1998 Engine Removal Instructions As each part is disconnected and removed it must be identified Photographs can be helpful for orientation of parts and components during engine re assembly NOTE If the engine is being removed to be placed in storage prior to engine removal accomplish the steps listed in the chapter on Indefinite Storage of the appropriate Maintenance Manual 1 Insure all electrical switches circuit breakers ignition switches and fuel selector valves are in the OFF position Remove all cowling and nacelle access panels that obstruct engine removal in accordance with the airframe manufacturer s instructions Disconnect battery Disconnect the starter cable Remove the oil sump drain plug and washer See Figures 14 3A B C D Oil Sump as applicable Completely drain oil from engine and replace plug and washer WARNING Oil must be caught in an approved container and disposed of properly 6 Disconnect and tag the engine wiring bundles and other connections from the following components in accordance with the airframe manufacturer s instructions Magneto ground terminal leads sensor unit lead if equipped Alternator Pneumatic pump Tach drive if equipped Oil temperature connection Cylinder head temperature connection s Exhaust gas temperature connection s Remove all wiring bundle attaching clamps and h
347. tire length of the guide Replace all valve guides that are worn beyond the required specifications in accordance with the procedures in section 15 6 6 Visually inspect the valve seats for any indication of burning pitting erosion or cracks Determine if the valve seat dimensions exceed the specifications in Figures 15 5A and 15 5B Any valve seats that are burned pitted eroded cracked or that do not conform with the specifications in Figures 15 5A and 15 5B must be replaced INTAKE VALVE DIMENSIONAL INSPECTION 1 Inspect the entire length of the valve stem outside diameter with a micrometer Discard valves with stems less than 0 4335 diameter 2 Using a micrometer inspect the valve head outside diameter Intake valves with heads smaller than 2 339 diameter must be discarded ROCKER ARM DIMENSIONAL INSPECTION 1 Dimensionally inspect the rocker arm bushing bore The bushing bore must be 8725 to 8755 inch diameter 2 Dimensionally inspect the rocker arm thrust width The rocker arm width must be 1 030 to 1 033 OCTOBER 2000 15 15 01193 NI NEN c Le oc ez Y ZA g 4 7 p Iz k FIGURE 15 4A CYLINDER FITS AND LIMITS 10 550 amp C 15 16 OCTOBER 2000 c TOP OF DOME Al 7 7777 LER f 5 260 5 268 5 263 5 265 NOTE Dimensions shown are finish size after
348. toning of the seal bore tighten the nuts against the plate and pull the seal squarely from its recess After bushing removal clean the adapters using mineral spirit solvent Insure that all lubrication passages are clear and unobstructed Bushings and oil seals must be installed in the magneto drive adapters using the following procedure and special tools a Arbor Press b Heavy Duty Drill Press c Size Range 25132 27132 Adjustable Blade Reamer Adjusted to 8150 Diameter d Large Spot facer e 90 Countersink Bit MAGNETO ADAPTER BUSHING INSTALLATION CAUTION Before reaming a new bushing plug the oil holes with beeswax to exclude chips from the adapter groove Be sure to remove the wax completely after the operation 1 2 Install the magneto drive adapter on an arbor press The rear flange of the adapter rather than the studs must be supported on a parallel and flat block Press a new bushing into each magneto adapter after dipping in clean aviation lubricating oil Bore the bushing to 0 8145 0 8155 diameter using the specified reamer and heavy duty drill press If necessary face the bushing flange until it projects forward 1 454 1 458 inch from the adapter parting surface If necessary chamfer the bore at the flange end 1 16 inch deep on a 45 angle and slightly break sharp edges at both ends The bushing hole must be concentric with the adapter pilot shoulder within 0 002 inch per inch of length Its flange th
349. traightened and chafing damage that alter the original barrel surface contour fin tip contour or reduce the thickness of the barrel fins Cylinder barrels with any of the above conditions must be discarded Remaining Cylinder Barrel Areas Thoroughly inspect the remaining cylinder barrel areas including the cylinder barrel fins and the areas between and adjacent to the fins for cracks sharp indentations chafing damage rust and pitting Inspect the cylinder barrel flange and flange radius for rust and pitting Cylinder barrels with bent fins in this area may continue in use provided that the fin is not bent more than one half of the distance to the next fin that no attempt is made to straighten the bent fin and there are no cracks or evidence of cracks Minor fin tip damage repair may be accomplished on fin tips in this area as described in section 15 6 OTHERWISE CYLINDER REPLACEMENT IS REQUIRED WARNING Corrosion pits reduce wall thickness and will cause stress concentrations and subsequent fracture Damage or removal of external barrel material that results in a reduction of the barrel wall thickness is strictly prohibited regardless of location and requires cylinder replacement 4 Inspect the entire cylinder barrel for electrical arc pitting or weld repairs Electrical arc pitting or weld repairs of any surface on the cylinder barrel is strictly prohibited if such conditions are present discard cylinder Inspect the cylinder bore f
350. ts cylinder number to facilitate re installation WARNING Fuel injection lines must not be bent or deformed Discard and replace bent chafed or deformed fuel injection lines 2 Fuelinjection line removal a Disconnect fuel lines 30 45 46 47 from fuel nozzles 31 b Disconnect other end of fuel lines from fuel manifold valve assembly 27 Compress spring legs of each clamp 33 and remove fuel lines from engine Fuel Nozzle Removal a Remove fuel nozzles 31 from each cylinder Remove attaching hardware 14B 40 41 42 Loosen and remove hose 29 from manifold valve 27 and fuel control 5 Loosen and remove hose assemblies 28 from fuel pump 3 and fuel control 5 Remove bolts 13 and washers 12 Remove throttle and fuel control as an assembly from the engine sump Remove cotter pins 15 linkage 14 14B 16 17 18 spring 22 and wave washers 19 from throttle 4A and fuel control 5 Remove nuts 26 lock washers 25 washers 24 and shroud 23 from fuel control Discard lock washers 25 Bend tab washers down and remove standoff bolts 11 Separate fuel control unit 5 from throttle 4A Discard tab washers 10 Place the throttle and fuel control unit in a clean protected area until they are to be overhauled Remove the crankcase backbone hardware that secures the fuel manifold valve to the engine and remove fuel manifold valve 27 Place the fuel manifold valve in a clean
351. uges Must be currently calibrated and the calibration must be traceable to the National Bureau of Standards 2 2 MAY 1998 POSSIBLE SPECIAL TOOL PROCUREMENT SOURCES NOTICE All tools in the Special Tool list are for reference only and not for the purpose of promoting or suggesting tools to be purchased from the indicated sources The following information is given as an aid for special tool procurement purposes COMPANY GENERAL PRODUCT SUMMARY ALCOR Box 32516 10130 Jones Maltsberger Rd San Antonio TX 78284 Ph 512 349 3771 KENT MOORE 29784 Little Mack Roseville 48066 2298 Ph 800 253 0138 CHAMPION SPARK PLUG CO Box 910 900 Upton Ave Toledo OH 43661 Ph 419 535 2461 EASTERN ELECTRONICS INC 180 Roberts St East Hartford CT 06108 Ph 203 528 9821 FEDERAL TOOL SUPPLY INC 1144 Eddy St Providence Rhode Island 02940 Ph 800 343 2050 AIRCRAFT TOOL SUPPLY P O Box 4525 2840 Breard St Monroe LA 71201 Ph 507 451 5310 McMASTER CARR SUPPLY P O Box 4355 Chicago Illinois 60680 Ph 312 833 0300 SNAP ON TOOLS 2611 Commerce Blvd Birmingham Alabama 35210 Ph 205 956 1722 KELL STROM TOOL COMPANY INC 214 Church St Wethersfield CT 06109 Ph 860 529 6851 FAX CORPORATION 210 South King St Danbury Connecticut 06813 Ph 203 748 6117 MERRIT PRODUCTS 201 W Mansville Compton California 90224 Ph 310 639 4242 AERO TEST INC 29300 Goddard Road Romulus Michiga
352. uing the crankcase using a straight edge insure that the rear crankcase half ends are flush with each other FIGURE 18 7 GENERAL BOTTOM VIEW WITH OIL SUCTION TUBE INSTALLED NOTE Have an assistant hold nuts on opposite side of cylinder when torquing through bolt hardware Through bolt nuts on both sides of crankcase must be torqued to the specified values 1 After all cylinders have been installed using the sequence shown in Figure 18 8 torque nuts at positions 1 through 52 to the following preliminary torques NOTE Crankcase and cylinder torquing requires two people WARNING The torque values specified for engine reassembly are for use with clean nuts bolts and studs with threads that are free of damage distortion and that have been pre lubricated with clean 50 weight aviation engine oil prior to torquing The torque wrench used for torquing must be currently calibrated and traceable to the National Bureau of Standards Incorrect through bolt torque may result in subsequent engine malfunction and failure 18 12 OCTOBER 2000 be 64 59 57 55 56 58 60 024 RIGHT CRANKCASE LEFT CRANKCASE FIGURE 18 8 TORQUING SEQUENCE CRANKCASE PRELIMINARY TORQUE VALUES 1 through 36 37RIL 38R L 39R L 40R L Using the sequence shown in Figure 18 8 torque nuts at positions 1 through 70 to the following final torques CRANKCASE FINAL TORQUE VALUES 790 810 12 point nut OCTOBER 2000 48 13 FIGURE 18 9A INST
353. um air conditioning compressor mounting kit components in accordance with instructions in section 6 12 Fluorescent Penetrant Inspection Any components exhibiting cracks must be discarded MAGNETIC PARTICLE INSPECTION The idler sheave support bolt 6 must be magnetic particle inspected in accordance with the instructions in section 6 9 Magnetic Particle Inspection Support bolts exhibiting cracks must be discarded COMPRESSOR MOUNTING KIT REPAIR AND REPLACEMENT 1 Replace all compressor mounting kit parts that require 100 replacement at overhaul 2 Any component failing to meet inspection requirements listed in section 11 4 must be discarded 3 Section 6 19 Application Of Accelagold applies to all aluminum alloy castings sheet metal and tubing Accelagold is manufactured by Turco Products Inc OPTIONAL COMPRESSOR MOUNTING KIT SUB ASSEMBLY NOTE All parts must be clean and free of debris before assembly 1 Install a new ball bearing 3 into sheave 2 and secure with new retaining ring 4 Using bolt 6 shims 22 and spacer 7 install sheave 2 on bracket 5 Do not torque bolt 6 at this time 2 Loosely assemble tensioning bolt and hardware 10 11 12 14 on bracket 1 Install sheave and bracket assembly 2 5 on bracket 1 using attaching hardware 8 9 13 14 15 Do not torque at this time 3 Store the compressor mounting bracket and related hardware in a clean protected area until final engine assemb
354. ump Torque 18 15 Checking Sheave 18 19 Sheave Alignment eios ttr re ete 18 20 Belt Tensioning eie tee diner bnc ce 18 21 Alternator Housing Modification 18 22 Checking Rocker Arm Clearance lO 550 A B amp C 18 24 Checking Rocker Arm Clearance 550 N P amp R 18 25 Rocker Arm to Rotocoil Clearance 18 25 Installing Pushrod 18 26 Timing Position e reote taches 18 32 Timing Position Step 2 ict emer 18 33 Timing Position Step 18 33 Timing Position Step 4 esee 18 34 Timing Position Step 5 18 34 Position Of Magneto Couplings 18 36 Coating Insulating Sleeve 2 22 2 22 2 2 1 18 38 lgritiori Wiring DIAG IAI fos 18 39 Coupling Nut Torque 18 39 18 1 18 2 GENERAL WARNING Use only parts meeting the engine type design Apply clean 50 weight aviation engine oil liberally to all bare steel surfaces journals bearings and bushings before and after installation except wher
355. uration can cause mount lug failure If interference exists it is permissible to enlarge the mount lug stud holes by drilling or reaming to a maximum diameter of 387 Standard hole size is 337 347 inch diameter 4 Insure that the alternator pilot enters the crankcase pilot bore squarely Forcing entry with the attaching nuts will stress the lugs causing cracking and malfunction 5 Install alternator 2 onto the engine With the alternator pilot properly engaged in the pilot bore install washers 8 lock washers 9 and nuts 10 Finger tighten nuts evenly and snug Torque nuts 10 to 180 220 inch pounds See NOTE on next page OCTOBER 2000 18 21 NOTE If Installing a new or rebuilt 60 amp 24 volt alternator and interference occurs between one of the crankcase through bolts and the alternator drive end housing perform the following a Using an appropriate grinding tool or a 750 812 diameter end mill cutter contour housing as specified in Figure 18 14 Insure a minimum radius at all corners of 005 and wipe away chips or dust Treat with Accelagold Aluminum Conversion Coating and apply enamel paint b Reinstall alternator in accordance with the previous installation procedure Verify through bolt does not contact housing center line of grind stone or cutter 38 41 R ref 750 812 dia grind stone or cutter 24 26 center line of grind stone or cutter 38 41 R ref e eg
356. ure 19 2 Post Setup Procedures 1 Insure that the master switch ignition switch and fuel selector are in the off position 2 Remove the engine cowling or cooling shroud in accordance with the aircraft manufacturer s instructions Remove all test gauges fittings and hoses that were installed for fuel system setup Reconnect all fuel hoses to their original locations support and torque all fittings to the specified value 3 Perform a complete fuel system leak check in accordance with the aircraft manufacturer s instructions Correct any discrepancies noted 4 Install engine cowling or cooling shroud in accordance with the test stand or aircraft manufacturer s instructions 5 Perform a complete operational ground run up and verify that all fuel system performance specifications are achieved 6 Repeat the setup and adjustments as required until the fuel injection system is performing within the published specification for the aircraft and engine 19 12 OCTOBER 2000 TABLE 19 1 TEST OPERATING SPECIFICATIONS For your convenience we have tabulated the following fuel system pressure and flow values to facilitate proper adjustment and optimum performance All top end values are shown for maximum rated RPM and manifold pressure ldeSpeeRPM OD Manifold Air Pressure at Idle in Hg Max 18 5 Fuel Grade Octane 100LL 100 Full Throttle Lbs Hr 142 150 146 156 152 160 125 130 150 160 229266 252273 213221 258273
357. urth Ring Groove Width 0 1000 0 1010 Piston Pin Assembly Length including plugs 5 205 5 220 Diameter 1 1243 1 1245 Measure piston diameter at right angles to pin bore Measurement must be made at 165 inch from bottom of piston OCTOBER 2000 15 23 15 6 CYLINDER ASSEMBLY REPAIR AND REPLACEMENT CYLINDER HEAD WELD REPAIR Only minor non structural weld repairs are permitted TCM allows welding repairs of the intake and exhaust port flanges rocker cover flange and threaded holes other than spark plug and requires that these repairs be performed under carefully controlled conditions using an approved procedure and process which meets the requirements of the applicable federal aviation regulations No structural weld repairs are allowed TCM does not allow weld repairs to the combustion chamber head structure and rocker shaft bosses Any cylinder head that is cracked or damaged in a structural area must be replaced WARNING Welding the cylinder head structure may destroy the assembly preloads and casting strength resulting in cylinder assembly failure CYLINDER HEAD FIN REPAIR Do not attempt to straighten cylinder head cooling fins If it becomes necessary to cut out a vee notch to stop a head fin crack use a slotted drill bushing to fit over the fin and a 3 16 inch twist drill to cut the notch Its apex and edges must be rounded If such repairs and previous breakage have removed 10 or more of the total cylinder head fin
358. ust washer lands in crankcase to prevent thrust washer halves from falling out during final assembly Install thrust washer halves 1 Insure that the bearing and thrust washer ends project equally and are properly seated Lubricate bearings with clean 50 wt aviation engine oil 4 See Figure 17 2 Install new o ring 21 on oil transfer collar 20 and lubricate thoroughly with clean 50 wt aviation oil With the aid of an assistant lift crankshaft assembly by No 1 connecting rod and propeller flange Have assistant hold 3 and 5 connecting rods upward carefully lower assembly into position guiding oil transfer collar sleeve into it s hole make sure o ring is seated properly Check to make sure bearings and thrust washers are still seated properly The connecting rod position numbers if properly installed will be toward the upper case flange Carefully place odd numbered connecting rods on the upper case flange 5 See Figure s 17 1A 17 1B and 18 2 as applicable Using clean 50 wt aviation engine oil lubricate and install governor driven gear 8 or 7 and camshaft 1 into crankcase Make sure that timing marks on camshaft and crankshaft align as gears mesh Number 1 connecting rod on crankshaft should be in its fully extended TDC position Governor driven gear may have to be turned slightly to allow camshaft to seat in its bearings properly Check governor driven gear backlash it must be 0 002 to 0 012 OCTOBER 2000 18 3 i o I
359. utlet holes Install two adapter assemblies 2 6 on the crankcase mount pads Adapter 2 oil hole must be aligned with the crankcase oil outlet hole Attach both adapters to crankcase using plain washers 10 11 lock washers 12 13 and nuts 14 15 Torque 5 16 nuts to 180 220 inch pounds and 3 8 nuts to 275 325 inch pounds Using new gaskets 20 install covers 21 and secure using attaching hardware 22 23 24 or 22 23 25 as applicable Torque nuts 24 to 90 110 inch pounds Torque bolts 25 to 75 85 inch pounds If installing an airframe supplied accessory insure that the proper gasket is used and install in accordance with the airframe manufacturer s instructions 18 12 VALVE MECHANISM 10 550 A B amp C See Figure 15 1A 1 Lubricate all tappet faces using Dow Corning G N Paste or equivalent Dow Corning is a registered trademark of Dow Corning Corporation Install new exhaust tappets into exhaust side tappet guides Install new intake tappets into intake side tappet guides Install twelve pushrod housings Using a Borrough s 68 3 Rod Spring Compressor or equivalent compress new spring 38 Place a new packing 37 between two steel washers 36 and install on the crankcase end of pushrod housing Place a new packing 37 between two steel washers 36 and install on the cylinder end of pushrod housing Insert housing into crankcase guide until other end with washers 36 and packing 37 can be aligned
360. vent WARNING Never use teflon tape on lubrication system fittings 1 Install plugs 12 13 Install new gasket 15 and new oil temperature control valve 14 into oil cooler 3 Torque plugs 12 13 in accordance with Table 6 2 Pipe Plug Torques Torque oil temperature control valve 14 to 440 460 inch pounds Safety wire oil temperature control valve in accordance with section 5 2 Lockwire Procedure 2 The oil cooler will be installed on the engine during final engine assembly Cover oil cooler and store in a clean protected area until final engine assembly Oil Sump 10 550 10 550 See Figure 14 3B 1 Install the four engine mount legs 14 and secure with four sets of attaching hardware 15 16 Torque nuts 16 to 275 325 inch pounds torque 2 The oil sump will be installed on engine during final engine assembly Cover sump assembly and store in a clean protected area until final engine assembly 14 26 OCTOBER 2000 15 CYLINDERS AND PISTONS SECTION PAGE 15 1A Cylinder Assembly 15 2 15 1B Cylinder Assembly 15 4 15 2 Cylinder and Associated Parts Disassembly 15 6 15 3 Precleaning Inspection 15 6 15 4 Cylinder and Associated Parts Cleaning 15 7 15 5 Cylinder and Associated Parts Inspection
361. vity with clean 50 weight aviation engine oil Install fuel pump on crankcase Secure fuel pump using attaching hardware 30 31 amp 32 Torque nuts 32 to 180 220 inch pounds Apply 646943 anti seize lubricant to fuel nozzle threads cylinder end in accordance with Figure 9 9 General Sealant Application Install new fuel nozzles 27 in cylinders 1 through 6 Torque nozzles to 55 65 inch pounds CAUTION Never use teflon tape on fuel injection system fittings WARNING Fuel injection lines must not be bent or deformed The fuel injection lines must be securely clamped to the fuel line support brackets Do not assemble in a binding configuration 4 Install fuel injection lines 26 35 36 37 between nozzles 27 and fuel manifold valve 23 Torque fuel line B nuts at nozzles to 40 45 inch pounds Torque fuel line B nuts at manifold valve to 55 60 inch pounds Attach clamps 29 to fuel lines Snap clamps 29 into brackets 28 Install fuel hoses 24 between fuel pump and fuel control unit fittings Torque hose B nuts to the specified limit in Table 6 4 Torque Specifications for Hose Fittings Install fuel hose 25 between fuel manifold valve 23 and fuel control unit 5 fittings Torque hose B nuts to the specified limit in Table 6 4 Torque Specifications for Hose Fittings Install fuel control unit shroud 19 on fuel control 5 Secure using attaching hardware 7 9 20 21 amp 22 Torque bolt 9
362. with cylinder head opening Move assembly outward until gasket has entered cylinder hole Release spring slowly until it is free Remove spring compressor See Figure 18 17 Installing Pushrod Housing Install the pushrod housings nearest to engine mount brackets first The spring compressor tool must lie close to horizontal in order to clear the crankcase flange Place engine in upright position Lubricate pushrods 39 with clean 50 wt aviation engine oil and install through cylinder openings into housings 35 OCTOBER 2000 18 23 FEELER GAUGE FIGURE 18 15A CHECKING ROCKER ARM SIDE CLEARANCE Before installing valve actuating parts on each cylinder turn the crankshaft until pushrods are at their lowest position Lubricate rocker assemblies new thrust washers and new rocker shafts using clean 50 wt aviation engine oil The rocker shaft beveled side must be installed facing toward the cylinder base Slide rocker arm shafts to side to allow rocker arm installation Install rocker assemblies 21 24 and thrust washers 27 in rocker bosses Slide rocker shafts 18 into place and secure with washers 19 and bolts 20 check side clearance between rocker boss and rocker arms it must be 002 015 See Figure 18 15A Checking Rocker Arm Clearance Torque bolts 20 to 90 100 inch pounds Measure exhaust rocker arm to rotocoil clearance See Figure 18 16 Rocker Arm To Rotocoil Clearance Measure dry valve gear lash at va
363. with screw hole in gear web Install new tab washer 21 and screw 22 Torque screw 22 to 75 0 85 0 inch pounds torque and bend tab up against screw head FIGURE 13 8A THREADING DIAGRAM FOR STARTER ADAPTER COVER OCTOBER 13 21 3 Lubricate spring and shaft gear liberally with clean 50 weight aviation engine Press worm wheel and spring assembly onto shaft gear 18 Install new ball bearing 24 on shaftgear 18 and secure with new retaining ring 25 Make sure retaining ring seats properly in it s groove Insert shaft gear and worm wheel assembly into adapter Make sure worm wheel and worm gear teeth are aligned 4 Install new o ring 26 on cover 27 Install cover 27 on starter adapter housing 5 Secure using three sets of attaching hardware 28 29 Torque nuts 29 to 180 220 inch pounds Install scavenge pump gear 34 and spacer 42 on shaftgear 5 Install a new ball bearing 41 and new oil seal 43 into body 35 The thrust side of bearing 41 must be facing forward toward the propeller Care must be taken to insure that oil seal 43 is inserted into the body housing to a depth of 0 to 03 below the casting surface 6 See Figure 13 8A Apply permatex to cover 27 flange and apply silk thread to flange Position thread as shown in Figure 13 8A Install body 35 and secure with three sets of attaching hardware 37 38 See Figure 13 8B On the attaching stud adjacent to the oil seal bore install retai
364. y Woodruff 8 Washer Plain 4 Nut Slotted 9 Washer Lock 5 Hub Drive 10 Nut 12 2 MAY 1998 12 2 ALTERNATOR DISASSEMBLY 1 The alternator assembly must be overhauled in accordance with the alternator manufacturer s instructions or Alternator Service Instructions X30531 3 12 3 ELECTRICAL CHARGING SYSTEM COMPONENT CLEANING 12 4 1 All electrical charging system components and associated hardware must be cleaned accordance with the instructions in section 6 7 General Cleaning and the following special instructions 2 All gaskets lock washers woodruff keys and self locking nuts removed from the electrical charging system must be replaced 10096 at overhaul Cleaning these parts is not required 3 Clean gears that have bushings using mineral spirit solvent and a brass wire brush Gears with bushings must not be cleaned using alkaline solutions Gears that do not have bushings can be cleaned using mineral spirit solvent or by immersion in an alkaline stripping bath if mineral spirit solvent is not effective After cleaning with alkaline solution the gears must be sprayed with steam removing all traces of alkaline After steam rinsing the gears must be thoroughly flushed with mineral spirit solvent CAUTION Alkaline cleaning solutions will cause corrosion to metals if not completely removed WARNING Do not pressure blast gears with an abrasive media Blasting will remove surface hardening ELECTRICAL CHARGING S
365. ylinder exhaust flange studs in accordance with section 6 23 Cylinder Exhaust Port Stud Replacement Discard studs Support the rocker arm on a ring that will allow the old bushings to pass through Press the worn bushings out using the proper size tool Discard the bushings Disassemble the remaining cylinders and rocker arms using the above procedure 15 3 PRECLEANING INSPECTION 1 Prior to cleaning the cylinder assemblies inspect them for any signs of head to barrel leakage leaking oil fuel exhaust or combustion residue and any condition that could indicate loss of integrity of the cylinder assembly or the cylinder head to barrel junction Inspect the cylinder barrel fins and fin tips for rust pitting and damage in the power stroke stress areas Discard any cylinder with the above described conditions Inspect the remainder of the cylinder barrel barrel fins fin tips and cylinder base flange for rust pitting and damage that cannot be repaired in accordance with the instructions in section 15 6 Discard all cylinders which cannot be repaired Discolored or burnt paint may indicate piston and piston pin scoring of the cylinder bore caused by overheating Scored cylinder barrel bores and barrel bores that have been overheated must be discarded and replaced Do not attempt to remove overheating damage by grinding cylinder bore to the next allowable oversize Cylinder barrel overheating can destroy the strength of the material 15

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