Teledyne Continental Motors GTSIO-520 Series User manual

OVERHAUL
MANUAL
FOR
GTSIO-520
SERIES
AIRCRAFT
ENGINES
FAA
APPROVED
MARCH 1981
FORM
X-30045A

CURRENT
STATUS
OF
PAGES
AS
OF
MARCH
1981
INSERT
LATEST
PAGES
DESTROY
SUPERSEDED
PAGES
THE PAGES IN
THIS
PUBLICATION
CONSIST
OF
THE FOLLOWING:
MODELS
GTSIO-520-C,
D,
H,
K,
L, M
and
N
PAGE
ithru
iv
V
vi
thru
viii
ix thru x
A-1-1
A-1 -2
A-2-1/A-2-2
A-3-1
A-3-2
A-3-3
thru
A-3-6
A-4-1 thru
A-4-13
A-4-14
A-4-15
thru
A-4-17
A-4-18
A-4-19
thru
A-4-20
A-4-21
thru
A-4-25
A-4-26
A-4-27
thru
A-4-29
A-4--30
A-5-1
thru A-5-4
A-6-1
A-6-2
A-7-1
thru
A-7-6
A-8-1
thru A-8-2
A-9-1
thru
A-9-3
A-9-4
thru
A-9-6
A-10-1
A-10-2
A-10-3
thru A-10-4
A-10-5/A-10-6
A-11-1
thru A-11-2
A-1 1 -3
A-1 1 -4
A-1 2-1
A-12-2
thru
A-12-3
A-12-4
A-12-5
thru A-12-6
A-1
2-7 /A-1
2-8
A-13-1
thru A-13-2
A-13-3
A-1 3-4
A-13-5/A-13-6
A-14-1
thru
A-14-4
ISSUE
Original
June
1980
Original
March
1981
October
1980
March 1981
June
1980
Original
March 1981
Original
Original
March 1981
Original
October 1980
June
1980
Original
June 1980
Original
March
1981
Original
June 1980
Original
Original
Original
Original
June 1980
Original
June 1980
Original
June
1980
Original
June
1980
Original
March 1981
Original
June
1980
Original
March
1981
Original
March
1981
Original
June 1980
Original
PAGE
B-1
B-2
B-3
B-4
B-5
B-6
B-7
thru
B-10
B-1l
thru
B-13
B-14 thru
B-21
B-22
B-23
thru B-25
B-26
B-27/B-28
C-1-1
thru C-1-7
C-1 -8
C-1-9
thru
C-1-16
C-2-1
C-2-2
C-2-3
C-2-4
C-2-5
thru
C-2-6
C-2-7
thru C-2-8
C-2-9 thru C-2-12
C-2-13
thru
C-2-16
C-3-1
thru
C-3-2
C-3-3
thru
C-3-4
C-3-5
thru
C-3-6
C-3-7
thru
C-3-8
C-3-9
thru
C-3-14
C-3-15
thru C-3-18
C-4-1 thru C-4-2
C-4-3
C-4-4
thru
C-4-20
C-5-1
thru C-5-2
C-5-3
thru C-5-4
C-5-5
thru C-5-8
C-5-9
C-5-10
thru C-5-12
C-5-13
thru
C-5-16
C-6-1 thru C-6-2
C-6-3
thru C-6-4
C-6-5
thru C-6-1
2
C-6-13
thru
C-6-16
C-7-1 thru
C-7-18
ISSUE
March 1981
October 1980
Original
March
1981
Original
June
1980
Original
June 1980
Original
March 1981
Original
October 1980
Original
Original
June
1980
Original
Original
June
1980
Original
June 1980
Original
June
1980
Original
June 1980
Original
June 1980
Original
June 1980
Original
June
1980
Original
June 1980
Original
Original
June
1980
Original
March 1981
Original
June 1980
Original
June 1980
Original
June 1980
October
1980

FOREWORD
i-7.
Chapter
C.
i-2.
This
publication
is
constructed
to
give
adequate
information
for
complete
overhaul
operations
for
the
models
covered
throughout
these
three
(3)
Chapters
A,
B,
and
C.
The
basic engine
overhaul
(Chapter
A)
is
written
to
a
hypothetical
GTSIO-520
engine model,
covering
the
most
common
basic
items
of
all
engines
involved.
Any
differences
between Chapter
A
(the
basic)
and
the
letter
model
engines
is
adequately
covered by
the
use
of
Difference
Data
Section,
Chapter
C.
Chapter
B
is
the
combined
listing
of
the
Table
of
Limits for
all
engines
covered
in
this
manual. Personnel
overhauling
any
engine
model
covered
by
this
consolidated
manual
will
be
con-
cerned
only
with
the
Difference
Data
Section,
indexed
by
the
letter
of
his
particular
engine
model,
Chapter
A
(the
basic),
and
Chapter
B
Table
of
Limits.
All
pages,
figures
and
tables
in
this
manual
are
numbered
by
the
following system:
Page
A-
13-7
refers
to
the
seventh
page
of
Section
1
3 of
Chapter
A.
i-3.
Chapter
A.
i-4.
This
chapter
contains
complete
overhaul
instructions
for
the
basic GTSIO
520
engine.
This
chapter
consists of
(14)
sections
numbered
I
through
XIV.
These sections
cover
the
Intro-
duction,
Specification
Limits,
General
Description,
Illustrations,
Special Tools
and
Equipment,
Unpacking
and
Preparation
for
Service,
Storage
or
Shipment,
Disassembly,
Cleaning,
Inspection,
Repair
and
Replacement,
Assembly
of
Sub-
assemblies.
Final Assembly,
Repair
and
Testing
of
Accessories
and
Testing
after
Overhaul,
of the
basic
model
engine.
Hereafter,
through
this
manual
Chapter
A will
be
known
as
the
basic
model
GTSIO-520.
i-5.
Chapter
B.
i-6.
This
chapter
consists
of
the
Table
of
Limits
for
all
engines covered
in
this
consolidated
manual.
The
index
numbers
on
the
Limits
and
Lubrication
Chart
are
listed
in
the
Table
of
Limits
and
are
referred to
as
reference
numbers.
i-8.
This
chapter contains
the Difference
Data
instructions
for
all
engine
models
as
listed
in
the
Table
of
Contents.
This
chapter
consists
of
individ-
ual
sections,
each
relating
to
a
particular
engine
model.
Each
section,
along
with
the
instructions
for
the
basic
model
in
Chapter
A,
provide
complete
coverage
for
overhaul.
The
instructions
in
the
Difference Data
Section
are
to
be
used
in
lieu
of
those
for
the
same assemblies
in
the
basic
model
i-9.
AVAILABILITY.
i-10.
Further
copies
of
this
and
other
Teledyne
Contintal
Motors aircraft
service
publications
may
be
purchased
through
Teledyne
Continental
Approved
Distributors
and
Parts
Dealers
for
air-
craft
engine
parts.
It
is
requested
that
all
orders
for
such
publications
be
placed
with
these
facilities.
i-11.
SERVICE BULLETINS.
i-12.
Important
changes
in
part
numbers,
inter-
changeability
of
parts,
urgent
inspection,
man-
datory
replacements
and
modernization infor-
mation
are
among
the
subjects
of
limited
interest
and
duration
covered
by
factory
Service
Bulletins,
which
are
distributed
to
all
Approved
Distributors
of
aircraft
engines
and
parts
and
are
available
for
study
at
their
offices.
Service Bulletins
of
interest
to
aircraft
owners,
operators
and
maintenance
personnel
may
be
obtained
by
direct
mail
on
an
annual
subscription
basis.
The
charge
for this
service covers
only postage
and
handling.
i-13.
SERVICE
REPORTS
AND
INQUIRIES.
i-14.
It is
the
policy
of Teledyne
Continental
Motors
to
handle
all
reports
of
service
difficulty
and
requests
for
information
through
Approved
Distributors.
These
facilities
are
constantly
in
touch
with
operation
and repair.
You
will
find
them
more
than
willing
to
help
solve
your
maintenance
problems
and
well
equipped
with
experience
and facilities
to
perform
any
necessary
maintenance
work
on
Teledyne
Continental
aircraft
engines.
There
is
an
Approved
Distributor
at
most
major
airports.
i-1.
COMPOSITION.
i

CHAPTER
A
(BASIC)
TABLE OF CONTENTS
Section
Forew ord ..... . . . . . ....... .
i-1.
COMPOSITION
...........
i-9.
AVAILABILITY ...........
i11.
SERVICE
BULLETINS.......
i-13. SERVICE
REPORTS
........
I
INTRODUCTION
1-1.
Scope
........... .
1-3. Difference Data
Sections...
1-5.
Related Manuals
.......
1-6
Definition
of
Terms.....
1-7
Cylinder Arrangement
....
1-9
Aircraft
Engine
Nameplates
1-8
Definitions
and Abbreviations
Page
i.
A-1-1
A-1-1
A-1-1
A-1-1
A-1-1
A-1-1
A-1-1
A-1-2
II. SPECIFICATIONS,
LIMITS AND
CHARTS
A-2- 1
III
GENERAL
DESCRIPTION
3-1.
Construction
.. .. . . .
3-2. Functional
Systems
.........
IV ILLUSTRATION
S
A-3-1
A-3-1
A-3-2
A-4-1
V
SPECIAL TOOLS
AND
EQUIPMENT
A-5-1
VI
UNPACKING AND
PREPARATION
FOR SERVICE,
STORAGE
OR SHIPMENT
6-1. Unpacking
...................
6-2.
Preparation
for Service
.............
6-3.
Preparation
for Storage
............
VII DISASSEMBLY
7-1 Aircraft
Parts and
Accessories
7-2
7-3
74
7-5
7-6
7-7
7-8
7-9
7-10
7-11
7 12
7-13
7-14
7-15
7-16
7-17
7-18
Extent
of
Disassembly
.........
Parts
to be
Discarded
..........
Disassembly
Stand ...........
Preliminary
Cleaning ..........
Ignition
System ............
Fuel Injection
System
.........
Induction
System ...........
Magneto and
Accessory Drives.
Oil
Sump ................
Oil
Cooler ....... .. . . . .. .
Alternator
Assembly ..........
Starter and
Starter Drive Adapter..
Oil
Pump Assembly ..........
Cylinders and
Pistons.........
Crankcase .. . . . .. . .. . .. ..
Camshaft
Assembly ..........
Crankshaft Assembly
..........
A-6-1
...
. . . . .A-6-1
...
. .. . .A-6-1
...
. .. . .A-6-1
A-7-1
...
. .. . .A-7-1
...
. .. . .A-7-1
...
. .. . .A-7-1
...
. .. . .A-7-1
...
. .. . .A-7-1
...
. .. . .A-7-1
...
. .. . .A-7-1
...
. .. . .A-7-2
...
. .. . .A-7-2
...
. .. . .A-7-2
.
...... A-7-2
.
...... A-7-2
.
...... A-7-2
.
...... A-7-3
.
...... A-7-3
.
...... A-74
.
...... A-7-5
.
...... A-7-5
ii
....

CHAPTER A TABLE OF CONTENTS (continued)
Section Page
VIII CLEANING PARTS
A-8-1
8 1 Materials and Processes.
...............................
A-8-1
8-2 Specific Parts.
....................................
A-8-1
8-3 Valves. .......................................
A-8-1
8-4 Cylinders. ......................................
A-8-1
8-5 Pistons. .......................................
A-8-2
8-6 Crankshaft. ..................................... A-8-2
8-7
Crankcase. .....................................
A-8-2
8-8 Ball Bearings.
...................................
A-8-2
IX INSPECTION
A-9-1
9-1 Definition of Terms .. .. ... ..... .. .. .. .. .... . ... . .. .. A 9-
9-2 Protection from Corrosion. ............................. A-9-1
9-3 Visual Inspection. ..................................
A-9-1
9-4
Magnetic Particle Inspection. ............................
A-9-2
9-5
Fluorescent Particle Inspection. ..........................
A-9-2
9-6 Dimensional Inspcction. ...........................
A-9-2
9-7 Protective Coating.
.................................
A-9-2
9-8 Application of "Alodine
1200".............................A-9-2
9-9 Repair of "Alodized"
Surfaces . . . . ........................
A-9-3
9-10 Enamel
Coatings. ..................................
A-9-3
9-11
Specific Inspections. ................................
A-9-3
9-12
Crankcase. .....................................
A-9-3
9-13 Crankshaft and
Propeller Driveshaft. ........................
A-94
9-14 Crankshaft
and Counterweight Bushings. ...................... A-94
9-15 Camshaft.
......................................
A-9-5
9-16 Connecting Rods. ..................................
A-9-5
9-17 Gears.
........................................
A-9-5
9-18 Pistons and Rings. .............. .................
A-9-5
9-19 Cylinders. ...................................... A-9-5
9-20 Hydraulic
Valve Lifters. ..............................
A-9-6
9-21 Intake Tubes. ....................................
A-9-6
9-22 Lubrication System.
................................
A-9-6
9-2 3 Fuel Injection System.
...............................
A-9-6
9-24
Ignition System. .................................
A-9-6
X
REPAIR AND REPLACEMENT
A-10-1
10-1 Castings. ......................................
A-1b-1
10-2
Stud Replacement. .................................
A-10-1
10-3 Helical
Coil Insert Installation. ...........................
A-10-1
104 Cylinders. ...................................... A-10-2
10-5 Crankshaft Assembly.
................................
A-10-3
10-6 Idler Gear. .....................................
A-104
10-7 Magneto
and Accessory Drive Adapter Assembly.
................. A- 10-4
10-8
Tachometer Drive Housing. .............................
A- 10-4
10-9 Starter Drive
Adapter. ...............................
A-1 0-4
10-10 Oil Pump Assembly.
................................
A-1O0-4
10-11 Ignition Cables. ...................................
A-10-4
10-12 100% Replacement Parts At Normal
Major Overhaul. ................
A-10-5
iii

CHAPTER A TABLE
OF CONTENTS (continued)
Section
XI ASSEMBLY OF SUBASSEMBLIES
11-1
New Parts .. . . . . ..... .
11-2 Tightening
Torques ..................
11-3 Final
Cleaning .....................
11-4 Lubrication . . ... . . . . . . . . . . . . . . .. .
11-5 Oil Pump Assembly ..................
11-6 Starter Adapter
Assembly ..............
11-7
Cylinders ........................
11-8 Piston and Ring Assemblies ..............
11-9 Pushrod Housings ...................
11-10 Crankshaft and Connecting Rods...........
11-11 Camshaft
........................
11-12 Alternator Assembly
..................
11-13 Crankcase .......................
11-14 Fuel Injection Control and Air Throttle Body Assembly
O il Cooler .......................
XII FINAL ASSEMBLY
12-1
General Instructions....
12-2
Crankcase .........
12-3 Crankshaft Assembly....
12-4 Camshaft Assembly ....
12-5
Propeller Shaft .......
12-6 Crankcase Reassembly...
12-7 Cylinders ..........
12-8 Oil Pump ..........
12 9 Starter Adapter ......
1 2-1 0 Alternator Assembly....
12-11 Oil Cooler.........
12-12 Magneto
and Accessory
Drive
12-13 Oil
Sump
.
12-14
Induction
System .....
12-15 Fuel Injection System ...
12-16 Magneto Drive Gears....
12-17
Placing Crankshaft
in Timing
12-18 Magnetos ..........
12-19 Ignition
Harness ......
12-20 Fuel Lines .........
12-21 Final Parts .........
Adapters
Position
XIII REPAIR AND TESTING OF ACCESSORIES
13-1 Hydraulic Valve Tappets .. ..
13-2 Disassembly .. . . . . .
13-3 Cleaning and Inspection........
13-4 Testing ................
13-5 Reassembly ..............
13-6 Oil
Cooler ...............
13-7 Testing ................
13-8 Lubrication ..............
13-9 Accessories ..............
iv
Page
A-11-1
A-1 1-1
A-11-1
A-1 -
A-1 1-1
A-11-1
A-1 12
A-1 1-2
A-1 1-3
A1 13
A-11-3
A-1 1-4
A-1 1
A-1 1-4
A-
11-4
A- 114
A- 12-1
A-12-1
A-12-1
A-12-1
A-12-1
A-12-1
A-12-2
A-12-3
A-12-4
A-12-4
A-12-4
A-12-5
A-12-5
A 12-5
A-12-5
A-12-6
A-12-6
A-12-6
A-12-6
A-12-7
A-12-7
A-12-7
A-13-1
. A13-1
A-13-1
A-13-1
A-13-2
A 13-2
A-13-3
A-13-4
A-134
A-134

CHAPTER
A TABLE
OF CONTENTS
(continued)
Section
Page
XIV
TESTING
AFTER
OVERHAUL
A- 14-1
14-2
Test
Equipment
....................
A-14-1
14-3
Engine
Test
After
Overhaul. ...........................
A-14-2
14-4
Starting
Procedure
...... ............
A-14-2
14-5
Preservation.
.....................................
A-14-2
14-6
Engine
Run-In
After
Top Overhaul
Of
One Or
More
Cylinders.
...........
A-14
3
CHAPTER A
LIST
OF ILLUSTRATIONS
Figure
No.
Title
Page
A-4-1
Cylinder Numbering
Diagram
...........................
A4-1
A-4-2
Three-Quarter
View
GTSIO-5
20-C.
.......................
A4-2
A4-3
Three-Quarter
View
CTSIO-520D
....................... ..
A-4-2
A4-4
Three-Quarter
View
CTSIO-5
20-H
........................
A4-3
A-4-5
Three-Quarter
View
GTSIO-5
20-K.
.......................
A-4-3
A4-6
Three-Quarter
View
GTSIO-520-L........................
A4-4
A4-7
Three-Quarter
View GTSIO-520-M.
.......................
A44
A-4-8
Gear
Train
Diagram
................................
A-4-5
A-4-9
Lubrication
System
Diagram.
..........................
A4-6
A4-10
Cutaway
View
of Hydraulic
Valve
Lifter.
....................
A4-7
A4-1 1
Magneto and
Accessory
Drives
..........................
A4-8
A-4-12
Oil Sump.
....................................
A-4-9
A-4-13
Alternator
Assembly. ..............................
A-4-1
0
A4-14
Oil
Cooler.
....................................
A-4-1
1
A.4-15
Starter
Adapter
..................................
A4-12
A4-16
Oil
Pump Assembly.
...............................
A-4-13
A4-17
Cylinder
and Piston
Assembly.
..........................
A-4-14
A4-18
Crankcase Assembly.
...............................
A-4-15
A4-19
Camshaft
Assembly.
...............................
A-4-17
A-4-20
Crankshaft
Assembly. ..............................
A-4-18
A-4-2
1
Stud Location.
..................................
A-4-19
A-4-22
Inspecting
Ring
Side
Clearance. ........................
A-4-19
A-4-2
3
Cylinder
Machining
Dimensions. .........................
A-4-20
A-4-24
Installing
Typical
Helical
Coil
Insert.
.......................
A-4-2
1
A-4-2
5 Installing
Spark
Plug Hole
Helical
Coil
Insert. ..................
A-4-21
A-4-26
Expanding
Spark Plug
Hole
Helical
Coil
Insert.
.................
A-4-2
1
A-4-27
Removing
Spark
Plug Hole
Helical
Coil
Insert.
..................
A-4-2
1
A4-28
Valve
Rocker
Bearing
Dimensions.
........................
A-4-2
1
A-4-29
Connecting
Rod
and
Bushing
Dimensions
and
Installation.
...........
A-4-2 2
A4-30
Counterweight
with
Oversize
Bushings.
.....................
A-4-2
3
A4-31
Installing
New
Starter
Adapter
Needle
Bearing.
.................
A-4-23
A-4-32
Exploded
View
of Ignition
System.
.......................
A-4-24
A4-33
Alternator
Drive
Gear
Installed.
.........................
A-4-26
A-4-34
Valve
Spring
Installation.
............................
A-4-26
A-4-
35
Alignment of
Timing
Marks.
...........................
A-4-26
A-4-36
Checking Rocker
Arm
Clearance.
........................
A-4-26
A-4- 37
Installing
Cylinder
Baffles.
............................
A-4-26
June
1980
v

CHAPTER
A LIST OF
ILLUSTRATIONS
(continued)
Figure
No.
Title
A-4-38
Torquing
Sequence .........................
A-4-39
Installing Cylinder..........................
A-4-40
Timing
Marks
...........................
A-4-41
Installing
Oil Seal
on Prop
Drive
Shaft Gear
................
A442
Prop Drive
Shaft
Gear and
Oil
Seal Installed
with
Retaining
Ring
and Spring
in Cavity
.. .. . ......... . .
A-4-43
Wiring
Diagram....................................................
A-5-1
Borrough's Cylinder
Base Nut
Wrenches.................
A-5-2
Starter
Adapter
Bearing
Installer....................
A-5-3
Piston Ring
Compressor
.......................
A-5-4
Push Rod
Spring
Compressor.
...................
A-5-5
Valve Lifter
Bleed
Down Tester
....................
A-5-6
Schematic
Diagram
of a
Differential
Pressure
Tester
............
A-5-7
Engine
Transportation
Stand .....................
A-5-8
Valve
Spring Compressor.......................
CHAPTER
B (TABLE
OF LIMITS)
LIST
OF TABLES
Table No.
1
2
3
4
5
6
7
8
9
10
11
12
Table of Limits......................
Tightening
Torques....................
General
Use -Tightening
Torques...............
Pipe Plugs
.......................
Magnetic
Particle Inspection...............
Critical
New
Parts Dimensions ...............
Inspection
Chart
.....................
Standard
and Oversize
Stud
Identification
...........
Stud Setting
Heights....................
Helical Coil
and Special
Tool Data ..............
Crankshafts
and Crankcases.................
Table
of Lubricants
....................
Page
A-4-2 7
A-4-27
A-4-28
A-4- 29
A-4-29
A-4-3 0
A-5-2
A-5 -2
A-5-2
A-5-2
A- 5-2
A-5-3
A-5-3
A-5-3
Page
B-1
B-9
B-9
B-10
B-11
B-
12
B-14
B-24
B-2 5
B-26
B-26
B-2
7
CHAPTER
B
LIST OF
ILLUSTRATIONS
Figure No.
B-1
B-2
B-3
B-4
B-
5
TITLE
LIMITS
CHART
(Chart
1) ............
LIMITS
CHART
(Chart
2) ............
LIMITS
CHART
(Chart
3)............
LIMITS
CHART
(Chart
4) ............
CRANKCASE
STUD
HEIGHTS
..........
vi
Page
B-5
B-6
B-7
B-8
B-24
. . . . . . . . . .
. . . . . . . . . .
. . . . . . . . . .
. . . . . . . . . .
. . . . . . . . . .
. . . . . . . . . .
. . . . . . . . . .
. . . . . . . . . .
. . . . . . . . . .
. . . . . . . . . .
....................
....................
....................
....................
....................

CHAPTER
C (DIFFERENCE
DATA)
TABLE OF
CONTENTS
Section
Page
1. DIFFERENCE
DATA SECTION
FOR THE MODEL
GTSIO-520-C
C-1-1
General Information
...............-.............
C-1-2
Detail Engine
Specifications ........................
C-1-2
Operating
Test
Limits
...........................
C-1-4
Major
Overhaul
Test Run..........................C-i-5
Start Oil
Consumption
Determination
C-1-5
Fuel Injection
System
...........................
C-1-6
Cleaning,
Inspection and
Repair .......................
C-1-6
Reassembly................................C-1-6
Induction
System.............................C-1-6
Cleaning,Inspection
and Repair
........................
C-1-7
Reassembly...............................
C-1-7
Crankcase ................................
C-1-7
Magneto
and Accessory
Drives........................C-i-7
Cleaning,Inspection
and
Repair........................C-1-7
Reassembly
...............................
Cx1-7
Turbocharger
Oil Inlet
Adapter
.......................
C-1-
Improved
Valve Stem
and Guide
Q
C-1-
II.
DIFFERENCE
DATA
SECTION
FOR
THE MODEL
GTSIO-520-D
C-2-1
General
Information
..............................
C-2-2
Detail
Engine Specifications ........................
C-2-2
Operating
Test Limits...........................C-2-4
Major Overhaul Test
Run .........................
C-2-5
Start
Oil Consumption
Determination.....................C-2-6
Fuel
Injection
System...........................C-2-6
Disassembly...............................C-2-6
Cleaning,
Inspection
and Repair
.......................
C-2-6
Reassembly...............................C-2-6
Induction
System
............................
C-2-7
Disassembly...............................C-2-7
Cleaning,Inspection
and Repair........................C-2-7
Reassembly...............................C-2-7
Turbocharger
Oil Inlet Adapter.......................
C-2-7
Improved
Valve
Stem
and Guide
Lubrication..................C-2-7
III. DIFFERENCE
DATA SECTION
FOR
THE
MODEL
GTSIO-5
20-H C-3-1
General
Information
...........................
C-3-2
Detail Engine
Specifications ........................
C-3-2
Operating
Test Limits...........................C-3-4
Major
Overhaul Test
Run..........................C-3-5
Start
Oil Consumption
Determination.....................C-3-5
Fuel
Injection
System...........................C-3-6
Disassembly...............................C-3-6
Cleaning,
Inspection
and
Repair .......................
C-3 -6
Reassembly...............................C-3-7
Induction
System
............................
C-3-7
Disassembly...............................C-3-7
Cleaning,Inspection
and
Repair .......................
C-3-7
vii

CHAPTER C TABLE
OF CONTENTS
(continued)
Section
Page
III CONTINUED
Reassem bly...............................C
3-7
Improved
Valve Stem and Guide.......................C-3-7
Turbocharger Oil
Inlet Adapter .......................
C-3-8
IV.
DIFFERENCE
DATA
SECTION FOR
THE MODEL GTSIO-5
20-K
C-4-1
General Information...........................CA4-2
Detail Engine
Specifications ........................
C-4-2
Operating Test
Limits...........................C-4-4
Major Overhaul
Test Run
.........................
C-4-5
Start
Oil Consumption
Determination.....................C-4-5
Exhaust
Assembly............................
C4-6
Removal
and Disassembly.........................
C4-6
Assembly and
Installation .........................
C-4-6
Hot
Prime Equipment...........................C-4-6
Removal
and Disassembly.........................
C4-6
Assembly
and
Installation .........................
C4-6
Induction
System .............................-
4-6
Removal and Disassembly
.......................... 4-6
Assembly
and Installation
.........................
C-4-7
Oil Sump...............................
C4-47
Removal and
Disassembly
..........................-
4-7
Assembly
and Installation
.........................
C4-7
Oil Cooler
................................- 4-7
Removal
and Disassembly.........................CA4-7
Assembly and
Installation
.........................
C-4-7
Oil Pump Assembly
............................
-4-7
Removal
and Disassembly
..........................-
4-7
Assembly
and Installation
.........................
C-4-7
V. DIFFERENCE
DATA
SECTION FOR
THE MODEL
GTSIO 520-L C-5-1
General Information
............................-
5-2
Detail
Engine Specifications .........................-
5-2
Operating
Test Limits
...........................
2-5-4
Major
Overhaul Test Run
.........................
C-5-5
Start
Oil Consumption
Determination.....................C-5-5
Induction
System ............................
C-5-6
Cleaning, Repair
and Replacement
......................
-5-6
Reassembly...............................C-5-6
Fuel Injection
System...........................C-5-6
Cleaning,
Inspection and
Repair ......................
C-6
Reassembly ...............................
-5-6
VI.
DIFFERENCE
DATA
SECTION FOR
THE MODEL
GTSIO-520-M
C-6-1
General Information............................C-6-2
Detail
Engine
Specifications ........................
C-6-2
Operating
Test Limits ...........................
-6-4
Top
or Minor
and Major Overhaul
Test Run
...................-
6-5
Start
Oil Consumption
Determination
.....................
C-6-5
Induction System
............................
C-6-6
Viii

CHAPTER
C TABLE
OF CONTENTS
(continued)
Section
Page
VI
CONTINUED
Cleaning, Repair
and Replacement......................C-6-6
Reassembly...............................C-6-6
Fuel
Injection
System...........................C-6-6
Cleaning,
Inspection
and Repair.......................C-6-6
Reassembly...............................C-6-6
VII.
DIFFERENCE
DATA
SECTION FOR
THE MODEL
GTSIO-520N
C-7-1
General
Information
.............................
C-7-2
Detail
Engine
Specifications..........................C-7-2
Operating
Test Limits
............................
C-7-4
Special Test
Items Required
or Equivalent
...................
C-7-5
Major
Overhaul
Test Run...........................C-7-6
Start Oil
Consumption
Determination
.....................
C-7-6
Inducation
System..............................C-7-7
Cleaning,
Repair and
Replacement.......................C-7-7
Reassembly.................................C-7-7
Fuel
Injection
System ............................
C-7-7
Cleaning,
Inspection
and Repair........................C-7-7
Reassembly
.................................
C-7-7
Fuel
Injection
Adjustment
Procedures....................C-7-18
CHAPTER
C
LIST OF
ILLUSTRATIONS
Figure
No.
Title
Page
C 11
Fuel Injections
System
(GTSIO-520
C) ....................
C-1-9
C- 12
Induction
System
(GTSIO-520-C) ......................
C-1-10
C- 1-3
Crankcase
Assembly
(GTSIO-5
20-C) .....................
C-1-11
C-1-4
Magneto
and Accessory
Drives
(GTSIO-520-C)
.................
C-1-12
C-1-5
Fuel Manifold
Valve Fitting
Location
(GTSIO-520-C)
..............
C-1-13
C-1-6
Control
Valve
Fitting
Locations
(GTSIO-520-C).................C-1-14
C-1-7
Fuel
Pump Fitting
Locations
(GTSIO-520-C)..................C-1-15
C-1-8
Cran
kcase
Stud Setting
Heights
.......................
C-1-16
C-2-1
Fuel Injections
System
(GTSIO-520
D) ....................
C-2-9
C-2-2
Induction
System
(GISIO-520-D)
......................
C-2
-10
C-2-3
Fuel Manifold
Valve
Fitting
Locations
(GTSIO-520-D) ..............
C-2-11
C-2-4
Control
Valve Fitting
Locations
(GTSIO-5
20-D).................C-2-12
C-2-5
Fuel Pump
Fitting
Locations
(GTSIO-520-D)..................C-2-13
C-3-1
Fuel Injection
System
(GTSIO-5
20-H)
....................
C-3-9
C-3-2
Induction
System (GTSIO-520-H)
......................
C-3-11
C-3-3
Control
Valve
Fitting
Locations
(GTSIO-520
H).................C-3-12
C-3-4
Manifold
Valve Fitting Locations
(GTSIO-520-H)
................
C-3-13
C-3-5
Fuel
Pump
Fitting
Locations
(GTSIO-5
20-H)..................C-3-14
C4-1
Exhaust
Assembly
(GTSIO-520-K).
.~....................C4-8
C4-2
[lot Prime
Equipment
(GTSIO-5
20-K)....................
C4-9
C4-3
Fuel Injection
System
(GTSIO-520-K)....................
C4-10
C-4-4
Induction
System
(GTSIO-520-K) ......................
C4-11
C-4-5
Oil
Sump(GTSIO-5 20-K).........................
C4-13
MARCH 1981 ix

CHAPTER
C LIST OF
ILLUSTRATIONS
(continued)
Tide
Oil Cooler
(G'TSIO-5
20-K)...........
Oil Pump
Assembly(GTSIO-520-K)
.......
Crankcase
Stud Setting
Heights
(G'TSIO-520-K)
..
Fuel
Pump
Fitting
Locations(GTSIO-5
20-K)....
Fuel
Manifold
Fitting
Locations
(GTSIO-5 20-K)..
Air Throttle
&
Controller Fitting Locations
(K)
...
Induction
System
(GTSIO-520
L) ........
Fuel Injection
System
(GTSIO-520L)
......
Manifold
Valve Fitting Locations
(GTSIO-5
20-L) ..
Control
Valve Fitting
Locations (GTSIO-520-L)...
Fuel Pump
Fitting
Locations
(GTSIO-520-L)....
Crankcase
Stud
Setting
Heights
(GTSIO-5
20
M).
Induction
System
(GTSIO-520-M)........
Fuel
Injection
System (GTSIO-520-M)
......
Manifold
Valve
Fitting
Locations
(GTSIO-520-M)
Control
Valve
Fitting
Locations
(GTSIO-520-M)
Fuel Pump
Fitting
Locations
(GTSIO-5
20-M)....
Crankcasc
Stud
Setting
Hcights(GTSIO-520-M) ...
Page
.. .......... .
.C
-4-14
.. .......... .
.C
-4-15
.. . . ... . ... . .
.C-4-16
.. ......... . .
.C-4-17
.. ...........
.C-4-18
.. ....... . ....
C4
-19
.. . . ..... . . . .
.C-5-8
.. . . .........
.C-5-9
.. . ..........
.C-5
10
..............
C-5-1
1
.. . . .........
.C-5-12
.............
C-513
.. . . ....... . .
.C-6-8
.. . . ....... . .
.C-6-9
.. . .... .. ....
.C-6-1
0
.. . . . .. . . ....
.C-6-11
. .. . . .... .. . . ... . . . . .
C -6-12
.. .... . .. . ...
.C-6-13
Induction
System
(GTSIO-520-N)......................C-7-9
Fuel
Injection
System
(GTSIO-520-N)
...................
C-7-10
Manifold
Valve
Fitting
Locations
(GTSIO-520-N)...............C-7-11
Fuel
Control
Fitting
Locations
(GTSIO-520-N)
...............
C-7-12
Fuel Pump
Fitting
Locations
(GTSIO
520-N)
................
C-7-13
Crankcase
Stud Setting
Heights
(GTSIO-520-N)...............C-7-14
Fuel
Flow
Limits
(GTSIO-520-N)......................C-7-15
100%
Power
Fuel Pump
Pressure
Limits
(GTSIO-520-N)...........C-7-16
Meterer
Fuel
Pressure
vs. Fuel
Flow
(GTSIO-520-N).............C-7-17
x
MARCH
1981
Figure No.
C-4-6
C-4-7
C-4-8
C-4-9
C-4-10
C-4-11
C-5-1
C-5-2
C-5-3
C-5-4
C-5-5
C-5 -6
C-6-1
C-6-2
C-6-3
C-6-4
C-6-5
C-6-6
C-7-1
C-7-2
C-7-3
C-7-4
C-7-5
C-7-6
Graph No.
C-7-1
C-7-2
C-7-3

SECTION
I
INTRODUCTION
1-1.
SCOPE.
1-2.
This
Chapter
comprises
the overhaul
in-
structions
for
a hypothetical
GTSIO-520 engine,
hereafter
referred
to
as the
"basic" engine. This
is a 6
cylinder
horizontally
opposed,
geared,
turbo-
charged,
fuel
injected,
air
cooled,
4
cycle
engine
manufacturered
by Teledyne
Continental
Motors,
Aircraft
Products
Division, Mobile,
Alabama.
1-3.
DIFFERENCE
DATA SECTIONS.
1-4.
Sections
I thru
XIV
of this
manual
contain
overhaul
instructions
for
the
basic engine.
Overhaul
and
test
instructions
for specific
models
are
pro-
vided
in
the latter
sections
by
the use
of Difference
Data
Sections.
1-5.
RELATED
PUBLICATIONS.
Detail
part
numbers
and
service
assemblies
for
this engine
are
contained
in
Parts
Catalog
X-30046A.
Operating
instructions
are
contained
in Operator's
Handbooks
as
follows:
GTSIO-520-C,
X-30047;
GTSIO-520-D,
X-30079,
GTSIO-520-F,
X-30128,
GTSIO-520-H, X-
30129,
GTSIO
520-L,
X 30532,
GTSIO-520-M,
X-
30533,
and
GTSIO-520-N,
X-30551.
a.
Service
instructions
for
the
Prestolite
Starter
and
Alternator
may be
obtained
from the
Prestolite Company,
Division
of Eltra
Corporation,
51 1
Hamilton Street, Toledo,
Ohio
43601.
b.
Service
instructions
for
the
Bcndix
Magnetos may
be obtained
from
Bendix
Electrical
Components
Division,
Sidney,
New
York
13838.
C.
Service
instructions
for the
Delco-Remy
Starter
and
Alternator
may
be
obtained
from
Delco-Remy
Division, General
Motors
Corporation,
Anderson, Indiana.
1-6.
DEFINITION
OF TERMS.
Front,
rear,
left
and
right,
as
used
in this
manual,
refer
to
the
engine
as
viewed
by
the
mechanic
in
a normal
position,
facing the
accessory
end.
1-7.
CYLINDER
ARRANGEMENT.
Cylinders
are
numbered
starting from
the
rear,
with odd
numbers
on
the right
and
even
numbers
on the
left.
1-8.
AIRCRAFT
ENGINE NAMEPLATES.
BEFORE Teledyne
Continental
Motors
can
issue
anyone
a new
nameplate,
the
person involved must
first
contact
his local
FAA
office
and
obtain
approval
from
them
in
accordance
with FAR
Part
45,
Section 45.13
(b).
In
addition,
if the
old
nameplate
has
been
lost,
it
will
be
necessary
to supply
a notarized
statement
to that effect,
giving
the
engine
model
and
full
serial
number
along
with the
evidence
of
FAA
approval.
The old
nameplate
(when
available)
must
be
submitted
to TCM
along
with
evidence
of FAA
approval,
and
a remittance
in
the
amount
listed
in
current
price
list
to cover
costs
involved
in
the
handling,
stamping
and
mailing
of
a
new,
permanently-stamped
nameplate.
Because
we did
not,
in
all cases,
make
it
mandatory
in
the
past,
we wish
to
emphasize
that
a nameplate
wll
not
be supplied
at
the request
of anyone
unless
the
remittance
is received
with
the request.
All
request,
along
with
the
correct
remittance,
should
be
sent
to
the following address
to expedite
shipment:
Teledyne Continental
Motors
Attn:
Service
Department
P. 0.
Box
90
Mobile, Alabama 36601
OCTOBER
1980
A-1-1

If, for
any reason,
it
becomes
necessary
to
check
on
the
status
of your nameplate,
call (205)
438-34
11
and ask
for "Service
Department,"
or address
your
inquiry
to
the Mobile
address
given
above
specifying
"Attn:
Service
Department."
1-
9. DEFINITIONS
AND
ABBREVIATIONS
Term Explanation
After
Bottom
Center
Approximately
After Top Center
Barometric
Before
Bottom
Center
Brake
Horsepower
Before
Top Center
Federal
Aviation
Administration
Cubic
feet per
minute
Center of Gravity
Diameter
Degrees
of
Angle
Degrees
Fahrenheit
Figure
(Illustration)
Propeller End
Foot or feet
Gallons per
minute
Water
Mercury
Inside
Diameter
Term
Explanation
in.(");
Inches
Hex.;
Hexagon
hr.:
Hour
Left Side: Side
on which
No's
2,
4 and
6
cylinders
are
located
Lbs.:
Pounds
Lock
Wire:
Soft
steel
wire
used to
safety
con-
nections,
etc.
Man.:
Manifold
or manometer
Max.:
Maximum
Min.:
Minimum
3 0':
Thirty
minutes
of
angle
(60' equal
one degree)
N.P.T.:
National
pipe
thread (tapered)
N.C.:
National
Coarse
(thread)
N. F.:
National
Fine (thread)
O.D.:
outside
Diameter
Press.:
Pressure
pS.i.: Pounds
per square
inch
Rear:
Accessory
end of
engine
Right
Side:
Side on
which No.'s
1,3 and
5
cylinders
are located
R. P.M.:
Revolutions
per minute
Std.:
Standard
T.D.
C.:
Top dead
center
Temp.:
Temperature
Torque: Force
x lever
arm
(125
ft. -
lbs.
torque
= 125
lbs. force
applied
one
ft. from bolt
center or 62-1/2
lbs.
applied
2 ft. from center)
A.B.C.:
Approx.:
A.T.C.:
Bar.:
B.B.C.:
B.T.C.:
F.A.A..:
c.f.m.:
Dia.:
0
F:
Fig.:
Front:
ft.:
G.P.M.:
1120:
Hg.:
A-1-2
MARCH
1981

PURCHASED
ACCESSORIES
TMEAUELMT
Accessory
Qty.
Controller................... 1
Regulator
Assembly, Fuel
Pressure...... 1
Magneto. ................... 2
Starter..................... 1
Alternator................... 1
Turbocharger................. 1
Oil
Cooler
................... 1
Intercooler.................. 1
Fuel Pump
.1.......... .
Spark
Plugs.
.................
12
IGNITION
SYSTEM
DETAILS
Feature
Value
Left
magneto
fires
lower
No.
1, 3, 5
and
upper
No.
2,
4,
6 plugs.
Right magneto
fires
upper
No.
1, 3, 5
and
lower
No.
2,
4,
6 plugs
Firing
order
(cylinder
numbers)
1-4-
5-2-3-6
Indicated
Condition
Minimum
Maximum
Oil
temperature
at
take-off
Oil
temperature
Cylinder
head
temperature
(bayonet thermocouple)*
Magneto
temperature
(at
coil
hold-down
screw)
75F
-
-
240
0
F
-
460
0
F
-
170F
*
Installed
in tapped
holc
in bottom of
cylinder
hcad. Applicable
only
with downdraft
cooling system.
PRESSURE
LIMITS
Indication
Minimum Maximum
Oil
pressure (idling)
10
psi
-
Oil
pressure
(in
flight)
30
psi
60
psi
Oil
pressure
(
with
cold
oil)
-
100
psi
OIL
VISCOSITY GRADES
Airport
Ambient
Air
Temperature
S.A.E.
Grade
CHARACTERISTICS
AND DIMENSIONS
Dimension
Va
Piston
strokes
per
cycle........
Number
of cylinders
.........
Cylinder
bore
(in.)..........
Piston
stroke
(in.)
.........
All
Temperatures
due
Or
if Temperatuers
Are:
4
Below
400
F.
6
Above 400
F.
15W
- 50,
20W
-
50
30
or
10W
-
30
50
5.25
4
Ambient
Air
Temperature
(Sea
Level)
June
1980
A-2-1/A-2-2
TEMPERATURE
LIMITS

SECTION
III
GENERAL DESCRIPTION
3-1.
CONSTRUCTION.
a.
GENERAL.
The
arrangement
and
appearance
of
engine
parts
and
components
are
illustrated
in
Section
IV,
Chapter
A.
Additional
information
will
be found
in
the
Limits
and
Lubrication
Charts.
b.
CRANKCASE.
Two
aluminum
alloy
cast-
ings
are joined
along
the
vertical
center
plane
to
form
the
complete
crankcase.
The
individual
cast-
ings
(with
studs
and
inserts)
will
be referred
to as
the "left
crankcase"
and
the
"right
crankcase"
throughout
this
publication.
1.
Bosses
molded
in the
crankcase
castings
are
line
bored
in
the assembled
castings to
form
bearings
for
the
camshaft
and
seats
for
the
pre-
cision,
steel-backed, lead-alloy
lined
crankshaft
main
bearing
inserts.
Provision
has
been
made
in
the
crankcase
halves
at the
top
front
to support
the
propeller
driveshaft.
Precision
guides
are
bored
through
lateral
bosses
for
the
tappets
and
for
the
governor
drive
shaft.
A needle
bearing
is
pressed
into
the
right
crankcase,
to
the
right
of the
rear
main
bearing,
to
support
the
front
end
of
the
starter
shaftgear.
2.
Cylinder
mounting
pads
on
the left
crank-
case
are
further
forward
than
the
corresponding
pads on
the
right
crankcase
to permit
each
con-
necting
rod to
work
on
a separate crankpin.
Each
pad
has
six studs
and
two through
bolts
for
attaching
cylinder
base
flanges.
The
governor
mount
pad
is located
on
the
side
of the
left
crankcase
at
the
lower
front
corner.
The
alternator
pad is
located
on
the
right
crankcase
at the
front.
3.
The
crankcase
interior is
ventilated
by
a
breather
consisting
of a
tube
and
baffle
assembly
with
a side
extension
for
hose
attachment.
The
breather
assembly
is pressed
into
the
upper left
crankcase.
C.
CYLINDERS.
The
aluminum
alloy
heads
are
heated
and
valve
seats and
guides
are
installed
prior
to the
head
being
screwed
and
shrunk
onto
the steel
alloy
barrel
to make
the
permanent
head
and
barrel
assembly.
Valve
guides
are
then
reamed
to
specific
diameters.
Special
18mm helical
coil
thread
inserts
are
installed
in upper
and
lower
spark
plug
holes.
Exhaust
valves
are
faced
with
a
special
heat
and
corrosion-resistant material.
The
solid
valve
stem tips
are hardened.
The
outer
valve
spring
retainers
are
locked
to
the stems
by tapered,
semi-circular
keys which
engage
in
the
stem
grooves.
Valve
rocker
covers are
stamped
sheet
steel
cadmium
plated.
Rocker
shafts
are
fully
machined,
chrome
plated
steel.
The
rocker
shafts
are
held
in
place
by
screws
in
the
cylinder
rocker
bosses.
Valve
rockers
are steel
forgings
with
pressed-in
bronze
bushings,
hardened
pushrod
sockets
and
rocker
faces.
Pushrods
are
composed
of
steel
tubes
and
pressed
in, hardened,
forged
steel
ball ends
which
are
center
drilled
for
oil
passages.
The
pushrod
housings
are
beaded
steel tubes.
The
bead
at the
cylinder
end retains
a washer
and
seal
ring. The
bead
at the crankcase
end
retains
a
heavy
spring,
washer,
seal
ring
and
a second washer.
d.
VALVE
MECHANISM.
Oil
fed
to
hy-
draulic
valve
lifters,
under
pressure
from
the
crankcase
main
galleries,
is divided
between
the
overhead
system,
the
lifter
guide
surfaces
and
the
reservoirs inside
the
lifters.
The
oil
which reaches
the
pushrod
ends
is
forced
through
the pushrods
to
the
drilled
rockers
and
the groove
between
their
bushings.
Each
valve
rocker
directs
a
portion
of
its
oil,
through
a
nozzle,
towards
the
respective
valve
stem.
The
oil
spray
from
the
rockers lubri-
cates
the valve
stems
and springs.
Oil
is returned
to
the
crankcase
through
the
pushrod
housings
which
are
sealed
to cylinder
heads
and
crankcase
by
rubber
seals.
Drain
holes
in
valve
lifter
guides
direct
the
returning
oil
to the sump.
e.
CRANKSHAFT.
The
six-throw
steel
alloy
forging
is machined
all
over
except
for
some
sur-
faces
of
the
crankcheeks.
The
main bearing
journals
and
crankpins
are
nitrided
after
grinding.
The
front
end
of
the crankshaft
has
an
internal
spline
which
mates with
a
quill
shaft
to
drive
the
reduction
gear.
The
reduction
gear in
turn
drives
the propeller
driveshaft
which
has
a
flange
formed
on
the
front
for attachment
of
the
propeller.
The
crankshaft
has
side
blades
projecting
from
the
A-3-1

crankcheeks
and
are machined
for
the installation
of
third
order
counterweights.
Oscillation
of
the
counterweights
on their
pins
dampen
crankshaft
torsional vibration.
The
crankshaft
gear
is
shrunk
onto
the
crankshaft
and is
located
by a
dowel.
A snythetic
rubber
oil seal
which
is
stretched
over
the crankshaft
is seated between
the
crankcase
castings
in
the front
shaft
exit, and
is
sealed
to the
crankshaft
by a
helical
spring
inside
the
seal
cavity.
f.
CONNECTING
RODS.
The
"I" beam-type
connecting
rods
have
split
bronze
piston
pin
bushings
and
two
identical
precision
inserts
(of
the
same
type
as
the main
bearings)
at
the crankpin
end.
Weight
variation
of two
rods
in any
one
bay
is
limited
to 1/2
ounce.
g.
PISTONS.
Pistons
are
aluminum
alloy
cast-
ings
or forgings. The
skirts
are
solid
and
have
cy-
lindrical
relief
cuts at
the
bottom
to
clear
crank-
shaft
counterweights.
All
GTSIO-520
series
engines
built
since
1975
incorporate
a
four
(4) ring
piston
and
ring
assembly
replacing
the
original
five
(5)
ring model.
Some
engines
in current
production
are
manufactured
with
a
piston
which
incorporates
a
cast
steel
insert into
which
the
top
ring
groove
is
machined.
Because
of
the
weight
difference,
these
piston
configurations
are
not
to
be
intermixed.
Piston
pins
are
full
floating
ground
steel
tubes
with
permanently
forged-in
aluminum
plugs.
Weight
variation
is
limited
to
1/2 ounce
in opposite
bays.
h.
CAMSHAFT.
A
steel
alloy forging
is
machined
on
four
journals,
nine
camlobes
and
the
gear
mount
flange
at
the rear
end.
The
lobes
and
journals
are
hardened
and
ground.
A groove
around
the
front journal
passes
engine
oil
from the
right
crankcase
cross passage
to the
left
crankcase
passage.
The
camshaft
gear
is
attached
by four
unequally
spaced bolts
to locate
its
timing
mark
in
relation
to the
camlobes.
A
cluster
gear
is bolted
with
the
camshaft
gear
and
drives
the fuel
pump
gear.
i. TAPPETS.
The barrel-type
hydraulic
tappets
may
be
removed
and
replaced
without
complete
disassembly
of
the
engine,
as
described in
Section
XIII.
The
construction
and operation
of
the
tappets
are
described
in paragraph
A-3-1d
and
figure A-4-10.
Current
tappets
incorporate
a new
snap
ring,
which
is
red
in
color. The
most
discernible
difference between
the
new and old
tappets
is that
the
ball
socket
of
the old
tapered
from
the
center
nearly
to
the
O.D.,
while
the
newer
design,
which
must
use
the
new
snap
ring,
shoulders roughly
half way
between
the
center
and
the
O.D.
The
socket
hole
diameter
differences
are
1/16"
for the
old
and 1/8" for
the
new.
3-2.
FUNCTIONAL
SYSTEMS.
a.
GEAR
TRAIN. Figure
A-4-8.
When
starting
the engine
torque
is
transmitted
from
the
starter
(16),
through
adapter
components
(17
thru
21)
to
the
crankshaft
gear
(1). As
the
wormwheel
(19)
is
turned,
the clutch
spring
(20)
is tightened
onto
the
wormwheel
hub
and
grips
the
knurled
drum of
the
shaftgear
(21).
After
the
engine
is
started,
spring
(20)
is
returned
to
its
normal
position,
thus
disengaging
the
starter.
The shaftgear
(21)
is
now
used
to
transmit
torque
from
the
crankshaft
gear
(1) to
the generator
drive pulley.
1.
Torque
from
the crankshaft
(2)
is trans-
mitted
by
the
crankshaft
gear
(1)
directly
to
the
idler
gear
(12)
and
camshaft
gear (3)
2.
The
idler
gear
(12)
drives
the
magneto
drive
gears
(14,
15).
Optional
accessories
mounted
on
the
crankcase
upper
rear
are
driven by
internal
splines
of magneto
drive
gears.
3.
The
fuel
pump
drive
gear
(22)
is
driven
by
the
camshaft
cluster
gear (3).
The
splined
end
of
the
oil
pump
and
tachometer
drive
gear
(8)
mates
with internal
splines
of the
camshaft gear
(3) and
transmits
torque to
the oil
pump
drive
gear
(9)
and
tachometer
drive
gear
(1 1).
The
governor
drive
bevel
gear
(6) on
the
front
of
the
camshaft
(4)
drives
the
governor
driven
bevel gear
(7).
4.
The
internal
splined
front
end
of
the
crankshaft
(2)
transmits
torque
to
the
propeller
shaft
drive gear
(24)
through
an externally
splined
quill
shaft
(23).
The drive
gear
(24)
then
drives
the
propeller
shaft
gear (25).
b.
LUBRICATION
SYSTEM.
Figure
A-4-9
1. The
engine
oil
supply
is contained
in
the
sump.
The
oil
is
sucked from
the
sump
through
the
oil suction tube,
to
the oil
pump to
fill the
volume
being
continually
displaced
by
the
rotation
of
the
pump
gears.
From
the
pump
gear
chamber,
oil
is
directed
to
the oil
filter
chamber
and
the
tacho-
A-3-2
MARCH
1981

meter drive
gear.
If the filter
should
become
clogged,
the
spring-loaded
by-pass
valve will
open
permitting
oil to
flow from
the gear
chamber to
the
oil filter
outlet.
From
the
oil filter
outlet,
a
passage
leads
to the
oil pressure
relief
valve.
If, at
any time,
the
oil pressure exceeds
the limit
of the
preset,
spring-loaded
relief valve,
oil
is passed
back
to the
inlet side
of the pump.
2.
From
the outlet
side of the pump,
oil is
directed to
the full
flow
replaceable
element
oil
filter.
A by-pass
valve is
incorporated
in the
filter
adapter
in the
event the
element
becomes clogged.
From the
filter
discharge
port,
oil
is directed
to
the
oil
cooler. Oil
passing
through the
oil temperature
control
valve is
directed either
through
the
cooler
or directly
to the
gallery in the
left crankcase.
This
depends
on the oil
temperature.
In this manner,
engine
oil temperature
is maintained
at
1700 F.
From
the right
crankcase
oil gallery,
oil
is directed
to
the right
side valve
lifter
guides and
valve
mechanisms.
Oil is directed
from
the right
gallery,
through
a passage,
to
the propeller
driver
and
driven gears.
Passages
from
the left gallery direct
oil to the
main crankshaft
bearings,
prop
shaft
bearings,
camshaft
bearings,
valve
lifter
guides,
valve
mechanisms
and the
governor
drive bearings.
Oil is
introduced
to the propeller
governor
through
a
drilled passage
and
port in the
governor
mount
pad. From
the governor,
oil
re-enters
the crankcase
through
a return port
in the
mount pad.
The oil is
directed
to the oil
transfer tube,
which
is located in
the center
of
the
propeller shaft,
and
on to the
propeller.
3. From
a groove
in the rear
main bearing,
oil
is directed through
drilled passages
to the
starter
adapter
bearing, idler
gear
bearing
and from the
idler
gear bearing
to
the two magneto
bearings.
4.
Oil
from
the starter
shaftgear
bearing
is
conducted
through
a
passage
in the
shaftgear
to
two
radial holes
from
which
it
is sprayed
onto
the
shaftgear
drum
and bearing
surface
under
the
clutch
spring. Other parts
of the starter
drive
are
lubricated
by this
spray.
Oil drains
back into
the
crankcase
through a
hole in the
bottom
front side
of the
adapter
and
a slot
in the
bottom
of the
clutch
spring
sleeve.
5.
Each
cylinder
wall
and
piston
is lubricated
by individual
oil squirt
nozzles.
These nozzles
direct
a
continuous
stream
of oil
at the
piston
inner
dome. Oil
in the crankcase is
returned
to
the
sump
through
drain holes.
6.
The
turbocharger
is lubricated
by oil
from
the
crankcase
left gallery
directed to
the
turbo-
charger
oil inlet
through a
hose. Oil
leaves the
turbocharger
at the
oil outlet
port
through
a hose
to an oil
separator and
from these
through
a hose
to the scavenge
pump inlet.
c.
INDUCTION
SYSTEM.
The
induction
system
consists
of a
turbocharger,
intake
mani-
fold
assembly,
intake
tubes,
air
manifold
tubes
and
air throttle
assembly.
In addition
most
models
include,
in the
induction
system,
an
inter-cooler
capable of
40%
effectivity
with a static
cooling
air
pressure drop
across
the
cooler of 6"
H2 0 pres-
sure.
The
exhaust gas
driven turbocharger
supplies
air at
a higher velocity
and greater density than
attain-
able from
ambient
conditions.
Air
from
the turbo-
charger
discharge
side is
directed
to the
air throttle
body
which
controls the
quantity
of air
to be
inducted
in
accordance
with the setting
of
the
injector
system
fuel control
unit.
From the
air
throttle
body the
induction
air is directed
through
the
manifold
riser and
intake tubes
to the cylinder
intake
ports.
The
turbocharger-to-fuel
injection
system
manifold
provides
pressurized
air from
the turbocharger
discharge
side
to the
fuel pump
and injector
nozzles.
In
most installations,
the
turbocharger
has
a dual
scroll
feature to
provide
turbo-bleed
air
for cabin
pressurization
in addition
to
the engine
require-
ments.
The
turbo-bleed
air is
provided
through
a
sonic venturi which
limits
the bleed
air to
approxi-
mately
six pounds
of air per minute
at
sonic flow.
d.
IGNITION
SYSTEM.
High
voltage
current
is generated and
distributed
to the
upper spark
plugs
of the right
side cylinders
and
lower spark
plugs of
the left side
cylinders by
a
magneto
mounted
on
the front
of
the
right crankcase
accessory
pad. While
the left
magneto,
mounted
on
the
front
of the left
crankcase
accessory
pad,
supplies
high voltage
current
to the
upper left
cylinder
spark
plugs
and
the lower
right
cylinder
spark
plugs,.
it is also
equipped
with a double
breaker.
The double breaker
magneto
serves a dual
A-3-3

purpose. When cranking the engine, the retard
breaker
and a starting vibrator
are in effect, causing
a shower of high voltage sparks to start the engine.
As the engine is started and cranking motor is
disengaged, the retard breaker and starting vibrator
are no longer transmitting spark and the engine is
running on the advance breakers from both
magnetos. The battery operated starting vibrator
furnishes electrical current to the magneto for
retarded ignition starting, regardless of engine
cranking speed.
Spark is transmitted
to the spark
plugs through high tension cables which pass
through braided, flexible, shielded conduit
assemblies. These assemblies are connected to the
magnetos by coupling nuts and to the spark plugs
by nuts.
e. FUEL INJECTION
SYSTEM.
1. GENERAL. The fuel injection system is a
simple, low pressure system of injecting fuel into
the
intake valve port in
the cylinder head.
It is a
multi-nozzle,
continuous flow
type system which
controls fuel flow
to match engine
airflow. Any
change in throttle position, engine speed, or a
combination of both, causes changes in fuel flow in
correct relation to engine airflow. A manual
mixture control and a flow gage, indicating meter-
ed fuel
pressure, are provided
for precise leaning
at
any combination of altitude and power setting.
The continuous flow system uses a typical rotary
vane fuel
pump. There are
no running parts in this
system except for the engine - driven fuel pump.
2. FUEL - AIR CONTROL
UNIT.
The
function of the fuel-air control unit is to control
engine
air intake and to
set the metered fuel
pressure for proper fuel-air ratio. There are three
control elements in this unit, one for air, and two
for fuel; one of
which is for fuel mixture
and the
other for fuel metering.
Main fuel enters the control unit through a strainer
and passes to the metering valve. The position of
the metering valve controls the fuel passed to the
manifold
valve and nozzles.
A linkage connecting
the metering valve
to the air throttle
proportions
air-flow to fuel-flow. The position of the mixture
valve determines the amount of fuel returned to
the fuel pump. The fuel control portions of the
fuel-air control unit is enclosed in a shroud and is
blast air cooled to help prevent vapor lock. A fuel
pressure switch, connected to the fuel control unit,
actuates to cause the auxiliary fuel pump to
operate at a high speed if the engine-driven pump
pressure drops below
5 PSI. The auxiliary
fuel
pump switch must be ON for the fuel pressure
switch to operate.
3. FUEL
DISCHARGE NOZZLES.
From
the fuel manifold,
individual fuel lines
carry
the metered fuel to the fuel discharge nozzles, one
for each cylinder. These nozzles are installed in the
cylinder heads outside each intake valve. An air
bleed and nozzle pressurization arrangement
supplies pressurized air to the nozzle. The air bleed
arrangement
aids in vaporization
of fuel and by
breaking the high vacuum at idle, maintains the
fuel lines solidly
filled and ready for
instant
acceleration of the
engine. Nozzles are
stamped
with a letter on the hex of the nozzle body.
Replacement nozzles must match.
4. FUEL MANIFOLD. From the fuel control
unit, fuel is delivered to the fuel manifold which
provides
a central point for
dividing fuel to the
individual cylinders.
In the fuel manifold, a diaphragm and plunger
valve
raises or lowers, by
fuel pressure, to open
or
close the individual cylinder fuel supply port
simultaneously. A piston type check valve serves to
insure that the
plunger fully opens
the outlet ports
before fuel flow starts. Thus, there is no unbalance
restrictions
to fuel flow in the
fuel manifold. A
fine mesh
screen is included in the
fuel manifold as
additional protection of the injection nozzles
against dirt or foreign matter.
5.
FUEL INJECTION
PUMP. The fuel
pump
is a positive-displacement, rotating vane type. It
has a shaft for connection to the accessory drive
section of the engine. Fuel enters the pump at the
swirl well of the vapor separator. Here, vapor is
separated by a swirling motion so that only liquid
fuel is fed to the pump. The vapor is drawn from
the top center of the swirl well by a small pressure
jet of fuel and is fed into the vapor return line and
returned
to the fuel
tank. Since the pump
is
engine-driven, changes in engine speed affect total
pump flow proportionally. The pump supplies
more fuel than is
required by the engines.
There-
fore,
a relief valve is provided
to maintain
a
constant fuel
pump pressure. A check
valve is
provided so that the auxiliary pump pressure can
A-3-4

bypass
the
engine-driven
fuel injection
pump
for
starting.
In
case of
engine-driven
fuel
injection
pump
failure,
the auxiliary
fuel
pump
will
operate
automatically
when
the
auxiliary
fuel
pump
switch
is
ON.
Incorporated
on
the fuel
injection
pump is a
variable
orifice
controlled
by
an aneroid
on
the
pump.
The
aneroid
is
controlled
by
the
super-
charger
discharge
pressure.
The
variable
orifice
controls
the pressure
from
the fuel
injection
pump
at
altitude.
A-3
-5 /A-3-6