MAINTENANCE AND OVERHAUL MANUAL WITH ILLUSTRATED PARTS LIST FOR AIRCRAFT ENGINE MODEL AGS 4-5 FORM No. X-30008 MARCH 1966 REVISED JULY 1968 F.A.A. APPROVED8 INTRODUCTION This book 1s a combined Operator's Manual, Main- tenance and Overhaul Manual and Ulustrated Parts List for the Continental A65 and A75 Series 8 Engines. ‘This maaual is intended for use by operators and ‘mechanics as a guide and reference book in the oper- ation and servicing of these engines. ‘The book 15 divided into five main groups: Opera- ting and Maintenance Instructions, Overhaul Instruc- tions, Table of Limits, the Mlustrated Parts List, and Accessories, Tt is. suggested that a careful study be made of this ‘manval. A strict adherence ta the instructions out- Lined herein will assure a fine operating record. However, if any point is not entirely clear, do not hesitate to contact the nearest Authorized Continen= tal Service Station or the factory Service Department. In the event of failure of any engine part, notify the nearest Authorized Continental Service ‘Station at ance, giving the engine serial number, and full particulars. Do not attempt any repairs without fac~ tory permission if any adjustment 18 expected. Contineatal Motors CorporationABLE OF CONTEN Section OPERATING & MAINTENANCE INSTRUCTIONS 3 TABLE OF SPECIFICATIONS... . . GENERAL DESCRIPTION . 1. DIFFERENCES BETWEEN. ENGINE MODELS... ss 2. CYLINDER CONSTRUCTION | |! 3. VALVE OPERATING MECHANISM | 4. CRANKSHAFT CONSTRUCTION . | 5. CRANKCASE & OIL SUMP CONSTRUCTION... 2... 6. CONNECTING RODS 7, PISTON & PISTON PIN CONSTRUCTION. 5... es 8. CRANKCASE Cover |) 12112 98, LUBRICATING SysTei |.) | PACKING, UNPACKING & PREPARA- TION FOR STORAGE... 2... SHIPPING BOXES. PACKING UNPACKING THE ENGINE, | 1) TREATMENT OF ENGINES FoR PERIODS OF IDLENESS. .. . PREPARATION OF ENGINES FOR SERVICE APTER TREATMENT INSTALLATION AND REMOVAL... 1, MOUNTING THE ENGINE 2)... 2, REMOVING THE ENGINE ||)! | GENERAL OPERATING INSTRUCTIONS 1. BEFORE STARTING... . +. 2) STARTING. 3, WARM-UP AND GROUND TRST | | 4. TAKE-OFF oe... ee eee SOFLIGHT.. DI I e LANDING 2D DD) T STOPPING: 20D Dot 8, CARBURETOR HEAT CONTROL . ¢ 9, MIXTURE CONTROL... . 10. GASOLINE & On, RECOMMENDATION: ENGINE TROUBLES & SERVICE REPAIRS vv te ee 1, FAILURE TO START ©) 12. 2. LOW OIL PRESSURE | 1.1) 7 3. HIGH OIL TEMPERATURE 1) | 4. LOW POWER OR SPEED. ©!!! 7 5. ROUGH RUNNING... 6. ENGINE FAILS TO ACCELERATE PROPERLY, 4, ENGINE FAILS TO IDLE PROPERLY... Page 10 10 10 10 10 10 40 10 ui ul un n aL ul 12 2 2 2 12 Section 7 OVERHAUL INSTRUCTIONS 2 10 u R ILLUSTRATED PARTS LIST re uu SERVICE INSPECTION & ‘ASSOCIATED MAINTENANCE . . 1, GENERAL . 2) INSPECTION & MAINTENANCE ADJUSTMENT, REPLACEMENT & MINOR REPAIR. so. ss 1, GENERAL... 2) dt 2. CARBURETOR |) 0112. 3. MAGNETOS 1) 1 Tt 4. MAGNETO INSTALLATION & TIMING TO ENGINE... 5. IGNITION WIRING. . 8, REMOVING PARTS... 2 1. GENERAL INSPECTION |. > 8, REASSEMBLY .. DISASSEMBLY, CLEANING & INSPECTION. . a, GENERAL |) o | PRELIMINARY OPERATIONS 2 3. DISASSEMBLY... bets 4 CLEANING... 2D De 5, INSPECTION . : REPAIR & REPLACEMENT... 1, GENERAL . : 2) REPAIR & REPLACEMENT OF ENGINE PARTS... . hae ASSEMBLY, TIMING & TESTING, . - 1, GENERAL. see ee 2, REASSEMBLY OF MAJOR SUB-ASSEMBLIES 3, FINAL ASSEMBLY PROCEDURE « 4. TESTING ENGINE AFTER OVERHAUL... = TABLE OF LIMITS. 5.2.0. es ILLUSTRATED PARTS LIST. . 6. NUMERICAL PARTS LIST... . 18 OVERSIZE & UNDERSIZE PARTS . ACCESSORIES. |. 2... sees 16 STROMBERG NA-S9A1 CARBURETOR 17 SCINTILLA MAGNETO TYPES, 18 SPARN-8& SFALN-B eee es HYDRAULIC LIFTERS 4 4 4 4 4 4 re 15 6 6 16 16 8 0 2 a 23 23 23 24 29 80 36 36 56 aL 63 6a 65 eo iINDEX FOR ILLUSTRATION Figure No. Title Page 1 ‘Three-Quarter Left Front View of AGS-BF wee vi 2 ‘Three-Quarter Right Rear View of AG-8F yt nnn 3 Performance and Fuel Consumption Curves 22 ee ee penile feo8 4 Deleted le Philip iii tiit 5. Section Through Hydraulic Tappet | 2 22 t Plililiiiiiii: 4 e Cutaway View Showing Gear Train os ee eect teen 6 7 Engine in Shipping Cradle... Dette 7 a Hoisting Engine with Crankshaft Lifting Eyes S22 Diliit os a Hoisting Engine with Crankease Lifting Eye | |) 1) It piliiiiil a 30, Typical Installation Diagram... 0... teense 8 ct Ignition Wiring Diagram 22 ii 4 12, Cylinder Flange Torque Sequence so 22 t Dlloas 13. Compressing Valve Springs for Installation and Removal of Locks |. 22. ett uv a Removal of Hydraulic Unit from Cam Follower Boly. . ell ii ii iiiiioar 15, Deleted ee Plititiiiiiiit 18, Stud Wentifieation, 2102) DED DP pili Dlllil ap i Assembling Rocker Shaft Bushings oe. ee tees 22 18, Installing Cam Follower Body tnto Crankease S22 Se Dll ba 13, Installing Crankshaft Bearings into Crankcase. |... DIDI D DIP p iii 24 20, Installing and Removing Crankshaft and Connecting Rods 2. ee ee 26 aa Installing Crankease 1-3 over Crankease 2-4... 0. 00s cv r rv ene BS 22, Installing Gears in Crankease |. tents 28 23, Installing Crankcase Cover to Crankease | 22) 2D tt Dll) 36 24, Installing Cylinder on Crankease. . es 0s ve eters es) 25. Determining Firing Position. . 2022 Dili tiiie 28 26. ‘Timing Marks on Flanged Crankshaft: 22 22. 2 DEDDDDII DDT i. as a7, Lubrication Chart - Cross-Section Views. 2 ete fll as 28, Lubrication Chart - Side View. 2.22 0s PLblibiliiililiiiil as 23, Lubrication Chart - Rear View... 2 - PIDDID ID DI pili ii iii las 30, Crankease. iit Pill bl itll se a1. Crankshafts, Connecting Rods and Pistons... 00 fe ete eee a 32, Cylinder and Valves ove ee ete eee 8 33, Rear Crankease Cover ané Gear Train. 2 Dll las 34, ‘Oil Sump and Oil Suction Tube... ee 6 35, Ignition System. see lees n ect se sven sas at 36, Ignition System. oe filipi heii: fis 49 a7, Carburetor, Air Intake and Filer System 0 22D tt 5 38, Camskalt, Push Rods & Valve Tappets Propeller Bab 5... piiiiit til 5a 39, OM Cooler Equipment. os ete ce te ee eect etter nae fis 58 40, Fuel Pumps topes r nett ese test ernnee 50 4, Showing Magneto Tuning Marks 2022 D222 D2 Dbl tiie 85 42, Timing Magneto. se ee etc ete ete 85 43. Breaker Mechanism. 220 2) ftp tects cee eee Lil 86 ‘TABLES ‘Table 1, Magnaflux Inspection Data. 6. ee ee ee eee OO“Ae-99¥ JO M9IA Wosg Yor] JaWeNH-vaUL T sanspySECTION 1 BLE OF SPECIFICATIONS GENERAL Tye ee Horizontally Opposed ‘Piston Displacement (cubic in)... ss. m Operating Cycle. | 2111... Otto(4 stroke) Namber of Mounting Bolts. vt. i. tt Coollag System Types SS es ‘Air Diameter of Maunting Bolts © aa" on 7/16" No, of Cylinders. st DLIL le overall wien. DDT) Jae Cylinder Arrangement |. 11! Ll ligee Fig. 12) Average Dry Weight (Series 8) |) << 1170 abs, Cylinder Bore... |). . All Models 3-7/8" Average Dry Weight (Series 9) || 1 2 1177 tbs. Strokes ss ltt ss AMLModols 3-5/8" Crankshaft Rotation 2. 11. sclockwise FEATURES PECULIAR TO EACH MODEL: Model ee SS AGS +an5 ‘Type Certificate No DDD DTT Pili ihiiiiiiiit 205 213 Compression Ratio. 2222S piliiiis piiliiiit Piles: 6.3:1 Rte@ RPM lei iii DDD 2 2800 2600 Rated Horsepower at Sea Level |. 1. PIDDI Illi 6 15 Maximum Allowed Manifold Pressure ia in. Hg. (at Fated RPM) DLE. ane 20.3 Recommended Cruising REM we ee ee 2150 2350 Maximum Recommended Manifold Pressure in ta, Hg, ‘at cruising RPM) 1... 22. 26,8 26,0 Minimum Fuel Octane Rating (Aviation Grade). ee 80/87 80/61 Maximum Allowable Cylinder Head Temperature GF). 2212211 Lit $0 525 Maximum Oil Temperature (Fo). ee eee ee 220 220 Oit Temperature im °F. (Minimum at Take-off) TL 90 90 Approximate Fuel Consumption in Gallons per Hr. (at eruising RDM) * fila 48 Approximate Maxtmum desirable Ol Consumption in pints per Hr... lL 3/4 4 OM Sump Capacity in Quarts ye ee eee ree pilia 4 Oi Pressure (Cruising) in Lbs. /Sq. ‘In. PEDDIE h lilt 30-40 30-40 Oil Pressure [laling) in Lbs. Qfinimam) |e Pill. lao 10 IGNITION: Types eve eee evs + «Dual Magneto Radio Shielding (Optional), . 6... CMC Magneto Type Various Spark Plugs (Shielded). . |. +. Champion628 Magneto Rotation (as viewed Spark Plugs (Shielded) EMAZE from Drive End)... . 2... .. . Clockwise Spark Plugs (Unshielded) . << Champion C27 Crankshaft: Magneto Speed Ratto:s SS. se 4 85 Ams Right Magneto Fires Upper Plugs BIC. 66s oe ee ee 30° 2 Left Magneto Fires Lower Plugs BTC |< | : 32° Firing Order oe : 15-264 NOTES: * Direction of rotation as viewed {rom rear of engine, 4 ATS is no longer in production. It Is replaced by model C75.‘TABLE OF SPECIFICATIONS - Continued FUEL SYSTEM LUBRICATION SYSTEM Feed rs HGravity Pumps see bees Gear Type Carburetor Type. |< . Float (See Catalog) Crankshaft: Pump Speed Ratios | 1) ose L.- Bo GifPrimer Connection |. +1). . 1/8" NPT. Pump Drive Gear Rotation. - . *Counterelockwise Carburetor Inlet... 222 21D lava oT. Sump Types re ee ee Wet ACCESSORY DRIVES AND INSTRUMENT CONNECTIONS Oil Pressure Gauge Line». 1/8" NPT. Crankshatt: Tachometer Drive Ratio...» «1:.50 ‘Tachometer Drive Shaft: Sd. SS. . SALE, Tachometer Drive Rotation... *Counterclockwise ACCESSORIES AND WEIGHTS +*Magnetos (2), Etsemann . . . . . -AM-4:10,69% **Carburetor (Stromberg NA-S3B} . . . . «2,608 Magnetos (2), Eisemann 12,02 Carburetor (Marvel MA“3PA} Magnetos (2), Scintilla . |) 1 1 ‘SARN- 20:10, 358 (Optional). sss pee ee 3.008 Radio Shielding 0 ot eee eo 2,28 E Fuel Pump (AC Diaphragm Type) |) ||, 158 Oil Cooler (Harrison). + Foil. 224002 Exhaust Flanges and Gaskets (4). 11 1 1 0.554 Air intake and Filter Assembly 1) 112.568 Rubber Mount Bushings (8) and 0.554 Propeller Attaching Parts Steel Washers (4). ee (Flanged Crankshaft)... se 5 0,808 Carturetor (Strombere NA-S8AX) (Optional) : Pe 2T0E NOTES: * Direction of rotation as viewed from rear of engine. ** Accessories included in Engine Dry Weight, ‘Add 1.04 Ibs. for Flanged Cranksha‘t (Series &F }. ‘Magneto Weights include Drive Gears. YF A Stromberg carburetor suitable for use witha pump {eed system savailable, Gravity feed requires the fuel tank to be clevated and located 0 that the stalle fuel head will be at least two inches ia the steepest climb and less than 90 inches in the steepest glide, ‘Ht The primer nozzles supplied for installation in the intake manifold ts effective at temperatures above -1°C. (20°F), For starting at lower temperatures a primer manifold system with jets in cylinder intake ports is recommended,spars ‘S3AUN9 NOLLGWNSNOD 134 ONY JONVMOINI JddO082 WddOO9e WiYOOr2 Wd¥0022 Wd¥000Z Wd400s! Wd¥O09! Wd' OOF! NOILAWASNOD 130 3- GVO1 ¥37T3d0Ud ‘ 1 ] 6 i + c) © { | © n YNOH Yad SNOTIVD 3 z 8 oO a > x m I ° a w m vu § m a ° oS g 8SECTION 2 GENERAL DESCRIPTIO! 1. DIFFERENCES BETWEEN THE AGS AND A75 ENGINES. 4, DIFFERENCES BETWEEN THE A65 and 475 MO- DELS, (@) GENERAL DIFFERENCES. la) Ail the engine models are {dentical in general construction with differences in the power rating of the engine, maximum R.P,M,, compression ratio, number of’ pision rings, exhaust valves, piston pin ciameter and connecting rods. (2) ENGINE RATINGS, (a) The engines are rated as stated in the table of specifications, paxe 1, (8) ENGINE COMPRESSION RATIO. (a) The enwines have the compression ratios and fuel Octane requirements shown in the tabla of speei- fications, 44) NUMBER OF PISTON RINGS. (a) The S63 and A75 engines have a total of three rinks per piston; two bevelled back, tapered face compression rings No, 530144 in the top and second grooves and one ol ring In the third groove. (5) EXHAUST VALVES, (a) The exhaust valves on these models are iden- {tical in construction with the exception that the valves, used on the A75 engines have stellite faces to elim- inate the greater wear experienced at the increased engine speeds, (6) CONNECTING RoDs, (a) The connecting rods on these engines are iden- tical in construction except that the rods used on the A75 engines have a 1/36 diameter drilled oil squirt hole in the cap end of the rod to provide increased lubrication to’ the cylinder wails and are busied for piston pins of smaller O.D, than used in model A65, Figure 2. GYLINDER CONSTRUCTION Heat-treated, aluminum alloy cylinder heads are serewed and siiunk tp stee! barrels, Close-spaced cooling fins are provided on barrels and eylinder headstoprovide ample and efficient eadiation surface, Cylinder bores are ground to a smooth finish and held within extremely close Iimits. Stainless steel helical coil spark plug inserts are screwed in place, while aluminum bronze intake and steel exhaust valve seats are shrunkintothe cylinder heads. Rock- er boxes are cast mtegral with cylinder heaes and are provided with ail sealed covers made of deep drawa sheet metal, They are seaveaged by the drainage of ofl back to the erankease through the pash rod housings. Cylinder heads have undersize exhaust ports to permit more positive exhaust seavenging. 3. VALVE OPERATING MECHANISM 4. General. Zero Inshhydraulie tappets fit aluminum alley guides machined in the crankcase and 0 sealed a5 positively to prevent oll leakage, Tappets are Grilled in sich a manner that ap ofl passage is pro- vided from the tappets to the push rods, rocker am bearings, and rocker end, Push rods are made of ight steel tubing with pressed-in ball ends, hardened and ground, and drilled their entire Length to provide an off passage ta the overhead mechanism, The push rod is fully enclosed, and the outer end fits into a socket in the rear of the valve rocker, The rocker acts directly on the valve through a Specially de~ signed “fool” so constructed ag to prevent side thrust on the valve stem, Splash and spray lubrication keeps valve guides oiled at all times. Oil 1s returned to the erankease by the push rod housing, Section Through Hydraulic Tappetb, Hydraulic Tappets. The ‘appets are tomposed of only four parts which ean be disassembled: the cup, cylinder, piston, and ‘cam follower body. They are designed to function properly with clear- ances ranging from .690 inch 10 «120 inch. Oil ines to tappots operate on full engine pressure and are located in such a way that they register with {appet ofl passages when valves are open. Oil under pressure from the lubricating system of the engine 1s supplied to the hydraulic lifer theough hate) to supply chamber (I) (See figure 6.) ‘With fave of the lifter on the base circle of the cam and the engine valve seated as shown io figure 5, the ight plunger, spring (&) lifts the hydraulic plunger {€) sc that its outer ond contacts the push rod, taking tp the clearanes at this point and all along the valve train, glving. zero lash. As the plunger (C) moves outward, increasing the volume in the pressure ad= justing chamber (L) the ball check valve (D} moves cif its seat and ofl trom the supply chamber J) flows in and fills chamber (L), ‘As the camshaft rotates, the cam pushes the liter ody ‘oltward, tending to’ decrease the volume of chamber (L) and forcing the ball check anto its seat. Further’ rotation of the. camshaft moves the lifter (A) outward and the confined body of oil in chamber (L) acts as a member in the valve opera- ting mechanism, the engine valve being lifted on & Column of olf, So long as the engine valve 15 off 18 Seat, the load 18. carried py this. column of of, ‘Diiring the interval when the engine valve 19. off its seaty a pre-determined slight leskage occurs be= tween plunger ana cylinder bore, whieh 18 necessary ta compensate for any expansion or contraction oc curring inthe valve’ train. immediately after the fgine valve closes, the amount of of required to Tebll the adjusting ‘chamber, (L) flows in arom the Supply chamber (J) thus establishing tne proper length ofvoil column to maintain zero lash during the next svete. qh basic principle of the hydraulic tappet is that it provides, between, the cam and. the push Tod, 8 column of ol whieh earries the load ‘while. the fngine valve is off ts Seat, and the length of which {automatically adjusted so'that each camshaft cycle gives zero las 4. CRANKSHAFT CONSTRUCTION ‘The alloy steel, one-piece, four-throw crankshaft is supported by six semi-circular steel-backed special, alloy precision main bearings which are easily replaced. ‘The crankshait is drilled for lightness and to provide pressure lubrication of crankpia jour- nals. The crankshaft end clearance is fixed by the front main bearing setting, between the forward crank eheek anda flange machined on the shaft, Shafts No, 530196 and 53099 have a thin flange with no taper, This flange rides in a narrow recess in crank- ease No, 59027-Al and acts as an oil slinger, 5. CRANKCASE AND OIL SUMP CONSTRUCTION ‘The crankcase is atwo-piece heat-treated aluminum alloy casting, bolted together at the vertical length~ ‘wise plane through the crankshaft and camshaft, Rigid transverse webs hold the three main crankshaft bearings and the three camshaft journals. A specially designed oil seal prevents oil leakage at the front end of the crankshaft, Large tanvet euides are formed in the crankcase in a plane below and parallel to the cylinders, Drilled oll galleries molded inthe castings provide pressure lubrication to the tappet guides, camshaft, and main bearings. Circumferential stiff- ening ribs under the cylinder pads give additional strength and stiffness to the cylinder hold-down bosses, Four engine mount bosses for 7/16-inch bolt are provided at the rear of the crankease for ‘mounting similar to Uiat of radial engines. To the rear and on the bottom of the erankease there is a large flange to which the oil sump is attacked. ‘The oil sump is a two-piece deep drawing shoet steel stamping, welded together at the flange. A heavy sheet steel mounting flange is securely welded at the top of the sump. A steel tiller tube with support bracket 1s welded to the oil sump body. A bayonet- type ofl gauge rod is combined with the oil filler cap. 6. CONNECTING RODS Connecting rods are of conventional split-bearing, design and of heat-treated alloy steel forgings. The split crank journal end bearing is of replaceable thin stool-back shell-type, lined with special alloy metal. ‘A pressed-in bronze bushing is used at the piston pi end, On late model A65 and allA75 Engines an oil squirt noleis provided in the connecting rods to insure more positive olling of the cylinder walls, 7, PISTON AND PISTON PIN CONSTRUCTION Pistons are heat-treated aluminum alloy pormanent mold castings. The ring grooves are arrangedtocarry ‘two compression rings and one ofl contrat ring above the pin on A6S and A7S engines. Piston No, 40731 is cam, ground to provide better fit in the cylinder at operiting temperature. It re~ quires the large diameter piston pin No, 630856, ‘The full-floating type piston pin isa case-hardened, seamless steel alloy tubing, machined and ground, Each end is fitted with an aluminum plug to prevent scoring of the cylinder walls, B.CRANKCASE COVER ‘The magnesium alloy crankcase cover casting at the rear end of the engine provides support for the magnetos, ol] pump, and tachometer‘drive. It also houses the ofl suction tube, the oil drain, of] screen, the pressure relief valve and oil lines to match the several crankcase oil lines. The entire assembly with accessories is removable as a unlt. 9. LUBRICATING SYSTEM To reduce the number of external oil nes, an oil sump is attached directly to the crankease, Oil drawn from the oll sump through a suction tube extending down into the sump and delivered under pressure to a screen from which it goes through Grilled passages in the crankease cover and crankcase 5Figure 6. Cutaway View Showing Gear Train, Figure 6 shows the complete gearing arrange- ment from the crankshaft power take-off to all accessories. ‘The arrow on each gear indicates Girectionof Fotation as viewed from the rear of the engine, and the following analysis describes each gear function with ts speed in relation to the crank- shatt. (2) The crankshaft gear isdrivenfrom the crank- shalt attached to the rear end of the crankshaft by cap screws and turns ina clockwise direction at crankshait speed. (2) The cam gear is driven by the crankshaft GEAR TRAIN ANALYSIS gear (1) at 1/2 crankshaft speed ina counter-clock- ‘wise direction. (3) The right and Jett magneto drive gears, dri- venby the crarkshatgear, turn ina counter-clock= ‘wise direction at crankshaft speed. (4) The oil pressure pump drivergear is driven by cam gear (2) through a male-female square coupling, and turns In a counterclockwise direction at 1/2 crankshaft speed, (6) The oll pressure pump driven gear is driven by gear (4), and turns ina clockwise direction at 1/2 crankshaft speed. to all drive bearings, through the crankshaft, and to the crankpins. Engine oil from the pressure pump is carried through drilled passages in the crankease to the lydraulic tappets, After entering the tappets, it travels out through the overhead mechanism through hollow push rods, and is spilled over the rocker arm and valve mechanism. As it drains away, itthoroughly ofls the valve stems and valve guides, The oil 15 returned to the crankease by way of the push rod 6 housing, and drains back into the of! sump through the opening at the rear of the crankcase, The cylinder ‘walls and piston pins are lubricated by spray, The excess oil in the crankcase is returned to the oil sump. The pressure relief valve is set to give ap- proximately 35 pounds of pressure at speeds of from 1900 to 2300 R.P.M, Refer to the Section on Table of Limits for Charts showing the lubrication system,OPERATING AND MAINTENANCE INSTRUCTIONS SECTION 3 1. SHIPPING BOXES Bach engine is packed for domestic shipment in a ight weight crate, the sides and top of which are of ‘wood frame and corrugated cardboard construction, ‘The erate base is constructed of wood planking with 4 skids on the lower side. The engine ls supported n the inverted position on a formed plywood cradle which 1s bolted to the crate hase, The engine crate must always be hoisted by a sling passed under the base or by a fork-lift truck so that the engine weight i8 never supported by the crate side panels, Overall Aimensions of the crate are approximately: 3477 wide 234" long x 30” high. 2. PACKING Four bolts and nuts attach the top engine mounts and the exankshait propeller Mange to the cradle, If the engine has a tapered crankshaft, the tapered end rests in a hole bored in the end of the cradle, ‘The propeller hub nut thread of a tapered shait is, covered by a plastic cap. The crankease breather and carburetor fuel inlet are plugged, and the car- turetor air intake flange and cylinder éxhaust flanges are covered by cardboard seals, A moisture.proof paper shroud is placed over the engine, Its edges overlap the edges of the base so that the nails which are driven through the side panel frames into the base planks pass through the shroud to hold it in Figure 7. Engine in Shipping Cradle. PACKING, UNPACKING, AND PREPARATION FOR STORAGE place, The Air Intake assembly and propeller hub, iC any, are attached to the base planks inside the shroud, ‘This packing is not intended for long-term storage, A heavier, all-wood crate is provided for export shipping, Internal corrosion preventive com- pound is applicd through the lubrication system and a8 a spray through the induction system and into spark plug holes and exhaust ports, The effective duration of this protection will depend ontirely on atmospheric conditions during storage. Crated engines Should be inspected at intervals of not more than thirty days during storage and re-presorved if a generous film of preservative oil is not found on all Internal surfaces and unpainted surfaces. 3. UNPACKING THE ENGINE Pull out the nails which attach the side panels to the erate base. Lift off the side and top panel assem~ bly and the engine shroud. Remove the air intake assembly from the crate. Attach 2 crankshaft lifting eye, such as those supplied by the Kent-Moore or- ganleation, to the crankshaft flange bushings or ta~ pered shaft hub nut thread, as applicable, Attach a hoist to the lifting eye and fake up the slack, Remove the shipping bolts which attach the crankshaft pro peller Hange to the cradie, While two men support the wear of the engine, remove the bolts which attach the top-engine mounts to the cradie, and lift the engine clear of the cradle, Raise the front end until, the engine is suspended by the crankshaft clear of obstructions, Place the engine on a suitable work stand, such as supplied by the Rorroughs Tool Co, , for installation of fittings, balfles, etc, ‘4. TREATMENT OF ENGINES FOR LONG PERIODS OF IDLENESS When the aircraft (or a crated engine) cannot be operated daily, or weekly in very dry climates, it Should be treated for storage as follows: 2. Drain the oil sump D, Remove all spark plugs and exhause port covers or éxhaust manifolas €, With 2 long, thin nozzle of suitable shape, and which produces & 90°, atomized spray, connected to a souree of dry, compressed air and’a clean con- laimer’ of internal corrosion preventive ‘compound spray each cylinder through the upper spark plug holes, moving’ the nozele in and out in step vith the pistod through two sweeps while the crankshaft isslowly rotated, Do not flood the eylinders, d. Direct the spray into each exhaust port while the crankshaft is rotated several revolutions, fe, Stop the crankshaft and again spray through each upper spark plug hole so as to sweep the cylinder ‘wall exposed, Do not turn the crankshaft thereafter, £ Spray the crankcase interior through the olf sump dram plug and the breather elbow. Attach the grain plug to the sump with a length of safety wire, Dut do not install it, g. Remove the pressure oil scroon and spray the pump through the screen housing, Replace the screen, hh. If the propeller is not installed coat the exposed end of the crankshaft ith a preservative grease, such as Federal Spec. $2-C-18, Grade 1, or AN-C* 124, and wrap it with grease-proof paper or fabric ‘or ton-hygroscopic tape, 4. Replace all spark plugs and extause port covers, Seal any openings to the interior of the crankease ‘with non-hyproscopie tape. J. In the vicinity of salt Water, the exterior aurtaces may be further protected by spraying with a water proof varnish, k, Crated engines should be protected from dripping water” by covering with a moisture-proof shroud, They should also be protected from sweating with atmospheric changes by storage in a location where the smallest possible variations intemperature occur. 1A tag should be attached to the engine crate (or aircrait instrument panei) to warn that the oll Supply lias been drained and the drain plug removed, ‘The tay should also stato the date of preservation. m, A pan of adequate size should he positioned to catch preservative oil dripping from the open sump Grain, ‘The internal preservative mixture recommended for use wilh this procedure is composed of one part Army Spec, AXS-934, Grade 2, corrosion preventive oil Will mixed with one part $.A.E, No, 30 aireratt ‘engine lubricating oil, AXS-994 oil is obtainable at most refineries and bulk storage plants, ‘The above preservation shoilld be repeated at intervals of thirty days during storage. 5. PREPARATION OF ENGINES FOR SERVICE AFTER ‘STORAGE Engines prepared for storage in accordance with the foregoing instructions may be placed in service after making the following checks: a. Turn the propeller slowly by hand through eight or ten revolutions to permit drainage nf preservative ofl from cylinders aud to listen for intake and ex- aust flow. If the valve action is not normal, remove rocker covers and check for sticking valves. Lubri- cate stems of sticking valvos with flushing oil or a mixture of lubricating ofl and gasoline. Continue to rotate the crankshaft until the valves all operate normally. If sticking persists, the cylinder must be removed and disassembled for inspection and neces= sary repair, b, Remove all spark plugs and wash out oil with Acetone, carbon tetrachloride, or clean, unleaded gasoline, Re-install spark plugs, using serviceable Baskets, See the Table of Limits for correct tightening torque, , Tistall the oil sump drain plug witha serviceable gasket, Fill the oil sump to the “Full”? mark on the Gauge rod with the recommended seasonal grade of aircraft engine oil, d. Remove any ‘seals, covers, or caps installed on carburetor air intake ‘and connectors such as the crankease breather, Connect the proper heses, tubes, ete, €. Check all engine controls for full range and free operation, proper support, and safe connection to the engine. Check fuel supply, primer, temperature, and gauge lines for tight installation, {. Drain any water from the fuel strainer. It is recommended that the oll supply be drained and the sump refilled with fresh oil of correct grade after approximately five hours of operation following removal from storage. While AXS-934 preservative should do no harm to the engine, this ofl change will assure removal of the preservative and any foreign material, It is always advisable to aveld mixing types of ofl, Figure 8. Hoisting Engine with Crankshaft Lifting Eye. Figure 8. Hoisting Engine with Crankease Tatting Bye.SECTION 4 INSTALLATION AND REMOVAL 1, MOUNTING THE ENGINE a. A lifting eye is permanently attached to the ‘crankcase upper flange by the third and fourth screws from the rear. A hook, such as that supplied by tre Borroughs Tool Company, may be engaged to the lift ng eye hole and the hoist attacked to it for lilting the ‘engine in the flight attitude, See figure 8, A special hoisting older engines not equipped with the crankcase lifting eve. b. Hoist the engine to its installed position in relation to the aircraft engine mount. Install the conical rubber mount bushings in the front and rear recesses of the four Engine mount bosses at the rear of the crankease. Place one steel washer (of the Riickness required to locate the engine C.G.) between each rear rubber bushing and its mount pad, and install the four mounting bolts. Install the front Washers, nuts and cotter pins. See figure Ll for mount details. Tighten the mounting bolt muts to the torque specified in the Table of Limits. This is very important. c. Remove the exhaust port covers and install the exhaust manifolds. Tighten the nuts to the torque specified in the tabie of limtts. @. Remove the shipping plug from the carburetor fuel inlet and attach the fuel supply line. fe, Connect the priming pump iniet Line tothe proper fitting as required by the aircraft fuel system, Connect, the priming. pump discharge line to the primer jet instalied In the intake manifold, or make tlenecessary connections if an intake port priming manifold is used. Test the system for fuel leaks when ready to start the engine. £, Connect the throttle control, ignition switch wires, all temperature gauge capillary, oll pressure gauge tine, and the tachometer cable and conduit nut to the proper points on the engine as illustrated in figures 10 and il. {§, Install the carburetor air intake assembly onthe carburetor lower flange with the air filter forward, Connect the carburetor air heater hose from the rear inlet to the source of warm air (100°F.). Install the air heat valve control wire in the valve lever swivel, fand check the valve and control operation for free movement and full range. hn. Mount the propeller on the crankshaft flange, using the bolts, flange ring, and moisture impervious, plate provided, If the engine is equipped witha tapered crankshaft install the hub assembly in the propeller and check track and balance before mounting it on the crankshaft. 2. REMOVING THE ENGINE a. Remove the propeller and engine cowling, 'b, Disconnect from the engine the throttle control, carburetor air heat control, tachometer cable, fuel Supply and primer lines, oil femperature gauge capil- lary, ‘oll pressure gauge line, and the magneto switch wires, ¢, It necessary, loosen the magneto attaching nuts and’ rotate the magnetos to clear the engine mount structure, ‘d. Attach a hoist to the crankease lifting eve, or attach the special sling to the engine and the hoist to the sling, Take up the engine weight on the hoist, fe, Reniove the lower engine mount bolts, Adjust ‘the hoist to prevent movement of the engine as the lower mount bolts are removed, While removing the ‘upper mount bolts it is advisable to have a second man controlling the hoist and the front end of the crankshaft to relieve vertical binding of the bolts and to prevent pitching of the engine. £, Observe points of possible interference and avoid damage to accessories as the engine is heisted clear of the aireraft. Place and fasten the engine on either a shipping cradle or a suitable work stand, Figure 10. Typical Installation Disgram,SECTION 5 era ave OPERATING INSTRUCTIONS 1, BEFORE STARTING ‘a, If the engine has been idle for over 2 hours, or if excessive priming has been used during starting attempts, make certain that ignition is turned {0 the “OFF” position, open the throttle wide and pull the engine through ‘by’ hand four or five complete revolutions. If fuel or oil 1s present in any combustion chamber, as evidenced by excessive compression, remove the spark plugs form that cylinder, drain all Liquid from the cylinder and intake pipes, and dry spark plugs thoroughly before replacing, CAUTION: Starting the engine with excessive oil or fuel im the cylinders may result inbentor broken rods, 'b, Set mixture control at «FULL RICH.” ©. Open cowling flaps (if installed), except in extreme cold weather, 4, Place carburetor heat control in COLD po- sition. 2. STARTING With throttle “CLOSED,” switch “OFF, and gasoline supply valve turned ‘/ON,” prime the engine three or four strokes (depending on weather con- ditions, warm engine, etc.) as the engine is turned over by hand five or ‘six times, Avoid overpriming, b, Turn ignition switch “ON” and open throttle slightly, Start engino by pulling propeller through, ¢. If engine fires on one or iwo cylinders with weak exhaust report and resultant black smoke, it 4s overprimed and should be unloaded in the fol- lowing manner: (1) Turn ignition switch “OFF,” ios), ORen, throttle and turn the engino backwards ive or six times, 4. For cold weather starting, a half or quarter stroke on the primer when the’ motor fires once or twice will enable it to keep running, In extremely cold weather the oll should be preheated, e, If the engine fails to start after 2 reasonable number of attempts, consult paragraph 1 of Section 6 for possible caus 3. WARM-UP AND GROUND TEST a. AS soon as engine is started, check oil pros- sure gage. If the gage does not indicate pressure ‘within 30 seconds, the engine should be shut down and investigation made, ’. All ground testing and running of engine will be accomplished with carburetor set at "FULL RICH? position and all controllable cowling Haps, grills, ete,, (if installed) will be in the full “OPEN” position. . After engino has run approximately 9 minutes ‘between 700 and 800 rpm, increase throttle gradually until tachometer shows from 1200 to 1600 rpm and run for an additional § to 7 minutes, 4. Test magnetos separately for proper firing, Speed of engine with steady throttle should not drop off more than 75 rpm on either single magneto from, a “BOTH magneto operating position, 10 NOTE: Prolonged running of the engine at or near “FULL THROTTLE” position should be avcided ou the ground, Under average conditions, for continuous ‘operation on the ground, speeds up to 1850 rpm are permissible. However, due to variations in the wooden propellers used, it is extremely difficult to give definite permissibie and top graund rpm, 4. TAKE-OFF a, Immediately before take-off, set brakes, Open to “FULL THROTTLE” for approximately 16 sec onds and check individual magneto operation. Check oil pressure, ofl temperature gages and carburetor air heater control. b. During take-off and climb the engine should be kept at “FULL THROTTLE,” When a safe altitude has been attained the engine can be throttled down, 5. FLIGHT a. The rpm, cylinder head temperatures, oll pret sure, and temperature give the most satisfactory indication of the engine's performance, I any of these appears irregular, the engine should be throt- tled and, if the cause cannot be eliminated, a landing should be made to investitate and remove the trouble, vb. In flight the mixture control can be leaned out ‘only when a higher rpm can be obtained, 1e., @ higher rpm must result from any leaning of the mixture, otherwise the mixture “control must be returned to the "FULL RICH” position, 6. LANDING a, The mixture control must e replaced in its “FULL RICH” position prior to landing. b, From eruising operation, slowly close throttle to 1000 rpm. ¢. The carburetor air heater should be used in long glides. d, When throttle Is closed while making long glides from high altitude, open throttle periodieally to clear the cylinders and to prevent ‘spark plug fouling. 7. STOPPING a. Under conditions of normal usage the engine should have cooled sufficiently during the glide and taxiing period to permit turning ignition switch "OFF" without additional idling, However, if there is an ex- cessive amount of taxiing the engine should be allowed to run two or three minutes about 800 - 1000 RPM before stopping. b. If the engine 1s equipped with a Stromberg NA-S3A1 carburetor, stop fram idling speed by turn ing the ignition switch to"OFF", As the engine stops ‘open the throttle rapidly and leave it open (o prevent aller-firing. If the carburetor is a Marvel-Schebler MA-3PA model, stop by moving the mixture controlto the full "LEAN" position, where it acts as an idle cuteoll, Do not open the throttle, because It actuates the accelerator pump and rapid dpening will flood the engine, 8. CARBURETOR HEAT CONTROL ‘The engine should be operated on “COLD” air at all times, except when operating under caneitions ‘where icing'is likely, in which case the carburetor air control should be placed in the “FULL HOT” position. If improved enzine operation is not obtained ne heat control should he returned tothe “COLD” position. 9. MIXTURE CONTROL ‘The following expressions are applicable to man- ual adjustment of the mixture control: a. “FULL RICH" is the setting of the mixture control lever in the position giving maximum fuel flow. b, “BEST POWER” is the setting of the mixture control lever which, with a given throttle setting, results in obtaining’ a higher rpm,, i.e, 8 higher rpm must reswit from any leaning’ of the mixture, otherwise the mixture control must be returned 10 the “FULL RICH?" position, 10. GASOLINE AND OIL RECOMMENDATIONS Engine Model Minimum Fuei Octane Rating: ‘AOS & ATS 80/87 Oil Viscosity Grades Engine Model Ambient Air Temperature SAE Grade AGS & ATS Below 40°F SAE No, 20 Above 40°F SAE No. 40 When average ambient air temperature is approximately at the dividing line of the above temperature ranges, use the Lighter vil, It is recom- mended that oll be changed each 20 to 30 hours, SECTION 6 ENGINE TROUBLE AND SERVICE REPAIRS 1. FAILURE TO START a. Lack of Fuel, (i) Check whether there is a sufficient level of asoline in the airplane tank to flowto the carburetor. ‘@) Check the gasoline flow at the carburetor, see that the carburetor float is not stuck, and that the jets are not clogged, (3) Make certain that the vent holes in the gasoline tank caps are open, ', Under-priming or Over=prtming.. G) Af engine 1s. undor-primed, Close throttle; with “gasoline supply valve turned on, prime the engine two or three strok (2) If the engine is over-primed, urn the igni- tion switch off, pen the throttle, and turn the engine backward to unioad the eplinders, Defective Ignition, G) Examine “ignition wiring for breaks im the insulation. (2) Check all sparic plugs for correct gap set~ ting. Whenever the gap 1s found to exceed . 025 inch, the electrodes should be adjusted to gap as shown in Continental Motors Service Bulletin M68-4, (8) Chock magneto points for clearance and pos~ sible pitted or oily condition, (4) Examine the ‘magnetos for correct timing to the engine. (Refer to section 11, paragraph 3, 1. } (5) Check ground terminal for possible shorting inside terminal housing, 2. Valve Action, G) Check valve stems to be sure they are not gummed with carbon and sticking open. @) Check condition of valve. springs and see that they are assembled to the valve stem correctly, (3) Check the working order of the rocker arm assemblies. (G) Check for worn or bent push rods, €, Cold Oil— With the ignition switch off, turn propeller over by hand to break the drag created by old ofl between the pistons, piston rings, andeylinder walls, In extremely cold weatier or ‘below zero temperatures, it is advisable to preheat engine and eybinder oil prior to any starting attempts, £, Hot Engine — Do not prime. The engine will frequently stazt without an additional prime over thst left in the cylinders’ when the engine was shut off, Te may be necessary to unload the eylinders by turning the propeller opposite to the direction of rotation. 2. LOW OIL PRESSURE a. Check for dirt in the oll screen, Remove screen and clean thoroughly. inb. Check for poor connections in the oil suction tube, causing the pump to draw air. ‘e. Cheek the quantity of oil in'somp, A minimum of two quarts of oll must be used, d, Inspect relief valve to se¢ whether plunger is operating smoothly in its guide and seating well, and the control spring is fonctioning properly, Clean, @, Inspect and clean oil screen at end of oil suction tube, 3. HIGH OIL TEMPERATURE 4, This condition may be due to the following: Gi) Insuthicient amount of off in sump. (2) Dirty oil. @) Failure toremove winter haffles, or inefficiency of loose battles. (4) Excessively lean carburetor mixture, (5) Worn or stuck rings, indicating. piston score, (6) Altitude contzol mixture not adjusted properly, (7) Operation at full throttle, low speed. 4. LOW POWER OR SPEED ‘a, Check propeller for track, balance, and pitch. 1b, Check spark plugs, wires, condensers, coils. , Check for air leaks at all’ connections of car- ‘urelor and intake manifold. 4. Check for full opening of throttle valve. e. Check for unrestricted flow of fuel to carbu- retor inlet and for proper operation of carburetor. 1, Check cylinder compression and valve action, . Check carburetor air temperature. Check for proper operation of carburetor heat control. h, Check tachometer to see that it is register- ing Correctly, 5. ROUGH RUNNING a. Check propeller for balance, track and cor rect installation on the propeller Imb and shaft. , Clean, re-gap, and bomb test spark plugs, ©. Check magneto operation, Check whether igni tion cables are breaking down at high speeds. 1d, Check valve operation, especially evidence of sticking, or any lag in valve operating mechanism, @, Check engine mounting bolts for tightness. £. Check engine mount for cracked or broken members, 8. Check carburetor air temperature, Check for proper operation of carburetor heat control. @. ENGINE FAILS TO ACCELERATE PROPERLY fa, Motor not sufficiently warm, b, Heater control not on, or not functioning properly. 6, Spark plugs fouled by long idling, 4! High float level, @, Worn intake valve guides and piston rings, 7. ENGINE FAILS TO IDLE PROPERLY a, Check for air leaks at points of carburetor and intake manifold and intake manifold elbow to cylinder connections, b. Leaking primer jets. c. Idle air bleed blocked by dirt, 4. Engine {dling jet set too lean or plugged. e. Worn intake valve guides and piston rings. SECTION 7 Noa (e4 3 1. GENERAL a, The work outlined in this section consists of the’ periodie inspection, cleaning, servicing, Iubri- cating, adjusting, and such maintenance work as is associated with the routine Inspection System. 2. INSPECTION AND MAINTENANCE a. Daily-Power Plant. () Check oil level, Replenish oil supply if neces~ sary. (2) Inspect for evidence of engine throwing oll. (3) Check security of carburetor air intake and its control valve for operation. (4) Ingpect carburetor for fuel leakage at con= nections, drain plugs, and passage plug. Clean fuel filter bowl and fuel tank sump if necessary. Make Sure drains are properly safetied. (5) Check throttie and mixture control connections to insure that no binding exists and they are tight 12 INSPECTION AND ASSOCIATED MAINTENANCE ‘and properly safetied, () Check all wiring terminals for tightness and condition of wiring. (7) Make visual’ inspection of entire engine for: missing or loose nuts, bolts, manifolds; proper safe- tying of all plugs, (8) Inspect the front side of the carburetor intake alr filter to make sure it is not restricted by dust and other foreign matter, The filter should be cleaned as often as it becomes dirty; every day under severe conditions, Whenever the intake air filter is found to be restricied by dust it must be removed and cleaned with mineral spirits solvent used for cleaning parts. Use fresh solvent for final cleaning, and drain the filter thouroughly. ’, Tgnition and Electrical. (i) 25-Hour. {a) Remove megneto breaker cover and clean brea- er housing.(©) Inspect magneto for damaged breaker felts or cushions. (c) Check for excessive lubrication. Clean and dry the breaker mechanism to insure that oll will not touch the breaker contacts, (@) Make certain all necessary ‘safely wiring or pins are installed, {e) Replace breaker assembly, if necessary. (@) Check security of sparkplug elbow terminal and shielding nuts on radio shielded engines. NOTE: When checking the elbow assembly, extreme care must be exercised that the barrel is not rotated ‘with respect to the shell. Discontinue the common practice of slightly tightening the elbow nut at each Déchour inspection. Never chock the tightness of the elbow by twisting te body of the elbow. (2) 50-Hour- Inspect all wiring for breaks in the insulation and proper securing of terminals, Replace, ifnecesaary, (8) 100-Héur. @) Remove spark plugs and clean, or replace with new OF reconditioned plugs of approved type. (0) Install serviceable spark plug gaskets. {c) Test Ignition cables for high tension leaks. ©. Fuel System, () 25-Hour, (a) Lubricate throttle shaft bearings, using light machine oil, (0) Remove fuel fiter bowl, Clean screen and bowl, Replace bowl and refill, Check for leaks and bubbles, Tighten how! and safety, (c) Remove float chamber drain plug, fuel strainer plug and strainer. Clean strainer. Flush out water and. sediment by. allowing fuel to flow through strainer and drain plug opening, 4. Ol System, (G) 25-Hour. (a) Drain engine oll after each 25-hours’ operation, ‘umless operating conditions indicate otherwise, and refill with the proper grade and quality of ‘fl, The draining should be done while the en= gine is hot, See table, page 18 for proper grade. () Check ofl’ sump for’ security of motmting and proper safetying of all nuts, {@) The oil screen assembly located in the crank cage cover back of No. 2 cylinder should be cleaned at least once every 25 hours. {@) 100-Hour - Clean oll serecn and ofl suction tube ‘@) At Engine Change -Clean oil sereens on newly installed engines at the following periods: (@) At completion of ground installation test. (b) At completion of flight test, , Cooling System. Gy 30-Hour, (a) Check air deflectors for cracks, security of fastening, and to make sure they ‘do not chafe cylinder fins, (o) Inspect cylinders for damaged or broken fins. £, Valve Mechanism, (2) These engines have internal automatic lubri- cation of the valve machanism which should be in= spected in accordance with the following periods and instructions: (a) 25-Hour-A complete inspection of the valve mechanism should be made at the first 26-hour inspection after the engine is installed. (b) 100-Hour-A complete inspection of the valve mechanism should be made at 100-hour inter vals. (2) In making the inspection set forth above, the following instructions should be observ (a) Remove rocker box covers, Inspect rocker arm for cracks, excessive side or end play, signs of interference with adjacent parts, () Check for broken springs, condition of valve spring retainers and security of valve spring ‘seat locks. (c) Make certain all oil passages are open before roplacing rocker box cover. Interior of rocker boxes souldshow complete coverage with engine . Manifold and Hose Connections, i) 25-Hour. fa) Check intake manifold for proper mounting and for security of the two plain nuts and palnuts, {(b) Inspect rubber hose connections and clamps on the intake pipes and elbows for proper and secure adjustment. h, Propeller and Accessories. Gi) 100-Hour. () Check propeller hub bolts for tightness and check propeller for track, making corrections if necessary, The propellér should track within 1/8 inch. i, General. (4) Check “engine mounting bolts for proper torque, (2) Cheek propeller hub and nut assembly for pro- per torque, Should be 200-225 ft, Ibs. (8) AIL unattached ignition cable ends must be cov= ered with friction tape or other suitable protective covering and secured. 3SECTION 8 ADJUSTMENT, REPLACEMENT AND MINOR REPAIRS 1. GENERAL ‘a. The work outlined in this section can be per- formed without the facilities usually available at major ‘overhaul shops. ’. This section of the manual contains all neces~ sary instructions for the replacement (but not repair) ‘of accessories and removal of external or readily removable parts. 2. CARBURETOR a. "The carburetor ss located at the bottom of the crankcase and 43 attached to the intake manifold, which in turn is assembled on the twa studs pro” vided in the crankease, , The carburetor is installed to the mounting pad of the Intake manifold with a gasket between the parting flanges, and is retained by four plain nuts together with suitable plain washers and Jock washers. ©. The carburetor air intake and filter assembly is mounted on the base of the carburetor with & vaskel, and is retained by four piain nuts with sult- able lock washers. foflzyomTIS connecting to the earburetor are as {1) The throttle control lever is at the right side of the carburetor as viewed from the rear of the engine, (2) The mixture control lever is located on top of the float chamber on the left side as viewed from the rear of the engine. . The carburetor may be removed from the engine ‘y detaching the fuel Line, throttle and mixture con- trols, removing the air intake assembly and the four castle nuts at the mounting pads, 3. MAGNETOS ‘The two magnetos are mounted onthe right and left sides of the crankcase cover. The mounting flange of each magneto is attached by two studs, plain washers, lock washers and nuts. 4. MAGNETO INSTALLATION AND TIMING TO ENGINE a, Rotate the magneto until the mark on the gear, visible through the inspection window, is in line with small pointer, which is also visible, This places the magneto in firing position for cylinder No, 1, Rotate engine in counterclockwise direction until the firing, stroke of No. 1 cylinder is reached. ». Installing the left and right magneto, set the engine as follows: AGS Series 8,---Right and Left Magneto: 30° BTC. ATS Series &,---Right Magneto: 28° BVT.C, [ATS Series 8,--- Left Magneto: 32° B.T.C, B.T.C. C. Tighten the mounting nuts enough to hol magneto {in position against the accessory case. Before check ing exact breaker opening position, rotate magneto u counter-clockwise by tapping the mounting flange until it 1s near the end of travel permitted by the slots, Turn crankshaft backward slightly, and Bring slowly up to firing position to take backlash out of the driving gear train. Insert a .0015-inch feeler between breaker points and tap magneto flange in a clockwise direction until the exaet point of release is reached, Tighten mounting nuts and recheck timing by backing up crankshaft and turning it stowly forward to determine if the fecler is released the instant the aise reaches the correct mark, Turn shaft only 5° or 0 to check impulse coupted magnetos. 5. IGNITION WIRING a. Refer to figure 11 where the complete ignition wire system is disgrammed and firing order given. b, The following table shows the individual ignition cable lengths in inches and the total amount required for te Series 8 engines with S4-RN magnetos: CYLINDER LEFT MAGNETO RIGHT MAGNETO ‘NUMBER TO LOWER PLUG TOUPPER PLUG 1 26" sar 2 2" 36" 3 ar 30" 4 a2" 35 Total length required per engine 24 fect NO, | UPPER NO. 1 LOWER WO. 3 UPPER NO 3 LOWER To_MAGNETO No 2 UPPER ‘swircH No 2 Lowen 9 UPPER 8.2 LBRER FRING ORDER OF ENGINE 13.24 Figure 11, Ignition Wiring Diagram. 6. REMOVING PARTS a4, Cylinder and Piston, (iy Remove ‘wires from spark plugs, and remove spark plugs rom eylinder head, (2) Loosen the hose ‘conections at the cylinder etbow fo the intake pips, Slide rubber hose toward carburetor. (3) Remove screws holding the rocker box cavers to the eylinders and remove covers, Push rocker arm shaft out with the finger, Make sure that the intake dnd exhaunt valves are closed, Remove rocker arms and push rods from push rod housings. (a) Loosen clamps holding the howe ennections at foot of posh rod housing, Push clamp and rubber hose Up the housing toward the cylinder head, (5) Remove the six cylinder base nuts, Remove the cylinder. from ‘the erankease, the piston nnist he at the outer end of the sircke, EECAUTION: Do not allow piston to drop down as cylinder 1s removed from it, or damage will result, (6) Push piston pin out and remove piston from the connecting rod. 'b. Valves - Compress the valve springs in the rocker box, using a Suitable valve spring compressor, Remove valve spring locks from valve stem, Remove spring seat, springs, and spring retainer. In removing valves, from guides extreme caution must be exercised that they do not scratch or mar the valve guide bores, 7, GENERAL INSPECTION a, Replace all spark plugs with new or recondi- tioned plugs, Carefully ‘inspect the entire ignition harness for serviceable condition, 'B, Remove all cylinder hold-down studs that are loose, broken, or have damaged threads, and instali proper replacements. Available oversize replace- ments are listed in the Hlustrated Parts List. . Check entire engine ‘and make sure ‘all nuts are tight in accordance with torque values set forth in the Table of Limits, and see that all safetying is complete and tight. Palnuts must be tightened as, follows: After the regular nuts are tightened to the desired torque, instalk palnuts with the smooth face against the pldin nuts, Tighten the palnuts with the fingers, then tura with a wrench until the nut is locked,’ or approximately one-sixth of a turn, Never Uighten paliuts more than one-quarter of a turn, Excessive tightening will render tiem unserviceable, CAUTION: Do not attempt to tighten or loosen the palnut and plain nut at the same time. 4, Inspect, tighten, and safety all engine mounting bolts, REASSEMBLY a, General-In this operation it will be assumed that all parts and assemblies are in a serviceable condition, thoroughly clean, and have been lubricated ‘with engine oil on their’ bearing surfaces, When assembling the engine, use new gaskets and packing throughout b. Valves—Clean and ofl valve guides and stems, Insert valve stems 1 guides. fc. Valve Springs. (i) Insert ‘valve spring retainer, valve outer and inner springs im rocker box housing! (2) Fit spring seat over springs, (2) Observe the following instructions before com- pressing valve springs for installation: (a) Place a block (having the same contour as the inside of the head) against the dome of the ‘combustion chamber to prevent the valve stems from descending in the guides when the springs are compressed for installation. {b) Compress valve springs and install Locks. 4. Piston Pins, Pistons, and Cylinders. (i) Install new rigs ‘on piston, Fit assembly to ts respective connecting rod with numbered side facing the propeller end of the crankshaft, Push piston pin carefully inta position, Be sure’ piston pin plugs remain in place, CAUTION: Piston must be carefully supported to avoid coming into contact with other metallic surfaces. (2) Turn crankshaft until its position is brought to the outer end of the stroke, Carefully wipe off cylinder with clean cloth, Oil bon cylinder and pis- ton, Use new cylinder ‘base packing between the cylinder base flange and crankease, (2) Install push rod housing rubber hoses on the housing and push back toward the cylinder head for clearance. (4) Before placing cylinder on the crankcase section, all of the cylinder studs and hold-dowm nuts should be examined for cracks, damaged threads, or other visible defects, Any stud’ or nut that is defective must be disposed of. The threads of the studs and hold- down nuts must be thoroughly cleaned, Both faces of the stud washors and the recesses in the cylinder flange for the washers will also be cleaned, and any roughness or burrs removed, (5) Assemble cylinder over piston, Rotate rings until gaps are evenly spaced about the piston, com= pross rings and slide the cylinder over them, 48) Tighten cylinder hold-down nuts in the follow= ing manner: First put on all mits and serew down, in contact_with flange using light pressure on hand wrench, Then torque each as specified in the Table of Limits in order shown on figure. Then retorque clockwise starting with #1, Tt is very important that the position of the wrench be maintained so that the turning axis of the wrenck always coincides with the vertical center line of the hold-down nut which is being tightened, All nuts will be tightened slowly and ‘smoothly untid the proper torque las been applied. Figure 12, Cylinder Flange Torque Sequence, CAUTION: Jerking of the torque wrench must always be avoided, Care must be exercised at all times to insure that the socket of the wrench does not contact the cylinder wall during the tightening procedure as such contact will cause an incorrect torque reading. (7) Cylinder hold-down nuts should be checked by installing the torque wrench on the particular nut and gradually turning to the desired torque limit, If any movement is noted during this check, the nul ‘will be loosened and retightened in accordance with instructions in paragraph (6) above, (8) Upon completion of the check specified in para graph (7) above, install palnuts, No further inspection, of cylinder stud hold-down nuts will be necessary between engine overhauls, (8) Slip rubber hose connections down in place on the ‘push rod housing and tighten with metal hose clamp. (10) Attach intake manifold and install intake pipes: and hose connections. (U1) Attach the carburetor, e, Rocker Arms and Push Rods. 6(Q) Rotate crankshaft so Bist intake and exhaust valve tappets are al their inward position, (2) Insert push rods in the housings, hold rocker arms in place, and push in rocker ‘arm shaft, If the tappets fill with oil, it will be necessary to come press valve springs while inserting the shaft, 1, Rocker Box Cover. (2) Fit gasket on mounting face of rocker box cover, (2) Pasten cover on rocker box housing with 1/4. inch serews, &, Spark Plugs, () Apply a small quantity of mica thread lubricant on the threads of the spark plugs, CAUTION: Do not allow any of the compound to collect on the electrodes, a8 subsequent fouling of the spark plug may result. (2) Screw spark plugs in cylinder head and tighten. NOTE: Spark plugs will be lightened to a maximum torque af 360-ineh pounds. h, Adjustment of Valve Tappet Clearances. As these engines are equipped with hydraulic tappets, ‘no method of adjusting clearances i8 provided. Tap- pets Will function properly with clearances ranging from .O30 inch to .110 inch. (with tappets deflated). OVERHAUL INSTRUCTIONS SECTION 9 DISASSEMBLY 1. GENERAL 2, Before proceeding with the operations of engine overhaul as outlined in this section, remove the engine from its packing box or the airplane in which at is installed, ‘as outlined in Section 4 and 5, Mount engine on an engine overhaul stand, 'b, Spray the exterior of the ongine with an ap- proved cleaner to remove all traces of dirt and grease, c, Remove all safety wiring, palnuts and cotter ping where necessary before each part ts disassem- bled from the engine, 2. PRELIMINARY OPERATIONS. a. Ignition Wiring Assombly -Unfasten at spark plugs, maguetos, remove nuts securing brackets and remove ignition wires from engine. 'b. Spark Plugs ~Remove upper and lower plugs, c. Magnetos~Remove nuts that fasten magnetos to crankease cover and remove magnetos, ‘4. Caruburetor Air Intake -Remove te four nuts that hold the carburetor air intake to the carburetor aud remove air intake. e. Carburetor Remove four nuts which fasten the carburetor to the inlake manifold and remove car buretor, 3. DISASSEMBLY , Oil Sump and Suction Tube - Remove the six nuts that hold the oil sump to the crankease, and the nut that fastens the oil filler bracket to the crankcase and remove oll sump, The oil suction tube inside the oil sump and attached to the erankease cover can be removed by unscrewing the hex portion at the top, using a 7/Bsinch openend wrench, , Intake Pipes and Manifold Untasten clamps which secure hose connections to intake elbow at cylinder, Slide the rubber hose down toward carbure- 16 LEANING AND INSPECTION tor. Remove the two 3/8-inch nuts holding intake manifold to erankease, Remove intake manifold and pipes by dropping straight down. ©. Rocker Box Covers - Remove the 1/4-inch serews ‘that fasten the rocker box covers to the cylinder head and remove covers. ‘d. Push Rods and Rocker Arms- After covers are removed, push out rocker arm shaft with the finger, or, if necessary, use aluminum drift and lightly tap oul, Remove rocker arms from cylinder head and push rods from their housings. CAUTION: make certain that the cam is in sucha position that the intake and exhaust valves are com- pletely closed before removing rocker shafts. ¢. Cylinder and Pistous. G) Loosen clamps holding hose connections at foot of the push rod housing, Push clamp and rubber ose back up on the housing toward cylinder head. (2) Turn crankshaft until piston within cylinder to be removed is at top of the stroke, (3) Remove the six cylinder hold-down nuts and pall off cylinder from the crankease, CAUTION: Do not allow piston and connecting rod to drop down when eylinder is removed, as damage ‘will result, (4) After removal, place cylinders on wood or appropriate carrier’ to prevent damage at bottom end of barrels. Cover crankcase openings to prevent dust or grit from entering the crankcase, (5) Push piston pin out and remove piston from connecting rod. If necessary, use aluminum drift to drive out piston pin, being’ careful to support the piston in the hand during this operation to prevent daniage to the connecting rod, (O) Remove the piston rings from the ring grooves of all pistons, Tie the set of rings for each piston together and tag, Number each tag with the number of the piston from which the rings were removed,(2) Placing the cylinder over 2 wooden stand, shaped to fit the inside of the cylinder head, com-, press valve springs in rocker box, using a suitable valve spring compressor, (figure 13), such as sup~ plied by the Borroughs Tool Company, remove the Seat locks with thin-nosed pliers, release the com- pressor, and remove the spring seat, inner and outer Springs, spring retainers and valves, CAUTION: Tn removing valves, care must be taken that they do not seratch or thar eylinder walls or valve guide bores. Figure 13, Compressing Valve Springs for Installa- ton and Removal of Locks, 1. Crankease. G1) Memove the four push rod housing flanges. by ‘unscrewing the muts which secure them to the Ural @) Remove the valve tappet cups on the push rod end of the bydraulle valve fapzets, Remove the hy= Graulie units of each tappet with the ald of a small ‘wire hook, (Figure 14.) Keep tappets numbered ac- cording {6 the order removed Reaping assemblies grouped together. NOTE: If the cylinder and piston of the hydraulte units do not come out together, it may be necessary to wedge a wooden plug into the cylinder of the hydraulic unit and remove cylinder in this manner, Care must be taken that the wooden glug does not damage cylinder, NOTE: The valve tappet eam follower body cannot be removed unlil the crankcase 1s disassembled, Place push rod housing connections over ends of cam follower to prevent their falling into crankease when erankease 1s Kfted off, See Fig. 21, page 25. (8) Remove the ten 5/16 inch nuts nolding the crankease cover to the crankease. Lift the cover off as a complete unit-the oil pump, relief valve and tachometer drive units remain intact in the crankease cover. (@) Remove the four 1/4 inch cap screws holding the cam gear to the camshaft and remove gear, (5) Remove the four 1/4 inch cap screws holding the crankshaft gear to crankshaft and remove gear. (6) Remove ail 1/4 inch nuts from the bolts holding halves of crankcase together, lovated on centerline ‘of erankease on both top and bottom of the engine. (7) Remove two 7/18 Inch nuts attached to long studs at front of erankease on the No, 2-4 cylinder side, t¥0 7/16 inch muts on the No. 1-3 eylinder Side’ anove the intake pipes between ihe cylinders. (8) Rotate the engine stand until No. 2-4 erank- case is lying on its side, check all crankease-to- erankcase studs to see that all nuts have been re~ ‘moved, and carefully lift the No, 1-3 crankease off and lay aside with contact surface up. Do not pry the parting faces of the crankease apart with 2 Screw driver as the contact surfaces maybe damaged, Figure 14, Removal of Hyciraulic Unlt from Cazw Follower Body. (9) Lift crankshaft, with connecting rods attacked, out of the crankease, (10) Remove craniease oil seal from front of shaft. (11) Remove camshaft and bearing shells fromboth halves af the crankcase. (12) Remove all connecting rods from the crank- shaft, carefully noting their position on the shalt Point up rod sumbers before disassembling. (13) Remove push rod housing connections from ends of cam followers and remove cam followers from both halves of the crankease, g. Crankcase Cover Assembly (Series 6) 7(1) Remove oll pump cover nuts holding the ofl pump gear plate é the inside of the cover and bft Eutthe two of pump gears, (2) Unserew the tachometer drive housing from te outside of the cover. NOTE: The housing. 15 attached to the crankcase aver with a left-hand thread, (8) Remove tie oil pressure relief valve cap, gasket, spring and plunger from tho outside of the (4) Remove oi screen and gasket from outside of 4. CLEANING a, MATERIALS AND PROCESSES (1) Equipment, materials and processes in yeueral use tn alreraft engine overhaul shops are satistactory for cleaning "A" Series engine parts. (2) Aluminum alloy parts can be degreased by spray~ ing withany fortified mineral spirit solvent or by brush application of the same liquid. Fortified mineral spirits are more effective when the partsare immersed tn them and allowed to remain for a short time to per- mit solvent action to loasen caked deposits. Carbon deposits and gum (oil varnish) may be removed moat easily by immersing these parts in a hot hath of an inhibited, mild alkaline cleaning compound. Trimer~ ton time should be only as long as necessary to re- movethedeposits. Carbon solvent should be employed fanly when carbon deposits are too hard and tick for removal by other solvents. Give special attention to ‘cleaning studs, tapped holes and drilled holes, Caution must be exercised in cleaning of all aluminum alloy ‘engine parts. Donotuse any strong alkaline solutions, to cleanaluminum alloy castings or wrought aluminum alloy parts, because strong solutions will attack and destruct a bare machined surface, Immedaitely after removing soaking parts from a caustic or inhibited mild alkaline bath, remove all traces of the alkali by ‘spraying the parts with a jet of wet steam ar by brush~ ing vigorously with a mineral spirit solvent, Cleaned parts may be dried by use of a jet of dry compressed air ta remove all solvent liquids. co Nl alkaline residues must be removed from crevices, recesses and holes, as well as from other surfaces, to prevent the formationof a foaming emulsion in the engine lubricating oil alter reassembly. (3) No polishing compound or abrasive paste or powder should be needed or employed for cleaning engine parts. Scraping, abrasion with wire brushes, sand paper or abrasive cloth and buffing wheels are dangerous methods to use on soft metals such as al- uminum. Scratches resulting from such methods allowa concentration of stress at the scratch and may cause fatigue failure. (A) Various blasting techniques can be employed to. 1B remove hard carbon deposits if suitable equipment is available. The most sultable types of grit for dry blastingare plastic petiets and processed natural ma~ terials, such as wheal grains and crushed furit pits or shells. Air pressure should be the lowest that will, produce the desired cleaning action. Small holes and Hnished surfaces whiehdo not require cleaning should be protected fram the blast by seals and covers, par~ Ucularly if the grit is sharp. Sand, shot and’metal grit are too abrasive and too heavy for use on soft metals such asalumisum, Alter any blasting process, blow off all dust with dry compressed air and make sure that no grit fas lodged in crevices, recesses and holes. b, SPECIFIC PARTS. (1) CYLINDERS, Precautions applicable to hoth atummum and steel must be exercised in cleaning and storing these assemnlies, Remove oil and loose ma- terial with a mild alkaline cleaner by spraying or brushing. If stubborn deposits of carbon remain on eylinder heads, the areas affected may be vapor blasted, AN machined surfaces must be protected from abrasive action during the blasting operation, 2) PISTONS, Donotuse wire brushes or scrapers of any kind, Softand moderately hard carbon deposits may yieldtosolventaction, I deposits remain, blast the heads with soft grit ar by the vapor grit method, first having installed tight fitting skirt protectors, Ring grooves may be cleaned by pulling through them lengths ot binder twine or very narrow strips of cro- cus ¢loti, Do not use automotive ring groove serap- ers, sinte the corner radii at the bottoms of the grooves must not de latered, nor any metal removed rom the sides. Discoloration and light scoring need not be removed from piston skirts, ‘The use of abra- ssive cloth on the skirisis nat recommended, because the diameters and cam-ground contour must not be altered, Heavily scored or burned pistons should be aisearded (3) VALVES. After degreasing valves, inspect them and discard any whose head is warped exces- sively, or which has insufficient stock to permit re- acing within specified limits, or whose stem 1s durned, scored, eroded or nicked, Carhon deposits may be ioosened by solvent action or they may be scraped off while the valve is rotated in a polishing head or lathe coliet. Apply crocus cloth moistened 1 ‘mineral spirit, and polish the stems with dry crocus cloth, (4) ROCKER SHAFTS, Degrease these parts by brushing onany mineralspirit solvent, Prior to mag~ netic inspection, polish the steel bearing surfaces with crocus elath moistened with kerosene, then with, dry crocus cloth. (5) PUSHRODS, VALVE ROCKERS AND OTHER SMALL STEEL PARTS, Degrease these parts with ‘mineral spirit solvent, paying special attention to re- moval of sludge from all oil passages,(8) CAMSHAFT AND CRANKSHAFT. All parts may be degreased by brushing or spraying with m eral spirit solvent. Pay particular attention to threads, oil holes and recesses. Before magnetic inspection, the erankping, main jovrnals, oll seal race of the crankshatt and all journals, cam lobes. and gear mount flange of the camshalt must be smdothed with crocus eloth, moistened ina mineral spirit. If possible, this should be accomplished while shatt 18, Fotated ina high speed lathe (about 190 rpml. AML gam (varnish) depasits must be removed to permit retiable magnetic indications, (1) CRANKCASE, The oll passages should be pressure-flushed with mineral spirit solvent and in- Spected with the aid of a flashlight, If the castings fare immersed in an alkatine bath, it is strongly re- ‘commended that such treatment be followed by spray- ing with jet of wet steam and this followed by flushing of the oll passages with solvent, After the castings dry, inspect them thoroughly for alkaline residues, and remove any traces of scum, (8) GEARS, Gears without bushings may be freed of hard deposits by immersion ina caustic stripping bath, when cold solvents are not effective, Bushings are disvolored by suchtreatment, hence bushed gears should be cleaned by other metiiods such as spraying and/or brushing with a mineral spirit solvent and brushing with a brass wire brush, (9) SHEET METAL PARTS, Clean these parts with a mineral spirit spray or by brushing with the same liquid, of use 4 cald emulsion type cleaner and flush with water to rinse, c. Immediately after cleaning bare steel parts spray them with of dip them in clean engine oil oF, for longer storage, in a corrosion-preventive oil mix- ture, Wrap ball bearings in waxed paper. Wrap or cover other cleanparts to protect them from abrasive dust in the air. 5. INSPECTION a, General. (iy After the sub-assemblies and parts ofthe engine have been cleaned and dried, place on a table for visual inspection, This inspection will be a basis for determining which parts have been defective or damaged in the course of operation, Parts that are damaged beyond repair, or worn in excess of the permissible tolerances, must be replaced. b. Magnaflux Inspection, Parts listed in Table 1 should be inspected at each overhaul by the Magnaflux process or an equivalent method of crack detection, ‘The Magraflux method is recommended whenever the necessary equipment 1s available, ‘Txhle I provides data for proper inspec- tion by the Magnaflux method, This method eraploys magnetic particles coated with a flourescent organic material whieh may be illurninated with “blacklizht”, as in the Zyglo process, to amplify weak indications. Ifa crankshaft 1s doubifel alter clreular magnetiza- tion ard inspection, demagnetize and remagnetize it Iongitudinally for further inspection, Before magnetic particle inspection, piston pins and valve rocker shafts must be polished with erucus cloth, ‘Before magnetic particle Inspection of any part, plug small hotes leading to obscure cavities with Hght-fitting wooden plugs or witha hardgrease which is soluble In lubricating oil to prevent particles from Iooging in places from whieh they would be difficult to remove and which places are aot subject to visual inspection, After magnetic particle inspection, re- move all such plugs and clean the part thorougiily in solvent; then dry with compressed air. Check for complete demagnetization, c, Flourescent Particle Inspection, ‘This process, Commonly known under the grade aame of "Zyglo”, is recommended for inspecting alumi num and magnesium alloy parts for invisible cracks, The standard operating technique for the process 3s applicable. 'b, Inspection of Engine Parts. G) Crankease. a, Check thoroughly for fatigue cracks. b, Examine bearing seats for cracks and scratches and excessive wear. ‘e, Check studs for damaged threads and straight (2) cytinders. a, Cylinder Heads~Examine cylinder head for eracks, Small cracks found at head fins are not cause for rejection. However, Hf cracks are of appreciable size and indicate ultimate failure, replace the cylinder. ’, Cylinder Barrels - Inspect cylinder barrel flange for’ nicks, evenness and for condition of cylinder hold-down nut recesses. Inspect inside of cylinder barrel for dents and scoring, for corrosion as indi- ated by rust and pitting, and for ring wear as evi- enced by a ridge near’ the top and bottom of the barrel, Also check inside of barrel for out-cf-round and taper, using dial indicator. fc, Spark Plug Inserts and Pins Bxamine for eros sed or otherwise damaged threads and looseness of insert in head, ‘d, Rocker ‘Shaft Bosses- Examine rocker shaft bosses for oversize and galling of bearing surfaces. fe, Valve Seat Inserts~ Examine for signs of erc- sion, burning, pitting or warping, . Valve Guides - Examine for wear and looseness. It Toose in cylinder head, ot if excessive clearance is found between valve stem and guide, replace, g, Roker Boxes Examine for smoothness of fin ished surfaces, h, Intake and Exhaust Flanges - Examine for nicks and burrs and smoothness of surfaces. (8) Valve Mechanisn:, a, Inspect exhaust and intake rockers for cracks, particularly around lubrication holes, Alsa inspect Foekers for straightness, nicks and condition of bushing, Check rocker shatt for wear. b, Bxamine push rocd for straighiness by rolling them on a flat plate, See that lubrication holes on bball ends are not obstructed, ‘e, Check valve springs for fractures, corrosion and’ for proper pressure and length as dpecified in Table of Limits, Inspect ends of each spring for splitting and cracks. ‘d, Inspect valve spring retainers and seats for cracks and wear, 0TABLE 1 MAGNA: FLUX INSPECTION DATA Method of Method of Possible Part Magnetization | Amperes | Inspection | Critical Areas Detects (Crankshaft Cireutar 2500 Wet Journals, fillets, ott | Fatigue eraeks,| Continuous] holes, erankpins heat cracks thrust flanges Connecting roa | Circular 1800 Wet All areas Fatigue cracks. Continuous: Piston pin Cireuler 1500 Wet Shear planes, ends Fatigue cracks, Residual stringers Rocker arms Cireviar 1800 Wet Rocker face, socket | Fatigue cracks Continuous Camshait gear | Circular 1800 Wet Teeth, holes Fatigue cracks Continuous Crankshaft gear | Circular 1600 wet Teeth, around screw | Fatigue, hest Continuous | holes cracks Ou pump gear | Circular 1800 Wet Teeth Fatigue cracks Continuous @, Inspect valve spring retainer locks for wear and’ galling on outside diameter, and for wear and it on valve stem, 1, Inspect exhaust valves carefully, using a mag~ nifying glass and magnaflux equipment, for cracks on end of valve stem, valve head and in grooves for retainer locks, Inspect valve stem and tip for scoring, pitting ahd wear. Check valve face for ‘warpage, pitting and burning. g, Inspect intake valves as discribed in preceding paragraph, 1h. Check hydraulic tappets in accordance with in- structions given in accessoxy section, (4) Oil Sump- Examine body of sump for excessive dents and possible fractures or cracks. Inspect oil filler body. Check drain hole for damaged threads. (5) Crankshaft and Connecting Rods, a, Carefully inspect crankshafl, Using magnaflux equipment, A fractured shalt mlust be replaced, 'D, Check keyway on front of shall for nicks or burrs if shaft is of taper end type. fe. Inspect comecting rod bearing surfaces for galling, scoring and for groper clearance with con- necting rods in accordance with the Table of Limits, ‘@. Inspect oil tubes for tightness in shaft and for freédom from obstructions, fe. Inspect oil plug and propeller hub nut Uneads at front of crankshaft, {. Inspect all connecting rods and caps for cracks, Check alignment of crankshaft bushing with piston pin bushing, The crankshaft hole and the piston pin hole must be parallel with each other within .001 per inch of bearing length, (6) Pistons and Piston Pins, a, Check piston pin plugs’ for smoothness, wear and proper fit in the piston pins, Discard piston pin 20 plugs which are cracked or show excessive wear, b, Check piston pins carefully for cracks, using magnaflux equipment, Also check piston pins for scoring, Hat. spots, out-of-round, straightness and for proper fit’ in’ piston, Piston pins which are eracked, out-of-round, bent, scored, or excessively ‘worn must be replaced, ©, Carefully inspect pistons for cracks, scores, corrosion and for proper size of skirt. Check ring Iands for cracks by applying a light sido pressure, Also check ring grooves and lands for proper width, inspect bearing surfaces in piston pin bosses for wear and scoring, @ Replace cracked oF bvadly-corroded pistons. Piston rings must be replaced at each overhaul, IE cylinder barrels have been reground, or if piston Ting grooves have been remachined, exercise care that proper oversize piston rings’ ure installed, (7) ‘Crankcase Cover, a, Inspect cover for eracks, particularly around stud holes and using a magnifying glass and, if necessary, by etching any doubtful portions for pos~ sible cracks. Inspect magneto mounting flanges for corrosion, burrs, scratches and flatness, b, Check all studs on cover for cracks and tight ness, Stretched or looge studs must be replaced, €, Inspect threads of oil pressure relief cap, oll suction tube, oil screen and tachometer housing. (8) Camshart, a. Inspeet cam lobes for scoring, wear and pitting. Crankcase bearing surfaces for camshaft shoutd be checked for out-of-round condition, for eracks and scoring, (9) Gears. a, Check magneto drive, cam and crankshalt gears for cracks, nicks, burrs, wear and proper fit. Section 10 Repair’ & ReplacementSECTION 10 REPAIR AND REPLACEMENT 1, GENERAL a. Special Tools required for repair and assembly wark may be purchased from the Borroughs Tool and Equipment Company, Kalamazoo, Michigan, b, Repair such damage to finished surfaces as scores, nicks, burrs and roughness by careful hand stoning, using @ fine Stone and gasoline, Polish with crocus eloth and gasotine, €. Lap flanged surfaces which are bent or uneven, toa Mat surface, 4. Repair slightly-damaged threads with proper thread chasers, 2. All loose, bent or otherwise damaged studs will be replaced by the next oversize stud. Re- placement of steet ‘studs driven in aluminum’ alloy Farts requires good judgment as well as a great deal Of care on tie part of the mechanic. Unies the re~ placement 1s properly made, more difficulties may be encountered than would have been evident had 00 attempt heen made to correct the original difficulty. (1) The first problem is not just to get the broken or damaged stud out, but to get it out without injury to the part in which it has been set. If the outside threads have been stripped, it is ustally a simple matter to remove the stud, A stud driver or a small pipe wrench, if necessary, may be used. Apply Pressure on the bandle of whatever tool is used in Such a manner that there will be no tendency to bend the stud. Back the stud out slowly to avoid overheating of the threads, It should be remembered that any thread lubricant or sealing material used when the part was originally installed bas probably congealed, and rapid ‘withdrawal of the parts may cause damage to the housing threads, Either of two ‘methods has been used successfully to remove studs broken off at or near the base, The center section of the stud may be drilled out anda square shanked stud remover instailed, Use a wrench of the proper size and back the stud out carefully, 1f thia method does not work satisfactorily, It may be possible to elec trie weld 2 short piece of steel bar stock nr a steel fut to the broken Stud. The bar steck or the nut may then be used to withdraw the broken place, ‘The welding must be done carefully to avoid melting or damaging the metat around the base of the stud. (2) The threads in whatever part the stud is to RRR @® | wean |S BREURWE ] ore Figure 16 Sud Ikentification, be replaced should be cleaned up before attempting to drive a new shud Be sure that the tap to be used is the correct size. New taps usually eut oversize, and the mechanic should handle them carefully, I the tap appears to be cutting material away instead of just cleaning cut the threads, withdraw it and use an lder tool. Rough edges or burrs on a tap may also cause it (o cut oversize, Carefully inspect all taps for evidence of this difficuily before they are used, (3) Ea stud was removed because it was loose, the next oversize stud should be installed, Oversizes Of .008 ineh,, .006 inch, and .009 inch for five digit studs and ,003 ineh, .007 inch and 012 inch for 6 aldgit studs are supplied to replace standard studs, These studs may be identified by the machining on the end that 1s driven into the housing, Hefer to figure 16 for section drawings showing the identifying shapes ‘on the ends of the studs, Examine the stud removed to determine what size it is, and install the nest Oversize stud available, If the Stud being removed was broken and is aot being replaced merely because ik iit loosely, install the same size stud that was, ‘taken out. (4) An’ approved tbricant shoulé be applied to the Uireads oa all studs before they are installed. The lubricant should be stirred before using and applied in conservative quantities, %5) Before installing a stud, make certain that it is the correct part and that’ the right end will be inserted ia the housing, Examine the new stud care- fully, since these parts easily become mixed in stock, (6) There is a definite height that each stud in the engine must protrude when it has been instalied. Check this height with the blueprint when such information is available, (2) Wheo driving the stud, feed it in carefully until reasonably sure the threads are meshing properly. Thea turn in slowly and steadily until the stud is approximately in position, A T-handle stud driver should always be used, (@) Do not turn the stuls in rapidly, or itis possible that the threads may overheat and etther Seize or be damaged, f, Dress washers, nuts, lock nuts and screw heads to reniove burrs, nicks, or scratches from outside surfaces, Nuts, Washers and screws used externally should be zine or cadmium plated to prevent corrosion, 8, Replace any part found to be cracked unless It ts an unstressed part that can be repaired by welding ‘without further damage of distortion to it h, Replace all gaskets and packings at the Gime of a major overhaul. REPAIR AND REPLACEMENT OF ENGINE PARTS a, Crankease, (i) Make repairs to the crankease in accordance ‘with instructions given in paragraph 1 of this sec- tion, Particular attention should be given to removing nicks and burrs from all finished curfaces, using a fine stone and polishing with erccus cloth, 4b. Cylinders. (2) Replace cylinder anc nead assemblies which are found to nave loose heads or cracks, except for small eracks near the surface of the eylinder fins. Small cracks ‘on the end of cylinder fins should be carefully removed by filing. Round off sharp corners. (2) Reniove micks on flanged surface of eylinder barrel flanges by liand stoning, Polish anges with erocus eloth. (3) Repair eylinder bores which are slightly cor rodéd, seored or pitted by homing, If the maximum, permissible out-cf-round condition, the maximum, permissible taper, or the average maximum barrel Giameter is exceeded, the cylinder bore should be reyround and ioned ty the first standard oversize that will remove af out-of-round and taper. If cylinders are ground oversize, Mt will be necessary 16 [it oversize pistens and yiston rings, Pistons are Avallable to Lt cylinders .015 inch oversize, (4) Reface valve seats which are pitted, burned or worn by removing the least amount of metat possible, Following the repair of valves, the valve Seats may then be lapped in with suitable valve~ grinding conspound, CADTION: After the valves have been ground and, Sheeked for proper seating, remove all traces of, grinding comouid with an approved cleaner. G) Replace valve guides if loose in cylinder head or if excessive clearance is found between valve stem and guide, If guides are scored, they should be replaced, Remove guides with the use of the proper tools and an axbor press. () Remove and replace spark plug inserts whieh are loose or leaking. Remove hard carbon from Usreads in Inserts With 2 tap, being careful not to remove any metal. (7) Remove burrs, nicks and roughness from ex- Assemble Bushings Flush With Bosses: As Shown 22949 8004 * . o008 Line Ream Bushing =703 # .0005 Line Ream Heaa —J Figure 17. Assembling Racker Shaft Bashings. aust flanges with a fine file or scraper. (8) Repair intake flanges by removing nicks with a stone. Polish flange with crocus eloth, Tighten Studs on intake flange, sf necessary, and dress threads, using thread chaser. (@) Stone finished surfaces of rocker boxes for nicks and scores, Polish surface with crocus cloth. Check rocker box covers for true flatness by rub- bing on a sheet of sandpaper placed on a surface plate, 22 NOTE: If rocker shaft basses are excessively worn, ‘aushings (No. 22049) may be installed as shown in Fig. 17. c. Valve Mechanism, (i) Remove nicks and scores from exhaust and intake rockers and polish fnished surfaces with crocus eloth, (2) Polish’ valve rocker bushings for siight scores and roughness, (3) Straighten push rods which are slightly bent by tapping inte proper shape, using Light mallet, Polish ball ends with crocus ‘loth, Loose or badly worn ball ends must be replaced by complete push rod assembly. (4) Valve ‘springs which are broken at flat eads cannct be repaired satisfactorily and therefore should be replaced, (5) Remove scores or burrs from valve spring seats by stoning and polishing. (6) Polish valve ‘spring seat locks with crocus clath inside and cutside diameter, (7) Stone valves to remove burrs and scores in the lock grooves and on stem tips, If tips are worn, they should be dressed with 2 fine emery wheel to Secure a flat suriace, square with valve stem. Replace warped or badly pitted valves, Use a standard valve refacing machine for conditioning valve contact faces and lap into valve seats as de~ scribed in paragraph 2, (b), (4) above, 4. Crankshaft and Connecting Rods. (i) Dress with proper dies damaged threads on front end of crankshaft, Remove all nicks and scores on bearing surfaces by carefut stoning and polishing with eroces Cloth, Stone keyway oa front of shut if taper end type ti remove scores, nicks, and burrs, (@) If main and connecting-rod bearings are worn, or if cheeks or cracks are visible, make replacement. (3) Remove all nieks and scores {rom connecting rods by stoning and polishing with crocus cloth, Remove slight scores in piston pin bushing by pol ishing with crocus cloth, If bushing appears burned or rough, replace, Repair slightly damaged threads fon connecting rod bolts, using proper dies, fe. Pistons and Piston Pins, (i) Repair pistons, pins and plugs which are slightly Scored or burred by careful use of a fine stone and by polishing with crocus cloth, CAUTION: Stone only enough to remove the metal which has piled up—deep sevatenes cannot be re~ moved, If scoring is heavy, piston and piston pin must be replaced. Do not at’ any Ume use a wire brush or buffer wheel on the pistons, (2) Replace piston rings at the thine of a major overhaul. If cylinder barrels have been reground of if piston ring groves have been remachined, care should be exercised in securing the proper oversize piston rings. (3) Replace cracked or badly eroded pistons with pistons which are within 1/4 ounce of the same weight, 1, Chankease Cover Assembly. (4) Make repairs to crankcase cover tn aecord= ance with instructions given in paragraph 1. (a) and {g) of this section, Particular attention shouldbe given 1 removing nicks and burs from all finished surfaces, using a fine stone and polishing with crocus eluth. (2) Carefully dress and chase with proper dies damaged threads in cover for the oll sereen assembly, oll pressure relief valve eap and tachonieter drivehousing. (8) Repair with proper thread chasers damaged threads on oil screen assembly, oll pressure relief valve cap and tachometer drive housing. (4) I oil pump gears are nicked or scratched, stone Lightly. Remove all burrs, If the gears are’ badly dented or worn, replace, (5) Roplace tachometer drive oil seal at the time of a major overhaul, . Camshaft and Hydraulic Tappets, (i) If loves on the cam are scuffed, stone lightly, (2) f eam followers are scuffed, stone light. Examine the tappets for wear and damage, If either the piston or cylinder is damaged, replace both parts, For complete information on Hydraulic Tappets Feter to section 18, CAUTION: Do not drop hydraulic tappets or allow them to come in contact with other metallic objects, as damage will result, h, Gears—Stone lightly crankshaft, magneto drive and’ cam gears if nicked or scratched. Remove all durrs, If the gears are badly dented or worn, they should be replaced. Cap screws should be replaced if heads or threads are damaged, 4, Intake Pipes, Connections and Clamps, (Y) Remove simall dents from intake pipes by aretul hammering on 2 suitable mandrel and without reducing the wall thickness of the pipe, to obtain a ‘smooth and even surface, Replace cracked or leaking intake pipes. (2) Replace rubber hose connections for intake pipes at the time of a major overhaul, (3) Replace intake hose clamps if broken or cracked, }. Push Rod Housing Flanges, Connections and clamps, (Q) Stone Mghtly all finished surfaces of the flanges to Femove all nicks and scratches, If flange is cracked, it must be replaced, (2) Roplace the rubber push rod housing connections at the time of a major overhaul. (3) Replace push rod housing clamps if broken or eracked. k. Ignition System—Replace all ignition cables at overhaul, For instructions ou repair and replacement Of ignition cables refor to Section 8 page 14. SECTION 11 1. GENERAL ‘This section covers the procedure of the reas- sembly of the major sub-assemblies, the final as- sembly of the complete engine, the timing of magnetos to the engine and the final testing of the engine fol- lowing the overhaul of each major sub-assembly and. separate parts as described in the previous section, 2. REASSEMBLY OF MAJOR SUBASSEMBLIES 4, Cylinder and Valve Assembly Procedure. G) Apply a Weht coat of off on valve stems. From inside of cylinder and head assembly, assemble intake valve through intake valve guide, Ih same manner, assemble exhaust valve through exhaust valve guide. @) Holding both valve stems so that head of each valve is against valve seat, mount cylinder and head assembly over suitable holding block on bench. ‘Assemble intake and exhaust valve spring retainers over valve guides, @) Assemble inner and outer valve springs over exaust valve and guide and onto the valve spring retainer, Assemble” valve spring seat over valve stem with spring lands toward springs. (4} Using a suitable valve spring compressor, (Fig. 13), assemble valve-spring seatlocks in groove fon valve’ stem so that large diameter of locks is, toward end of valve stom, (6) Assemble valve spring over intake valve and ‘uide in same manner as described above. (6) Assemble new rubber push rod housing con- nections and clamps on the push rod housings, pushing them toward the cylinder head for clear@ ance when cylinder is assembled to crankcase, ASSEMBLY, TIMING AND TESTING (7) Install new cylinder base packing on cylinder barrel base, using a very thin film of sealing com~ pound on the cylinder flange on the fat surface that ‘Will contact the crankcase, CAUTION: Do not pick up cylinders by push rod housings as they are only pressed into the rocker box and are easily bent, Any bending or misalighment ‘will result in an off Teak, b, Connecting Rods to Crankshaft, (Q) Snap beth halves of the connecting rod bushings into the connecting rod and cap, (2) Assemble connecting rods in their proper po~ sitions on the crankshaft with the connecting rod numbers pointing up. NOTE; The connecting rod bolts must be assembled fon the connecting rods with the threaded end pointed toward the piston pin bushing, Torque nuts to low limit - if cotter pin will not enter increase torque gradually up to high Limit only. If cotter pin will not enter inthis range replace nut and repeat. In no case Shall nuts be torqued below low limit or over high limit, (Refer to Section 12 for torque limits), ¢, Pistons and Piston Pins, (1) With top of piston upward on bench, assemble the il control ring in the third ring groove from top of piston, Assemble the compression rings in the second and first grooves from top of piston. As- semble each ring on piston with the part number or sword "TOD" towards the top of the piston, The oll control ring is symmetrical 2d is functional with either side up. The compression rings are of the inside bevel design and it is imperative the inside evel be assembled towards the top af the piston, 23Figure 18, Installing Cam Follower Body into Crankease, (2) Assemble the piston pin and plugs temporarily nto pistons, 1. Crankcase Cover Assembly Gi) install off screen assembly into crankcase cover. @) Install oil pressure relief valve plunger, spring, gasket and cap into crankcase cover. See ‘that the plunger works treely in its cage without sticking. (3) Press tachometer drive oil seal into tachometer housing. Assemble ofl pump drive gear Into cover with square coupling onthe inside of the cover. Insert driven gear into mesh with drive gear. Assemble oil pump cover over studs, if utilized, and gear shaft on inside of cover. Holding cover in place with one hand, assemble tachometer drive housing (with ol] seal pres- ‘sed in place) and gasket over end of drive gear shaft ‘on outside of cover, pushing the shaft through the oil seal. It Is advisable to use a 3/8 inch rod to lead the shaft through the packing in order that it will not be pushed outof position, Screw tachometer drive hous- ing securely to cover. NOTE: The tachometer drive housing has a lefthand thread whieh secures it to the crankcase cover. (4) ‘Test the oll pump gears for free running in the case. If they are free from binding, assemble wash- ersandnutstothe pump cover and safety wire, If cap screws are utilized, assemble screws and washers and safety wire, e. Intake Pipes and Hose Connection. (1) Push one 1 1/2 inch hose and one 13/4 inch hose (one inserted into the other) over one end of intake pipe. (2) Run four hose clamps over end of intake pipe, (3) Push another set of hose connections over other end of intake pipe. (See (1) above, 3. FINAL ASSEMBLY PROCEDURE a, Preliminary. (i) Mount No, 3-4 crankcase (referring to cylinder numhers) with contact face, or inside of crankcase up, on a suitable engine stand which will permit ‘tilting the erankease to horizontal and upright position. Lay crankcase No, 1-3 with contact face up on bench. Puta very thin film of sealing compound on the contact face of crankcase No, 2-4 and on the front of the No, 1-8 crankcase where the oil sealis pressed in. a Figure 19, Installing Crankshaft Bearings into Crankcase. (2) Dip cam followers in light oil and insert inte the push rod housing pads from the inside of the erankease (Fig. 18), Install in both halves of the erankease, NOTE: Insert push rod hose connections over the ends of the cam followers installed in the No. }-3 crankcase to prevent them from slipping out when crankcases are assembled together, (@) Insert bearings in both cases and gently tap into place, (Fig, 19), The shell-type bearings have “tangs” and can only be replaced in their proper positions, On Series 9 engines lay starter gear bushing in position on the No, 2-4 crankcase with flange on outside of the crankease and with the oil hole in the bushing in line with the ofl passage in the crankcase, (@) Oil camshaft and lay in No. 2-4 crankcase. Check camshaft for end clearance in accordance with limits as set forth in the Table of Limits. 's, Installing Crankshaft and Connecting Rods. (i) OW bearings thoroughly, Lay crankshaft, with connecting rods assembled, into place in the No. 2-4 crankcase, (Fig. 20). The No, 2 and No, 4 connecting rods must Ue carefully guided through’ the No. 2 and No. 4 cylinder ports of the crankcase, taking care that they do not strike and damage the openings. (2) Check end clearance of crankshaft in the crank- case as specified in the Table of Limits, and Connecting Rods.¢, Assembly of Crankcases and Component Parts. (iy install oft seal on front of crankshaft, pushing securely into place on the No. 2-4 crankcase, (2) Lay No, 1-3 crankcase in place on No, 2-4 crankcase, carefully guiding connecting roas Xo. 1 and No, 3'through cylinder ports. (Fig. 21.) Be sure dowel bolts are in their proper locations. Check camshaft and crankshaft for free running to see that crankcases are installed in their proper positions, Remove push rod hose connections from cam follawers on No, 13 crankcase, (8) Assemble the ‘six (6) 1/4 inch cap screws, washers and nuts at top of the erankease. Assemble the five 1/4 inch cap screws, washers, and nuts at bottom of crankcase, Three dowel cap screws are used for properly lining up the crankcases. Assemble remaining cap screws, washers, and nuts on front end of crankcase, Assemble remaining washers andnutsto crankcase studs, Install breather connection in tap provided in side of No. 1- crankcase opening pointed toward the bottom of the crankcase, (4) Rotate engine stand so that front of engine is, pointing straight up, Tighten all nuts holding the two halves of the crankease firmly and evenly. Install propeller hub key in keyway if taper end type crank~ Shaft--tapping carefully in place with mallet, Install palnuts on all nuts holding crankcase together. 4d, Installing Gears and Crankease Cover. (Q) Rotate engine stand until rear end of crankease is pointing straight up. (2) Assemble crankshaft gear to crankshaft with four 1/4 inch cap screws, turning them down as far ‘as possible by hand, NOTE: The holes in the crankshaft gear and camshaft ear are so spaced that it is impossible to assemble the gears to the shafts incorrectly, (8) Install cam gear to camshaft with four 1/4 inch cap screws. The timing mark on the cam gear must mesh between the two timing marks on the crankshaft gear (Fig, 6), Place a screw driver in fone of the lightening holes in the cam gear and rolate gear until screw driver is blocked against the crankcase, preventing gears from turning when cap serews are tightoned, If cam gear does not have ightening holes utilize other suitable means, such as a proper wedge between the teeth of crankshait and eam gears to prevent the gears from rotating when the cap screws aretigitened. Be surethe wedge does not damage teeth of the gears. Tighten cap screws fon cam gear and crankshaft gear with standard 1/4 inch wrench (Fig. 22). Figure 21, Installing Crankease 1-3 over Crankease 2-4. 25Figure 22, Installing Gears in Crankease, (4) Remove serew driver or wedge from cam gear and check backlash of gears, (6) Safety wire cap screws on both gears. Care must be taken to press wire tightly against the gear body to avoid a possibility of interference with the studs, if utilized, of the otf pump cover. (6) Place crankcase cover gasket over end of crankcase and mounting studs. Assemble crankcase cover assembly over gasket and studs (Fig. 23), (7) Rotate engine stand so that crankshaft is horizontal. Install washers and nuts to studs. Tighten nuts securely and install palnuts, NOTE: Safety wire oil pressure relief valve cap to nearest stud holding crankcase cover to crankcase, and secure with painut, , Installing Oll Sump and Oil Suction Tube, Gi) Rotate engine stand so that the crankcase cover is facing up. (2) Cut “otf the portion of the crankease cover gasket which erosses the ofl sump opening, (8) Install off suction tube in the tapped hole in the bottom of the crankcase cover, tightening with a 28 7/8 inch wrench, Safety wire suction tube to eranie- case cover in holes provided, (4) Install off sump gasket to mounting studs on bottom of erankcase and caver, Mount oll sump on the six mounting studs on the case and cover and Ait oil filler bracket over stud in crankease mounting arm. Secure sump with washers and castle nuts on the case and cover and install out and palnut on stud holding oi! filler bracket. f, Installing Hydraulic Units and Push Rod Housing Flanges. (1) Rotate engine stand so that crankshaft s_hori- zontal, Oil hydraulic units with thin coat of ight oll, NOTE: Be sure that the hydraulic unit is working Properly and smoothly by depressing the piston ‘with the thumb several times, Units shouldbe partially deflated of trapped air and oil by releasing the ball check. Insert a 3/32 inch diameter rod in tube of ‘unit (rod should have a dull end) so as to lift ball check from seat while piston is being depressed. Refer to page 67 for complete information, (2) Insert hydraulic units, tube end first, into the cam follower body. Insert tappet cups on top of hydraulic units in the cam follower body, (3) Place push rod housing flange gaskets over studs on housing pads in crankease, Install push rod housing flanges over studs and gaskets, (4) Secure flanges to crankcase with suitable wash- ers and nuts, NOTE: Tighten middle nut of flange first, Do not tighten nuts excessively, as the flange may be cracked, (1) Rotate engine stand so that the front of the Figute 23, Installing Crankcase Cover to Crankease,engine is facing up. @) O11 piston pin bushing on connecting rods. Install piston pin plugs into’ piston pin. Oil piston, thoroughly and work oil into piston’ ring grooves. ft piston pin and install piston (with rings assembled) to the connecting rod. Install piston with the mimbers toward the front of the engine. The connecting rod must be fully extended through the port. (8) Stagger gaps in piston rings on’ the piston so that they are evenly distributed around the piston to prevent blow-by. Assemble steel clamping bandaround the piston, compressing the piston rings and also retaining ‘the piston pin and plugs in the piston, (4) Coat inside eylinder barrel with a thin coat of engine oi, (8) With one hand compressing the steel clamping band around the rings, insert the cylinder barrel over the top of the piston. (Fig. 24.) CAUTION: Do not pick up cylinders by push rod housings as they are only pressed into the rocker hoxes and are easily bent. Any bending or misa~ Ligament will result in an oil leak, (6) Steady the cylinder with the body, push the cylinder carefully back to the mounting studs, moving the steel band back on the piston. Remove steel band ‘when eylinder is pushed on the full Length of the piston, (7) Assemble cylinder flange over studs on crank= case, Be sure that cylinder base packing 1s properly in place and not twisted, Assemble nuts on studs and tighten slowly and evenly. Install palnuts, CAUTION: Do not tighten muts excessively as the studs may be stretched or broken, See Table of Limits for the proper amount of torque to be applied on nuts, Figure 24, Installing Cylinder on Crankease,(8) Rotate crankshaft so that intake and exhaust valves are closed, Insert push rods into the housings, hold rocker arms in place, and push in the rocker arm shaft. (9) Assemble gaskets on rocker box flanges and install valve rocker box covers and secure with fillister screws, (10) Skip push rod connections and clamps down over push Tod housing flange, and tighten clamp moderately, {11) Assemble remaining cylinders in the same manner as described above, h. Installing Air Intake System, (i) Assemble carburetor to intake manifold se~ curing ‘with four nuts, The aut nearest the altitude control of the carburetor should be installed first ‘to facilitate assembly, (2) Assemble intake manifold (with carburetor attached) to the crankcase on the two studs pro- vided at the bottom. Secure with suitable washers and nuts, ‘Tighten nuts, (9) Place gaskets on intake flanges, Attach intake elbows on the two studs on tho flange, and secure With suitable washers and nuts, (4) Assemble intake pipes (with hiose connections and clamps installed) to intake manifold and elbow, pushing outer hose connections over ends of manifold and intake elbows, Tnstall clamps on both ends of ‘each connection and tighten securely. 4, Installing lmition System. (i) Assemble lower spark plugs with gasket in cach epinaer, (2) Determine the tiring position of cylinder No, 1 in the following manne: (a) Place Uming disc on the tapered crankshaft 0 that the slot in the hub fits over the Key on the shaft, The top center (T.C.) mark stamped on the timing dise must line up with the split of the two cerankeuses on the top dead center of the compression stroke, (©) To determine that the piston ia on the com= pression stroke, glace thumb over upper spank piv hole and tum ¢rankshaft in direction of rotation, The intensity of the pressure will indicate that the piston is on the compression stroke, (¢) When the piston is on top dead center with the top center (T.C.) mark in line with the split of the crankeases, tim crankshaft in a clockwise direction until the tlining ise 18 set as gpecified in the Table of Specification, Section 1, for the particular engine being timed, The piston 13 then set at its firing pox sition, (See figure 25.) (3) Installing “and “Timing Magneto to the Engine, 2) “Before installing magnetos, insure that. they have been correctly timed and checked in accordance ‘ith the section covering the accessories, (b) Rotate the magneto drive gear, attached to the ‘magneto, until the. timing marks on the chamfered tooth of’ gear and timing pointer are opposite each cther as seen through the timing window inthe magneto cover. At this position the breaker contacts should begin to open. (@) All adjustments for exact timing to the engine are made at the drive end and not by altering the Position of the contact points, See that the mounting faces are clean and smooth. With the timing marks (as deserted in’ (b) above) opposite each other, 28 el. Figure 25, Determining Firing Position, install the magneto on the engine and secure with its mounting nuts. Exact timing is obtained by turning the magneto through the angle provided by the slots in the magneto flange. (Figure 43, page 65. (@) Before checking the exact breaker opening vosition, rotate magneto counter-clockwise by {ape ing the mounting flange until it is near the end of the travel permitted by the slots, {e) Turn erankshaft backward a quarter turn, then bring up slowly to firing position to take the backlash ‘out of driving gear train, (0) Insert a 0018 inch fecler between breaker points (cellephane may be used as a substitute), and fap mounting flange In a clockwise direction until the exact point of release is obtained, (Figure 26.) Figure 26, ‘Timing Marks on Flanged Crankshaft,NOTE I a Bendix SeintiMa No, 11-851 timing light or equivalent is available, It should be used todetermine the opening of the conlacts rather than using a fecler gage or cellophane strip. The use of shim stock or Cellophane feeler strips invariably introduces a pos- sibility of fouling the points, since oll and dirt is nearly always present on such fecler strips. If the strip is of aoft material such as cellophane, brass, ‘or foil, particles of the strip itself are likely 16 remain’ between the contacts, causing unsatisfactory magneto operation. () Tighten the mounting nuts. Check timing by backing up the crankshaft and turning it slowly forward to determine if the feeler 1s released the instant the timing dise reaches the mark specified ‘on the particular engine being timed. NOTE: If cellophane is used instead of a feeler or a timing light all traces of the cellophane must be removed before replacing the breaker cover. (h) Install other magneto on the engine following the procedure outlined above. (1) Remove timing disc from the crankshaft. () Assemble upper spark plugs with gasket in each cylinder. (a) On engines using a tapered crankshatt, place a timing disc on the shaft so that the slot in the hub fits over theky onthe shaft, ‘The top centor (T.C,) mark stamped on the timing disc or the propeller flanged ‘edge of aflanged crankshaft must line up with the split of the two crankcases on the top dead center of the compression stroke. Use a flat metal indicator or square to align the marks with the split. (b) When the piston is on top dead center with the top center (T. C. )markin ine with split of the crank- cases, turn crarkshaft in a clockwise direction until timing disc, or degree marks on flange are set a5 specified inthe Table of Specifications, Section 1, for the particular engine being timed, The piston is then set at its firing position. (See figure 25 or 26,) 4}. Installing Radio Shielded Ignition Wires, Refer to figure 11 where the complete ignition wire system is diagrammed and firing order given, (1) When it is necessary to install new ignition wiring {i.e., at an overhaul period), refer to section 5, paragraph 5, for length of cables. 2) Slip the’Knurled nut, brown bakelite ferrule, and the rubber gland over cable in the order named, (3) Strip insulation from exble end about 1/4 inch and attach terminal clip ty inserting bare cable Strands throwgh the note of the clip and secure wth solder, (4) Fit spark plug elbows over the end of the cable and secure it by means of the union nut and cone, (5) Check wiring by a recognized standard elec~ ‘trical test. (6) Reassemble brackets to ignition cables, 4. TESTING ENGINE AFTER OVERHAUL it is very important that an engine be carefully run-in after a complete or top overhaul, The length of time necessary for this depends upon the new parts installed during the overhaul and the facilities available for the running-in process, A flying propeller does ot cool the engine properly if the airplane is not in flight. If it becomes necessary to run-in an over~ hauled engine ia the aircralt a 4-bladed Test Club type propeller should be used. The cowling should not be installed and the aircratt should be headed into the wind to provide the best possible cooling. It is also advisable to have a thermocouple attached at the base of the spark plugs and not allow the cylin dor head temperature to exceed 500°F. ‘When new pistons or bearings are installed, at least 70 minutes of run-in time should be put on’the engine. New rings may be broken in sufficiently for flight in possibly 3 to 4 hours. ‘The engine should be filled with a light grade of oil and run at approximately 800 r.p.m, until the oit is thoroughly warm. Then at intervals of 15 to 20 minutes, the speed ‘should be increased by 100 r.p.m. If a special propeller is not being used, a speed of approximately 1400 r.p.m. should not be exceeded for more than a few minutes at atime with the airplane on the ground, If a thermocouple is used, speeds may be increased until the cylinder head temperature reaches 500°F. The remainder of the run-in, after installing the cowling, may be put on in cruising flight, with a final run’ of about 30 minutes at a speed approximately 100 r.p.m, less. than full-throtile, Any Might run-in should be made ‘over the airport in order that a quick landing may bbe made if any trouble develops, Preservation. If the engine i8 not to be installed in an aircrait and placed into service immediately, the last 15 minutes of operation should be used to, circulate a corrosion preventive off mixture (suitable for flight operation), This will be an additional period, since the engine must be stopped to change oll, During the same period, unleaded gasoline should be supplied to the carburetor. Inspection, After completion of the test run, inspect the following features: {a) Remove oil screen, and inspect for metal par- cles. (b) Remove oil gauge, and check oil quantity and quality. (c) Remove all spark plugs, and measure electrode gaps. Readjust if necessary, and clean any fouled plugs before reinstalling, (@) Using a flashlight for illumination, inspect all cylinder bores for scoring while the propeller is turned slowly, (e) Replace spark plugs, and test for uniform cyl- inder compression by turning the propeller, or use a cylinder pressure gauge before installing the upper. set of spark plugs, Actual pressure values will depend on several variables, but they should be uni- form among eylinders.30 Ref, Fig. No. No, 10m 2 27 3000 4m 5 om 6 7 7 om 8 om 9 2 1027 uot wot BO uo& 13 21 1% 27 moon 1 oT 17 2 2 a 27 2 2F 23 aT 23 oT Om 2 oT 2 on 2 2628 NOTES: SECTION 12 Deseription PISTON (40731) in Cylinder (A65) Top Blards se ee see dias Topotskint set! aia: Bottom of skirts |S 1 pene lll dias PISTON (40577) in Cylinder (A75} Top lands so ee et ee dias Qndand 3rd lands. lL dia Skirt | filiiit pees aia PISTON RING (side clearance) Piston ring in top groove (comp. ) (A865) side clearance: Piston ring in 2nd groove (comp, )(A65) side clearance: Piston ring in 3rd groave (oil) (A65)_. side elearance: Piston ring in top groove (comp, )[A75) side clearance: Piston ring in 2nd groove (eomp.) (A75) side clearance: Piston ring in 3rd groove (oll) (A75) . side clearance: PISTON RING (gap) Compression rings in cylinder barrel... . gaps Gil rings ineylinder barrel... | 2 L gap] Compression rings...) 1 ly “tension: * Orie DL tension: + PISTON PIN Plug in piston pins... we dla: Piston pin and plug in cylinder . | ‘end clearance: Piston pin in piston. 2 2) tae Piston pin in connecting rod bushing | 1 1) | : CONNECTING RODS Piston pin bushing in connecting rod... . aia: VALVE ROCKERS, SHAFTS, PUSHRODS Rocker shaft in rocker bearing... 2. au: Rocker shaft in cylinder head bosses. . ) ss. dia: Valve rocker bushing in valve rocker»... dia: Valve rocker... 2... . ~~ + side clearance: Push rod (overall engi). 112) SS : Valve stem to rocker clearance (lifter deflated) * CYLINDER. Exhaust valve inguide so. Inlake valve in guide . <2. a Exhaust valve insert in cylinder head! 111! Intake valve insert in eylinder head. Valve guide in cylinder head. 2). Cylinder barrel bore maximum allowable taper Cylinder bore out-of Cylinder bore (standard) 2. diameter at any point. Fo Cylinder bore (reground to.015"°0.8,). 1 1 1 | ‘aia: Cylinder bore surface roughness (Micro Inches, RMS). ee Pete ae Cylinder barrel in erankease. 62222121 d Connecting rod bearing on crankshaft. - < ° |) ‘aia: Connecting rod to crankshaft... . . vend clearance: TABLE OF LIMITS Serviceable Limit 037 L lois L lon b -087 L fog? L ‘020 L = 009 ‘007 008 1009 1007 1008 033 1033 10 Ibs. 9 lbs, -003 1, 1060 E 10018r, L004 L. = 008 1, #007 L 016 40,785, 007 L 1005 & st 002 e+ 1002 9, 802 3.897 25 +006 L los New Parts Min, Max. 08 LOB L 1009 bois 1008 E009 028.032 L 2028 1032 L. old loiT - 0045 = 0065 003 1005) $0017 004 70085 0065 1003: 005 +0017 004 +008 +028 1013 1028 Ll bbs, 14 bs, 1 tbs, 14 lbs. 0005T 0025. 1010 L L040 looort, = ooo7n, lors, = ooaty, -002 T =. 0045 -0010L 0025 sooozL. = 0017L. 1002 T = 004 T :004 Sou 10.797 10, 827 +030 “110 0027 = .0047L. S001 L 1003 L. [00st = 0078 005 T 008 T S001'T 00257 000 001 +000 1001 3.875 3.877 3/890 3.802 30 40 008 L 010 L [0005L 1003 1. 1008 ‘010 (+) Measure piston ring tension on diameter perpendicular to gap when ring is compressed to specified inch gap, (2) If necessary use .005" oversize rings to maintain specified mits in cylinder bore to Service Limits,‘TABLE OF LIMITS (Continued) Ret. Fig. Serviceable New Parts No, No, Deseription Limit Min, Max, CRANKSHAFT & MATN BEARINGS 27 28 Crankshaft main journals {std.).. . - . 2. . .diax ff 1,870 Lore 1,073 28 © 28 © Crankshaft in froat bearing... +. end clearance: 1025, 1004 0152. 29°28 Crankshaft in main bearing ©. 2. ss es ee dine [0055 =: 00081. 9035L, 30 28 Crankshaft in main bearings {center & rear} . dia: 10085L =" 0005L 0035, S128 0 Crankping =. ee ee ee dias TP 1,984 1936 1.997 31 28 0 Crankpins 2.2. 2221.2. lout-of-round: Too1s +000 £001 32 28 Crankshaft run out (center main) (supported at front & rear mains)... = : +010 = 000 +010 83 28 Crankshaft run out (at frost of taper? (supported at front & rear mains) vs set eee ee : 008 000 = 008 3428 Crankshaft flange ran out (near perimeter on face ‘of flange) (shaft supported at front @ rear mains) . + +005, 000 +005 CAMSHAFT JOURNAL 35 28 Journals in crankease - 2-2. 2-2 ee dias 7 008 L001 L003 L 36 28 ‘Rear journal in crankcase. |... . . end clearance: 1012 1004, 008 37° 27 - VALVE TAPPET INCRANKCASE. ... . . - dia: 10035L = '0005L_ 002 L Ol. PUMP, 38 28 Oil pump shafts in crankease cover... «dia 0085L =. 0015 003 39° 28 «© Oil pump shaft in plate... =. 0. tee dia To0ssL = loo1st 003 4028 Gears in oil pump housing 22). SS end clearance: Toe S008 +005, 41 28 Goars in oll pump housing |... 00g L003 L008 L 42° 28 Front crankshatt oll seal in erankease 2). ~ oo T = ‘oor T. 43°28 Crankshaft gear on crankshaft pilot :0005T = 0015L 44 28 Camshaft gear on camshait pilot. . |) 1... 1 dia: looost — 00u5L 45 28 Oil seal in tachometer housing. » <<: foor't Loot T 48 28 Magneto pilot in accessory case. |) 1 oor 1005 L “i Deleted 4@ 28 Oi pump drive shait in camshaft gear « 2020L 007 L188. GEAR TEETH BACKLASH 49 29 Crankstaft gear to cam gear... sees +013 +008 009 50 29 Magneto drive gears to crankshail gear...) 1: “ons “08 on BI 29 Oilpump gears ss tila 025 lo ‘oz NOTES: (12) if Cylinder Barrel exceeds these limits, replace, re-arrel or regrind .015" 0. 8, (779) If Camshaft Bearings exceed these limits they must be reamed and .020" 0, 8, shaits fitted. (f) 1 Hocker Snaft Bearings exceed loose fit, install bushings, Part No, 22940. (71) Crankshafts worn below limit must be reground to ,010""U,S, Ref. Fig. No,’ No. Deseription Torque Limits in In, Lbs, TORQUE LIMITS TL 2 Spark plugs eee 300-860 in. tbs. T2 28 hug, oilsumpdrains 22D DID. ou tight 3 2M Nats, 7/16+20, cylinder to crankcase thru studs F122 400-450 in, Ibs. TH 2 Nuts, 9/6-24, cylinder to crankcase thru bolts» 2 Ls: 410-480 in. Tbs. Nuts, 7/16-2, cylinder to crankcase thru bolts & deck studs. | | | | 490-510 in. Tbs, Nuts, 3/8-24, crankease to crankcase. ee ee 310-390 In. Ibs. T) 21 Nuts and cap screws (1/428)... sees ttt tts 900110 in. Ibs, Nuts and cap serews (6/16-24) 22 211 PEED ITLL DD 190-220 in tos. TE 27 Nuts, 3/8-24, connecting rod bolts #2 D1) oad in, lbs, NOTE: Torque limits apply to oiled studs (not Alcoa Thread Lae). 4 Torque to low limit - if cotter pin will not enter increase torque gradually up to high limit only. If cotter pin will not enter in this range replace nut and repeat. Inno case shall nuts be torqued below low Limit or over high iimit. aI9 Tio Ret, No. 32 53 84 54 32 ‘TABLE OF LIMITS (Continued) Bolts, 1/4-28, gear to erankshatte oe ee eee 1MO-18D Inu tbs Bolts, 1/4228) gear tocamsmat 2 220222222512 tocteo in tps, Pat Wire Compress New Parts Used Parts Description Ho. Dia, To bss min. Ibs. max. Ibs. min. Spring, valve inver 21585 105 in, 80 in, 88,5 32.5 31.5 ‘Spring, valve outer ‘21366 135 in, .95 in, 52 56 49 Spring, oll pressure relief valve 691706 083m, 1.561n, 6,08 6.31 3.75 ‘Spring, oil pressure ‘elie! valve 2138204 in, 1.5m, 5.2 5.37 ae‘CROSS SECTION THRU ROCKET SHAFTVB ve dt ae 8t “MOEA pig - UMD YORLOLIANT “Be st M9 os woiLans) Tio 3oNan¥9s: SNIONS @ SAMS MZIA TENICALIONO? rl ~ qo aunss 34VIEW SHOWING PRESSURE OIL THRU_OIL SCREEN INTO CIL GALLERY & PRESSURE RELIEF VALVE REAR VIEW SERIES 8 ENGINE, Figure 29. Lubrication Chart - Rear View. WE Pressure on SCAVANGE OIL (suction: HE scavance ow (ORAIND 35/36SECTION 13 ORO WE ae) EE INTRODUCTION GENERAL ‘This catalog lists and describes the parts for the ‘models A865 and A75 series 8 engines manufactured by the Continental Motors Corporation, Muskegon, Michigan. ‘The Group Assembly Parts List consists of the complete engine divided into ten (10) main groups. Each assembly listed is followed immediately bY its component parts, properly idented thereunder, to show their relationship to the assembly, Compo- nent parts of the complete engine which are not included in any assembly but which are used in conjunction with, attach, or attach to a certain assembly, are listed immediately following the last, detail ofthat assembly and in line with the major assembly. The quantities specified in the Assembly Parts List are those used at the location shown, and not necessarily the total number used per engine, Refe to the Numerical Parts List for the total quantities ‘used per engine, Parts which may be obtained in oversize or under- size are indicated throughout the eatalog by an asterisk (*) precoding the part number Refer to the “Oversize and Undersize Parts List? for the sizes available, ‘The reference numbers appearing on the ilus- trations ‘are numerically arranged in the Assembly Parts List and are used mainly to assist in locating a part in the Group Assembly Parts List after it has been found on an illustration, Spare parts are sold only through Continental Authorized and Approved Service Stations and Dealers, When ordering be sure to give name and address of person or organization to whom parts are to be shipped, the part number, the exact description as Usted, ‘the quantity required, and the engine model and serial number. INSTRUCTIONS TO C.M.C, DEALERS: C.0.D. orders ‘cannot be accepted unless’ arrangements have been ‘made in advance with C.M.C. Service Department, ‘We will make any shipment by any means of trans— portation specified, subject to the transportation company’s regulations. AIL shipments will be earefully packed before leaving the Factory. Continental Motors Corporation shall not be hela liable for damages to engines or parts incurred while in transit —our Uability ceasing when shipment is delivered to the ‘transportation ageney. If damage is evident on receipt of shipment, see that a notation is made on the shipping bill and filé a claim with the transportation agency. If the contents do not show damage until alter the container is opened, have the carrier's claim agent make an inspection before unpacking, then file a claim for damages. ‘Telegraphic orders will be accepted and immediate shipment will be made, However, all telegraphic orders should be confirmed by mail, Care shouldbe exercised in composing telegraphic orders that sufficient words are used to clearly indicate the intended meaning, USABLE OW CODE 65, [a 75 37Fig, & Index No, Part Number 30- 627386-A1 30327-AT 627386-A2 No Number a No Number “2 No Number 3 2265 3 2925 “4 ‘AN900-10 os 2024 6 21080 “1 #2465 “3 +21075 “9 #22423 10 *23030 Tul 25329 =12 #25330 21325331 sid #25361 sis *402127 “15 +2206 nis *653398 Tit 833399 18 ¥7530058 n16 4440297 EA 319 693141 =20 620775 29 *28329 a 24251 =22 24252 =23 20522 24 ‘ANS60-516 =25, ANSS6AAIE 26 2497 27 24879 28 24878 23 25166 50 20522 o31 ANGS6A4I6 “32 2491 -33 2474 34 24a =35 2561 -36 2415 237 2443 -38 2958 “39 22387 40 21530 oa 22653 sat 21845 42 21007 -43 agai a4 530019 45 ANBA2-10, (1) New style crankcases have had a groove added to accomodate thrust washers P/N 683141. bearings with thrust washers, 38 Description Usable 12345 @y. On Code Crankease Assembly, Complete... 2. seta Grankease Assembly, Completes). see eee 1 8B + Studding Assembly, Grankease | 2). 22111 Daa 1 Studding Assembly, Grankease | 2220221102 NS OB I. Crankease, 1-38ide 2... DLDDD DDD D Ios ap Sl Grankease, 2-4S8ide 2202202 NS AB 2 Plug, Crankease Ol Lines. 2. 1. Plibiiil 2 ow 1 Plug, Crankease Oil Limes. |) 21S : 2B Ll Gasket; Anmlar st Pilliiil 2 oa 2 Plug, Oi Pressure Gauge Connections 4.2... 1 AB 1 Dowel, Crankease Cover to Crankease 20. 621. 2 AB 1D stud, 5/16% 1-3/6 in, se 10 AB Di stud /exSinag lilt 1 AB Dl stud 4 Pte in We LE ae ap DD Sind) 5/16 X1/I6 ia age DT Dilill 2 ap Dt stud, 7/16 Xe-g/s2imag Dre 4 AB DT stud, 710X958 in dee le 2 AB Dl sud ie Kiama lb AB Dl stud, 9/8 23/Bin de le 2 AB Dl Stud, 9/8 X1-17/9Rin dg il bak DL Sd, 8/8 X1-3/8in de eB 1 Bearing, Crankshaft, center & rear, 1-3 Side) 21) 2 AB 1 Bearing, Crankshaft, center & rear, 2-4 Side) > 1) | 2 AB { Bearing, Crankshalt, front... ef ee ee ee 2 AB T Bearing, Crankshaft, fronts 20022000 2200202 AB D washer, Throst ete st Dlibl a BB 2 Bolt, Crankease Thrv, 7/16-20%'20,60im Igo 1222 A P Stud, VIG X6-B/82in We ee eee 2° 28 Dserew, 2a x ta/dinig, DD DDL Dl AaB 1 Serew, Dowel Pilih lil 3 AB TWasher, Plain S22 ma L Washer, Plain 2 ISPS. blll gap Lwasher, bok 222 PEED DIL! 28 AB Not Plain Hes 22D TDI I IT. BAB 2 Bye, Engine Lifting. | 02D ot pies a AB ATTACHING PARTS SSW ee ee seen 2 AB Lwasher, Special DDD PDI rt 2 AB I Washer, Plain eee ees 2 AB Twasher, Lock 22222 DTTP IIT! 22 AB Dmut, Plain, Hes 20D D DTI D IIIT. 2 AB ~ Washer, Plato, 9/8. 0 06 eee eee eee eee 2 AB Donut, Plain, Hex, 3/824. 00200200000 002 1 AB Draw, Yeo DTI i lt 1 AB I Washer, Plain, 7/6 0 Die to2 0 AB To Mut, Plain, Hex, 7/1626 0222 DID l 2 ae 2 Paltut, 7/16-20 2. PILDDDI pli) 2 ap 2 Bushing, Engine Mont 22D DDD It a AB I Washer, Engine Mount 2202222222. 4 a 2 Plate, Identification. 6 22222007 piiiilo oa oa 1 Plate; Identification, © 00 2DDDe flit a 8 ATTACHING PARTS sSereW, Dre. eee eee eee ee ee 6 AB Seal, Oil, Crankshaft 0 1 AB Seal, Oil, Crankshaft (For Flanged Shaft). 0. 220.2 1 AB Elbow, 6/8 Hose, Breather Connections |)... 0020 AB Use 530058 Cases not having this groove must use old style bearing P/N 40237. © Oversize or Undersize parts available.Figure 30. Crankease,Fig. & Index No, Part Number a1 530196 4 No Number a 50446 2 630851 “3 500388 “4 500400 530199 3 No Number 6 22386 a 29769 8 23770 9 35956 -10 (3901 “1 2a767 m2 24768 a8 35897 ‘A35160-A2 ‘A35159-A2 “14 No Number 15 25369 a5 21003, ag 580219 “17 24804 18 2501 40731-A1 Ag0377 -19 0 ¢ 40701 sig 40877 40 220 #530144 sat * 530145 + 530856 *25127-A1 22 "530897 22200725197 23 530828 23 25117 Crankshaft Assembly sooo ee bees + Crankshatt and Tube Assembly. 2... pliiitt 1 Crankshaft and Tube Assemblys Sv Le 1 Dowel, Stepped... Preiiibiiiine Plug, te3/te-te xine DTT Key, Propeller Hub.) 00D Crankshalt Assembly, Complete (Optional) (21 «Crankshaft and Tube Assembly... 2... tee 1 Dowel, Stopped. ve ee Piiiiit Bushing, Propeller Hub Flanges 1 0.002000 1 Plug, Hubbards... se ries Plate, Moisture Impervious |) 112222 D et Flange, Propeller ub... Lv pee ee tt Washer, Propeller Hub Flange Bolt. |. Piiiiis Bolt, Propeller Hub Flange... 0+ 2. +s piiits Beating, Connecting Rod. +. piniiiiit Connecting Rod Assembly | ite ee Connecting Rod Assembly |) tle : + Rodand Cap, Connecting | 222 le 1 Bushing, Piston Pins. te see te ne 1 Bushing, Piston Pla 2 2212s Phiiiiiit 1 Bolt, Connecting Rod 2 St piiiiii 1 ut,'Slotted, 3/624 1122222 D iD. D ile Pin, Cotter eee lla eee eee Piston & Pin Assembly, Complete + ¢ Piliiie Piston & Pin Assembly, Complete |) 1111! Dit + Piston, 6,3:1 Compression Ratio. 2). e022 piston, 8,3:1 Compression Ratio. |.) lls. eee 1 Ring, Piston, Compression, top & 2nd grooves. 2. 1 Ring, OU Control, third groove... Dliiit {Pin and Plug Assembly, piston. 5. 2... fiat Pin and Plug Assembly, pistou. 1. so. bese + Pin, Piston. eee pietisiiiiit Dp piston DTD DDE i lilt Dt Ping, Piston Pins De te Il ping, Piston Pins 2D Dilils * Oversize or Undersize parts availableFigure 31, Crankshafts, Connecting Rods and Pistons, aFig. & Index No, Part Number 32. B-3762-a2 B-3762-B. 1 2493 22 2958 3 2457 a4 2561 BO3T62-AL B-3762-B1 B.3762, 8 520112 “6 2024 “7 #401885: -8 *401983 9 #24805 s19 #24806 cr #25276 Tap eerais “13 21284 “14 No Number 15 22211 215 21ai3 16 21959 “1 21365 o18 21966 -19 airs =20 21025 221 21361 A24122 -22 No Number 223 24122 =24 21007 225 #21153 =26 590162 <2 40762 28 ANDSEASI6 229 535081 -30 aue77 “31 21493 231 28378 232 22022 2 Cylinder Assembly, Complete Cylinder Assembly, Completes. ee ATTACHING PARTS Nat, Plain, Hex, 7/16-20. . Palnut, 7/16-20 Nut, Plain, Hex, 3/8-24 1°: Palnut, 3/8-242 22 Cylinder and Valve Assembly - 6. see eee Cylinder and Valve Assembly 222222 2D le + Calinder Assembly . Insert, Spark Plug, : 2 Plug, ‘Primer Jot Hole Stud, 5/16 X 1-5/16 in, 2 Sud, 1/4 X Lin Ig. + Guide, Exhaust Valve . 1 Guide, Intake Value. ¢ + + Housing, Pushrod Head and Barrel Assemtly. |) 1)! piiiiit 1 Valve, Exhanst. 2... + Valve, Exhaust. 20. Valve, Intake 2. Spring, Valve, Inner + ¢ Spring, Valve, Outer < { Seat, Valve Spring . . + + Retalner, Valve Spring | Lock, Valve Spring Seat. 1 Rocker Assembly, Valve + Rocker, Valves. + + + Bushing, Valve Rocker < 1 Plug, Oil Passage. . + Bhatt, Valve Rocker... 1 Gasket, Rocker Cover.» + Cover, Valve Racker. | 1S Insert, Valve Seat, Exhaust |) 202220222) {Insert, Valve Seat Indake. od Ig Slide z wanna Bes aston tern Besrene mm astants nen ATTACHING PARTS Washer, Lock... Screw, 1/4-20 % 1/2 tn. te. Packing, Cylinder Base. Gasket, Exhaust Flange. + + Gasket, Exhaust Flange. Nut, Plain (Brass) 5/16-24 * Oversize or Undersize parts available. Usable On CodeIndex No, Part Nember gee 4877 AASE7-AL ‘A4587-A, “2 2aia 23 ANageasi6 “4 2430 4587 3 No Number “8 *22423 7 #23207 “8 aud a 631706 “9 21352 =10 ANSO0-14 “a 21113 72 ANO0-28, 23 A3568 14 ANS00-10 235 24142 “16 632085 -16 — AN00~22 1 21163 aa 21208 =19 626972-4 220 3982 221 21343 222 21160 -23 20322 224 22597 25. 530641 -26 21346 a 3506 -28 21346 “4 Description 12345 Gasket, Crankcase Cover To Craakcase. . 2 Crankcase Cover Assembly, Complete...) 2... 2 Crankease Cover Assembly, Complete, 2222221 22 ATTACHING PARTS Washer, Plain, 5/16... ee ee ee Washer, Lock DDT ld Nut, Plain, Hex, /ie-ad 22222 22D D TILE + Crankease Cover Assembly. 2 ee ee + Cover, Cramkeage. ee + Sud, AX L/int L Stuc, 5/16 K1-/2in es + Plunger, Oil Prossure Relief Valves 2.) 22. 11 ¢ + Spring, OU Pressure Relief Valve. | 22222222 Spring, Oil Pressure Relief Valve... 2. Dll LGaskel, Annular, ee le ! Cap, Ol Pressure Relief Valves 212 LPT D IE ! Gasket, Oll Screens... tele | Oil Screen Assembly. 222212 E TTI TITS : Gasket, Ammar eee s Plug, 8/818. iit Gasket, Tachometer Drive Housing <2.) 2. ) Gasket, Tachometer Drive Housing |) 222221 t F Seal, Oe eee ! Housing, Tachometer Drive 2 2d : Caplug (Shipping Only)... Die : Gear and Drive Sat. et i GearandShatt so 22 LDP P lil iiit ! Gover, O11 Pressure Pimp. 2D TD TTT ITT ATTACHING PARTS e Washer Plo eee ec eee eee ees 1 sere, Drilled, 1/4-26%5/8't0, ig TLS IE Gear, Crankshatt an ane . See ee ‘ATTACHING PARTS * Serew, 1/4208 16 Ig eee Gear, Camshaft... ne ATTACHING PARTS Screw, 1/4-20X 7/16 in. Ig... * Oversize or Undersize parts available. ay. 10 10 10 Usable On Code AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB ABFig. & Index No, Part Number ae 3577 No Number “2 20922 “3 22661 4 2473 5 21218 6 "No Number af *No Number “8 ANGO0-10 “9 2285 =10 ‘AN9O0-10 ou 22301 Description 12345 Gasket, Oil Sump... Oil Sump Assembly, ‘Complete |. > ATTACHING PARTS Washer, Play 1/4... Nut, Elastic Stop, 1/428 221. . Washer, Plain, 5/16 Nut, Elastic Stop, 5/1 + Oi! Somp Assembly... 1 Oil Gauge and Rod Assembly | | | Gasket, Annular Plug, O8 Sump Drain. 2112 Gasket, OM Suction Tube. Oi Suction Tube Assembly, | | > oy. Usable On Code AB AB AB AB AB Aa AB AB AB ‘AB AB Aa NOTE: (*) When ordering oll sumps, specify the mmber stamped on the flange or advise airplane make and model or engine serial mimber, o> ne GY 7 EY Ya Lig Md 6 Figure $4, Oi] Sump aud Oil Suction Tube,Fig. & Description Usable Index No. Part Number 12345 sy. On Code 35-1 s00276 Gasket, Magneto Flanges 26 ee ee seen BOB 24739-A1 Magneto and Gear Assembly 2) 2) DLT Lt iB 2 24739 + Magneto, Eiseman RH. AM-4 (without impulse) | 2) 1B 3 3513 Gear, Magneto Drive oe ee ee ee D1 B 50405-A1 Magneto and Gear Assembly 220) 1111) pila B 4 50406 + Magneto, Eisemau, LH. AM-# (with impulse)? |] |) 1 B 5 36087 { Gear, Magneto Drive. teeererl) TB ATTACHING PARTS 6 2555 Washer, Special, 5/16... rr re) a] 2439 Not, Plain, Hex, 8/16-24 2022222 2D DD 1 E tila B 8 2560 Palnot, 5/16 Piilililog 8 A-21082-2 Ignition Cable Assembly... oe. bees 18 8 21082 Cable, Temtion TDD DDD) warp =10 2908 2 Terminal, Spark Plug Cable satety L a B “1 25142 +, Clip, Magneto Terminal... fiiiiiiioa B a2 22460 Spark Plug, Champion 62622222) Dt 2: 8B 13 22493 Bracket, Ignition Cable (Or Magneto Stud) | 2122220200 B 2agat Bracket, Ignition Cable (On Cylinder Studs 1 222) D1 4B “4 22495 Grommet, Ignition Cable. sw. se riiiiliog oB IGNITION CABLE LENGTHS CYLINDER NO, a4 RIGHT MAGNETO | 23" | 30) LEFT MAGNETO. a5" | 33" Figure 85. gnition System, aPig, & Index No. 36-1 2 3 4 o3 6 1 -8 “9 -10 ou a2 13 a4 “15 216 “17 218 219 *20 221 222 25 224 225 226 “21 -28 223 “30 “31 Part Number 538324 36087 3513 530209 380225 401508 ANS36ASIG 2439 A257 25314 25315 25316 25317 25318 e27067-A1 AN936-10 ‘ANSO1-10-10 627067 21082-31. 50 2182-36. 50 21082-3600 21082-35.00 325305 40794 62702, #28387 27668 21082-25, 21082-86, 2108-21, 21082-82, 2308 531116 22493 22435 25145 Description 12945 Gasket, Magneto Flanges oe ee Gear, Magneto Drive (Left Magneto)... pled Gear, Magneto Drive (Right Magneto). 222 222 t Magneto, Left Side... ee ee ee eee Magneto, Right Side. 22 Dt ATTACHING PARTS Washor, Plain ee ee eee eee : Washer, Lock «2... peste piieiiiit Nat, Plain, Hex, 8/16-24 2222 2 Dili Kit, Ground Terminal. oo se ee Washer, Pin... 22d : I Sleeve, Insulating: |e { Forrule, Inner. see te + Ferrile, Outer sve eles © Nut, Hex, Coupling Lip it Harness Assembly, Ignition Completes |... | ‘ATTACHING PARTS Washer, Lock se ve es bebe eee serew + Cable and Plate Assembly, Right Mayneto. 1 cable, 21 Cable, 2 Cable; 1) Cable, Plate, Ignition, Right Magneto to Cylinder #1 11. 1 Ignition, Right Magneto to Cylinder #3 1 1) 1 | Igaition, Right Magneto to Cylinder @2 11 1 1 Ignition, Right Magneto to Cylinder #4 +... Cable Quel. 1 Grommet, Cable. 2 50 60 00, 00 Il Washer, Terminal oe ft Screw, Terminal. ee 2 Cable and Plate Assembly, Left Magneto. + Cable, Ignition, Left Magneto to Cylinder #1. 11 Gable} iunition, Left Magneto to Cylinder #3. 2 Cable, Ignition, Lett Magneto to Cylinder #2. {Cable} Tgnition, Left Magneto to Cylinder #4. | | 2 Terminal, Spark Plog Endy vp ve ee Bracket, Ignition Cable. ss eee 2 Bracket, Ignition Cable te 1 Grommet, Ignition Cable 20212122 2 Bracket, Ignition Cable. te NOTE: (*) Parts 19 through 22 also part of assembly 627666. 48 Usable on Code p> pepo D>bpea> b> DO >baoeeeoberemeDeDFig. & Index No, Part Number ar 4780-1 4 2ai4 22 ANQSOABIE “3 2597 “4 No Number “5 401806 “6 21182 a 22800 “8 21285 9 36151-N “10 21327 “ 3585 ary 4602 “1 2osae a4 ANO36A416 a5 2437 18 AN4022-1 "1 ‘ANBOOC2 “1 20720 “18 AN805-2 19 24081 20 627365 20 3628 21 AND60-416L 22 ‘AN93GAGI6 =23 2437 24 +4071 25 21323 ‘40793 440522 -26 ANDSGAGIO 22 2487 -28 50895 -28 450256 627361 -29 35923 -30 40599 31 24806 -32 24908 -33 Ag5917 “34 aan =35, ANSOIA10-5 50 Deseription 12345 Intake Manifold Assembly... ATTACKING PARTS Washer, Plain, 8/8 se eee ee eee see Washer, Lock... Piliiiiiiiin: Nut, Plain, Hes, 9/b2d 12012 fons + Manifold, Tatake sv LSid, VAX Leia igs te Pipe, Intake... Hose, 1-3/4 0.D. Intake Pipe To Manifold & Elbosr |. | Hose, 1-1/2 0.D. Intake Pipe To Manifold & Elbow + | | Clamp et tele Gasket, Intake Elbow 22D Dil! Elhow, Intake Cylinder No, 2&8 02020222200 Elbow, Intake Cylinder No. 1&4 2 2 Dt AVTACHING PARTS Washer, Plain, V4 ee ee ee Washer, Locks. tebe Nut, Plain, Hex, 1/428 Primer Jet, Intake Manifold. 6.1 2 ee eee Gone, Union. peiiiiiiiiis Gone, Union We Lili lt Naty Unions tte Gasket, Carburetor To Air Intake Assembly... 2. Carburetor, Marvel-Sehebler No. 10-4233 - Carburetor, Strombery NA-S3AL. 2... ss pill ATTACHING PARTS) Washer, Plain... + Bete eee tees Washer, Lock 21 DDD PD iit Nut, Plain, Hex, 1/428 22. ee Sud, YAK BIN Ig ee ee Gasket DDD ls Carburetor Air Throtile Assembly... ct Carburetor Air Throttle Assembly. 6 2222221 ATTACHING PARTS Washer, Locks 2. ce ee ee ee ee eee Nol, Plain, Hex, 4-28 222222 + Houshg Assembly sos ee ee {Housing Assembly 2222 Fiter Assembly. 2022222200008 s Gasket reer e tite Dimiter DD DE Piliibiiis 1D Stud, Fasteners 22D EDD DL Lpinfcross Tle Support ‘Assembly, Carburetor Aix Intakes 21.) ATTACHING PARTS Washers ee ee Steen eee ee screw. DTI T Tt! Pliibiiiiis + Oversize or Undersize parts available, penne ee eee bee ee ne en coe wee Boenad Usable On Code AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB AB25- . = , ee a5 J —: Figure 37, Carburetor, Air Intake and Filter System,Fig. & Description Index No. Part Number 12846 sar 7 40586 Camshaft ee Th 4 4546 Comsat EDT Tt ut 1 537870 Pushrod Assembly. 22222 Dit 21509 Valve Tappet Assembly. | 1) > Dliiiiiiits 3 21608 = Body Perse c clit ii iliiihs 4 533309 Dayarauie We PITT PIII ELI LIL “3 25042 Tsomet oD TDD Et pili “6 530940 ysmpRing ITT a 530926 Gasket, Pushrod Housing Flange 2222) 4 21170 Gasket, Pushrod Housing Flange 22222202 “4 590163 Flange, Pushrod Rousing...” PiDiliiiiit ATTACHING PARTS “8 20522 Washer, Plait, V4 ee eee ee eee s10 AN36A4I6 Washer, Lock DDD in 2437 Nut, Plain, Hex, Vale Tt -12 $3940 Connector, Push Rod Housings vv ee ee 122214 Connector, Push Rod Housing 13 536386-1 Clamp, Hose ee ee teed “1321282 Clamp, Hose LISP lilt A-aT46 Propeller Hub Assembly 22 LT : 143785 1 Mb, SAE #0 Taper shaft 22 15 g89r | Flange, Propeller Hab. 2 2 222 pili ‘ATTACHING PARTS -16 21488 + Bolt, 3/8248 1/4 MB “7 2eia 1 Washer, Plain 7/8 00 DLT 1182458 D Nut, Castle, S/aeza TTD pile =19 2506 Pin, Cotter, 3/82K3/4in lee Le -20 21202 «Nut, Propeller Hub yo eee rat 21203 T Rim, Samp ee elle lt saz ANSD2-11 1 pany 17a 11/32't0, ge pili 223-2500 1) Pin, Cotter, 1/16 X 8/8 in ig 22D fhDDn! 52 + P/N 40584 can only be used in AGS Engines if crankcase halves are P/N 0794 & 6795, Otherwise you must use 4546 cam in both A65 & 75. + Oversize or Undersize parts available,Fig. & Index No, 39- 54 “4 “2 “3 4 “5 “6 7 -8 “3 “10 “i “12 13 o14 -15 o16 a a8 219 =20 21 -22 =23 24 225, -26 227 28 223 =0, “31 =32 33 234 235 -36 231 238 “39 40 a4 Part Number £g5198 22131 22132 2234 22139 3675, 22133 3883 nar 24d 2561 2649 2848 ‘AN900-10 2265, 20882 20295 22236 22130 22a) 22293 Egsisa + 20899 21064 4732 2418 Das 22133 3883 244 24d 2581 2848 2840 ‘AN300-10 2265 20288 20271 22198 22130 530208 22199 2076 Description 12945 OU Cooler Equipment (Under Engine). os ee as Bracket, Crankease 2-4Sié0 . 0 1 tltelle Bracket, Crankease 1-3Side 2) 2) 22 ATTACHING PARTS. + Screw, 1/4-26X25/4in Meee | Washer, Bracket To Crankease Spacer ©) 121111 «Adapter, Ol Cooler. ees beeen eee + Gasket, “Oil Cooler To Adapter. 2.22 peal Loncoter ITIP IT) ATTACHING PARTS + Master, Plain 9/8. 9 vs ee ee Nut, Plain, Hes, 3/826 222 2200 2D D0 002 Paint, 3/8 eee ETT Dt + Ball, By-Pass Valve, V6. ee Spring, By-Pass Valve 2) 2) 1) 11 ra Gaskets II Di iit 2 Plug, 9/8 Hextead 22 PDT P DID 2 Plug, 1/8'NPT. 2. 2 Piibiiiiit 2 Elbow, 45 Degree, 3/8 NPT Street 2 Dt + Bibow, 45 Degree, 3/8 NPT XS/8 Tube. ss ss + Sleeve, Crankease Oil Ling se ee lt Elbow, 90 Degree, 3/8 Pine to 3/8 Tube 12111) )t Tube, "Oil Cooler To Crankease 2. 1 Oil Cooler Equipment (Side Mounted) 22. 2222201 Stud, 5/MXI-/4in lg et + Gasket, Adapter To Crankease. 2222202 Dd! D Adapter, Ol Cooler, et pestis es ATTACHING PARTS Washer, Plain, 816 20 ee ee Nut, Castle, s/46-26 22211! pibiiiin. «Gasket, Ol Cooler. eee Doicomer. TIT bbl ATTACHING PARTS + Washer, Plain, 9/8. 0 ve ee ee eee SONut, Plain, Hex, 3/8-24 02020 2. peer iill Palnut, 3/8... pepe t il iliiiit «Ball, 1/16, By-Pass Valve oe ee an Spring, By-Pass Valve.) rt S Gasket, By-Pass Valve Plugs 22 t + Plug, By-Pass Valve... pied iiit 2 Plugs VANPT. lit Elbow, 90 Degree, 3/8 NPT Street. 22 De De + Tube, "Oil Cooler To Crankease 2. Le tees b Sleeve, Oil Line oe + Elbow, 90 Degree, 3/8 NPT X 3/8 Tube Tube, Oil Cooler To Crankease ss 2 Plug, 8/8NPT. oe pete t enters * Oversize or Undersize parts available, ey. Usable On CodeFigure 39, Oil Cooler Equipment,Fig. & Description Usable Index No, Part Number 12345 &y. On Code 49 5Q5148, Fuel Pump Boulpment. 60. 2 ee ee seen D “OF 20001 1 Shad, IX LFin ig 2 “02 21064 ) Gasket, Fuel Pump. 2s tee pieiiiit 1 03 40585 [Fuel Pump (AC#IS89051) 2 od ATTACHING PARTS -04 2473 . Washer, Plan, 5/16 ee ee 2 05 2439 DoNut, Plain, Hex, 8/1824 ee 2 -06 2580 D Paint, 5/16. ee Piliiiiii 2 -07 49584 + Camshatt oe ee eee bee e eee dT 589546 1 Crankease, t-a'side 22D DID Dll 1 AI52334 2 Fuel Line Assembly <2 2 Pisa ieiice Dod ANTOO-4 1 Elbow, 1/8 Pipe X 7/1620 0 ve 1 25306 I Ethow, 1/4 Pipe X7/16-20 Ve toa 21619 1 Bthow, Flared Tube. 2 Ste Piliiiiet a 7 Figure 40, Fuel Pump. 38PART NUMBER ANG022-1 ‘ANSO1-10-10 ANT9O-4 ‘ANSOOC2 ‘ANA05-2 AN842-10 ‘ANB00- 10 AN000-14 ‘AN900-22 ‘AN300-28 ANQS2-11 ‘ANS36-10 ANSSGA4I6 ANOS6A516 AN9RGAGIB ANGO0-4161. ‘AN960-516 ‘A21082-A2 421599 422301 ‘24122 4252394, A2827 ‘A35159-A2 ‘A35160-A2 3568 AS35017 ABTS ‘40522 40522 ‘40877 40793 ‘Aass? ‘A4587-8, ‘A4sa7-AL ‘ASOLAL0-5 50256 5044s Wats Tors Rd FIG, & SECTION 14 ory PER INDEX Assy. 37-16 36-14 40- 37-17 37-18 30-45 30-04 39-14 34-08 34-10 39-13 39-93 33-10 33-16 33-12 33-22 36-13 30-25 30-31 32-28 ard 31-22 37-28 38-10 38-03 36-05 37-02 37-21 30-24 35- 38. 34-11 32. 40- 36-07 31 31. 33-13 37-33, 38- 3T- aT sl st 33- 33+ 33 37-35 37-28 31-01 49° 10 aa LIS PART NUMBER 50495, Bsi62 B-a762-A1 B-9762-A2 B-3762-B B-3762-BL EQ5148 95198 £Q5199 20001 2024 2025 20288 20822 20720 20882 20976 20080 21003 24007 21025 21051 21064 21075 21080 21082 21082-21, 00 21082-25. 50 24082-31.50 21082-32, 00 21082-38..00 1082-36, 00 21082-36, 50 21082-36. 60 21n3 2inl4 21119 21153 21160 21163 auto FIG. & INDEX 37-28 32 32- 32- 42. 32- 40- 39. 39. 40-01 30-05 32-06 30-03 39-95 30-23 30-30 33-23 34-02 37-13 38-08 ST-17 39-15 39-41 59021 33-15 30-42 32-24 32-20 37-19 39-22 40-02 30-08 30-06 35-09 36-25 36-28 36-15 36-28 36-18 36-17 36-16 36-24 33-11 38-08 32-19 32-25 33-22 33-17 38.07 ary PER ASSY oe ee 5 87PART NUMBER aure2 21185 21202 21208 21208 zis 2naT4 21ne2 21284 21323 21327 21343 21346 2ass2 21359 pager 21363 21366 2149 21445 21es@ aug 24479 2aa93 21550 2x608 21619 22008 22022 22130 2231 22132 22133 2234 2239 22198 22199 22211 22271 22293, 22295 22208 22386 22387 22423, 22460 22403, 58 FIG. Qty & PER INDEX ASSY 37-06 37-08 38-20 38-21 35-18 34-05 38-12 38-15 32.13 37-25 37-10 33-21 33-26 33-28 8-08 32-16 92-21 3217 32-18 32-12 30-41 38-18 32-30 32-15 32-31 30-49 38-03 40- 0-15 32-32 39-18 39-38 39-01 39-02 39-08 39-26 38-03 39-06 39-37 39-40 32-15 39-19 39-36 39-20 39-16 30-17 31-08 30-39 30-09 33-08 35-12 35-13 36-29 PART NUMBER 22405 29837 2285 22053 22661 22800 23030 2306 23287 24122 2a14a2 24251 24252 24306 24308 24921 2437 2438 paar 2403 2457 2458 2465 Dart 2473 2ara9 24738-A1 2an4 FIG. & INDEX 35-14 38-30 33-24 40-08 34-08 30-14 39-34 80-41 34-08 37-07 30-10 35-10 36-27 83-07 32-23 33-15 30-21 30-22 37-31 37-32 30-43 30-26 30-32 37-15 37-23 37-27 38-11 33-04 35-07 36-08 40-05 30-34 39-09 39-29 30-37 32-01 39-25 32-03 38-18 30-07 37-34 33-02 34-04 39-24 40-04 35-02 35- 30-33 37-01 38-17 ary PER ASSY te 16 154 10 10 15+PART NUMBER, 244 2475 24767 24768 2469 24770 24804 24805 24806 Dagar 24878 2ae7e 2500 2501 25042 2506 2otry 25127 25127-Al 25142 25245 25164 25276 25305 25306 25914 25315 25316 25317 25318 25328 28330 25331 25361 25369 25376 25387 2985 2557 2560 2581 2840 2648 2649 2958 3508 FIG QTY &” PER INDEX ASSY 39-08 39-28 3 3 9 30-352 Bill 6 3126 3107 8 3108 Brat 2 32-0901 329001 35. 4 30-28 2 go-27 1 3Be23 1 aia 38-051 B19 6 sim siezz 1 31 1 3-0 ot 36-312 30-29 2 sen 36-19 0- 1 36-08 1 35-091 86-101 sen 1 36121 30-14 30-200 «2 6 2 a 2 1 4 30-12 30-13 30-14 31-15 52-81 38-22 35-06 34-03 35-08 40-08 4 4 2 4 2 a 30-351 32-04 18 39-103 39-908 3 39-32 1 30120 1 sok 1 393101 » 6 2 3202 1 30-38 33-2n PART NUMBER 3513, 3562 3577 3585, 35807 35923 36956 36087 36151-N 3628 3748 bats ass 3991 401508 aoze08 401885, 401963, 402127 40237 402711 40877 40584 40585 40599 40731 40731-A1 40762 40704 4546 4577 4502 4952 4780-A1 500278 500398 500400 50327-Al 50¢08 50408-A1 520112 530019, 590058 530144 580145 530162 530109 530196 FIG, Qty & PER INDEX ASSY 35-08 38- 1 1 2 33-200 1 3401 1 B72 51138 37-231 3-031 35-051 36-02 1 2 59PART NUMBER 530199 330208 530209 530213 580225 530641 530828 580856 330887 530928 530940 581116 583389 583546 585081 535324 586385- 1. 25 60 FIG, & ary PER INDEX ASSY aie, 30-39 36-03 31-18 36. 33-25 31-28 a 31-22 38.07 38-08 36-28 38-04 40. 32-28 36-01 38-13 PART NUMBER 587870 539840 526972-4 927002 27275 827361 627365 627380-AL 827386-A2 27667 e27667-AL 627668 30651 531708 682085 633141 633398 633399 FIG, & ary PER INDEX. ASSY 38-02 38-12 33-19 36-21 30-20 37 81-20 30- 30- 36- 36- 36- 31-02 33-09 33-16 30-19 30-18 30-1820001 Po0S, 20001PO08 20001903 20980P003 2oseaPa0s 20930009 21075 P0038 2107006 21075003 21183P005 21419005 21419010 21419 Po20 22006 P003 22008 PONS 22006 PODS 22386P005 22423 P003 22495 PODS 22423P000 23030P008 23030P006 280307009 23297 POS 25297 P008 28297 POS 2465003 2485 PO06 2465 P009 24805P002 24805P010 24805 P920 24805 P030 24806P002 24806P010 24806 P020 24806 P030 25127005 25278P008 25276010 25276 P020 NAME, Stud Stud Stud Stud Stud Stud Stud Stud Stud Shact Guide Guide Guide Stud Stud Stud Dowel Stud Stud Stud Stud Stud Stud Stud stad Stud Stud Stud Stud Insert Insert Ingert Insert Insert Insert Insert Insert Piston Pin Guide Guide Guide SECTION 15 VERSIZE AND UNDERSIZE PART DESCRIPTION 003" OS on PD 006" OS on PD (009 OS on PD 003" OS on PD 1008" OS on PD 003" OS on PD 08 on 08 on 08 on gge 8 08 on 8 538 = 005" OS on 003" 08 on 1006" O$ on 1008" 08 on Bes 8 003" OS on PD 1006" O8 on PD 1908” OS on PD. 903" O$ on PD 906" OS on PD. 1003" OS oa PD 003" O8 on PD 906" O8 on PD. 1908” O$ on BD. 902" OS on OD. 1010" OS oa OD £020" OS on OD 080” 08 on OD 002" OS on OD. 1010" 08 on OD 1020" O8 on OD 1930" O8 on OD. 008" 08 on OD 005” OS on OD 1010" OS on OD 1020" OS on OD PART NO. 253288003 25329008 233287009 253830P003 25330P008 25330P009 25381003 23331008 25381003 283617003, 25361PO08 25361009 35897M010 633396M010, ea3393Mo10 401806003 401806 P007 401806 PO12 o1aaspoos 401885PO0T 401885P012 401963 P03 401363P00T 401985PO12 402127 P00s 402127 P00? 402127 PO12 40237M010 402711 P03 4027 1POOT 402711PO12 40877PO15 40584P020 40731 POTS 4546020 58005aM010 NAME Stud Stud Stud Stud Stud Stud Stud Stud Stud stud Stud Stud Bearing C/Rod Bearing C/Shatt Bearing C/shaft Stud Stud Stud Stud stad Stud stud Stud Stud Stud Stud Stud Bearing C/Shait Stud Stud Stud Piston Camshaft Piston Camshaft Bearing C/Shatt DESCRIPTION +003" OS on PD. £006" 8 on PD. 008” OS on PD +008" O8 on PD. 008" OS on PD 1008" OS on PD. 003" OS on PD 1006" OS on PD. 008" OS on PD. 10" US on 1D 010" US on 1D 010" US on ID 003" OS on PD 1007" O8 ea PD. 1012” 08 oa PD 003" O8 on BD 1002" O8 on PD. 1012" 08 o PD 003" O8 on PD. 007°" OS on PD 1012" 08 on PD 003" OS on BD 1003" OS on PD 1012” O8 oa PD :010” US on ID 003" OS on PD. 1007" O8 on PD £012” O8 on PD -015" O8 on OD 020" 08 on OD -015" OS on OD -020" OS on OD -010" US on ID 8OVERSIZE & UNDERSIZE PARTS (Continued) PART NO, NAME DESCRIPCION —-PARTNO, NAME DESCRIPTION sa0144005 Ring 005" OS on OD 590856700 Piston Pin Assy 006" OS on OD SS01MPOIS Ring 1018" OS on OD 580857P005 Piston Pau 005" 0S o OD s90145Po0s Ring 098" OS on OD 801450015 Ring O15" Os 9106908517005 Dowel 005° 08 on OD GASKET SETS PART NO, DESCRIPTION size coe aor0se1 Gasket Paste - Tie Seal, Lightweight oz, tube ap paers Gasket - Complete Overnaul Standard A solss-at Ring Set « Complete Engine Standard ap s901s4-a1P905 Ring Set - Complete Eat 005" 05 on 0D AB sa0144-a1P01 Ring Set» Complete Engine 015" 0S on OD AB 0231-41 Bearing Set» Cranksatt standacd aa 40237-A1Mo10 eating Set - Crasshat L010" US9019&B se00se-as Bearing Set ~ Crantenat, Standard ap 50058-33010 Bearlig Sel - Crunkshat 010" USon DAB e20s01-1 Enamel = Gold, Engine 1 auact AB cassia Enamel - Gold, Engine 1 Galton AB sason1 LLockvire = .040 in da, steel Osder by the toot AB seansa Loctouire = 020 in, dla, set Order by the foot AB 62SECTION 16 TROMBERG CARBURETOR TYPE NAS3A1 SERVICE INSTRUCTIONS a. Installation, () The carburetor should be so mounted on the engine that the float chamber is at the side of the throttle barrel, preferably with the fuel infet to the rear, With the carburetor in this position, the throttle lover, which is adjustable to any radial’ position, is at the right side of the carburetor as viewed from the rear of the engine, The mixture control lever is located on top of the float chamber on the right hand side. The Juel inlet ts a 1/4" pipe tap connection Iocated at the back near the buttom of the main body. if the carburetor is installed as above. When the Juel level is set at the factory, a pressure of nne~ half pound per square inch at the carburetor is used. As these carburetors will undoubtedly be used on engines having a gravity feod system, It is recom= ‘mended that the tanks be located so that the mininsum, head of fuel at the carburetor inlet is nineteen (19) inches under all normal conditions of Hight, b, Starting. (GQ) As these carburetors are not equipped with a printing device, the following procedure Is reeom= mended for stirting, With the mixture control. in (he full rich postion and the tirotile closed the engine should be turned over two or three times before the ignition is turned on, This will draw fuel up through the idle system and then if the lgnition is turned on the engine will usually start on the ext turn over, As suo as the engine starts to fire it is usually necessary to open the throttle slightly to keep the engine running and to warm it up sul ficiently for normal operation, Adjustment. GQ) The ‘main metering jet used in the carburetor is of Ue fixed orifice type, and its size as well as the remainder of the carouretor specifications has been determined by test work as previously mentioned, so thal no adjustment for cruising and full throttle speeds is required except at altitude when the mixture control niay be used to obtain best power, An idle adjustment is provided totake care of alight production, variations in the carburetors and engines, The small knurled serew on the throttle valve body, may be agjisted to control the richness of the mixture at idling speeds, ‘Turning this screw in a clockwise direction closes off the passage leading to the upper idle discharge hole and leans out the idle mixture ‘Turning in the opposite direction of course gives a richer mixture. A throttle stop is provided on the throttle shaft next to the throttle control lever ‘waich Should be adjusted to obtain the desired idling speed, Both the throttle stop and the idle adjustment should, bbe set with the engine hot to obtain the proper idling ‘speed ana smooth operation. 4, Servicing. (i) Once the carburetor is properly installed and the idle adjustment made, very little attention Ls required in service, A fuel strainer is provided near the fuel inlet of the carburetor, and may be removed by the removal of the large hexagon head plug on the side of the float chamber. A smialt square head plug is provided as a drain in the bottom of the carburetor. The strainer and drain plug should be removed frequently to get rid of any dirt or water which may have accumulated in the steainer chamber or the fleat chamber, The entire carburetor should also be inspected to ‘see that all parts are tight and properly safety wired, e Description and Functioning of Carburetors. (2) FLOAT MECHANISM: A conventional hinge type of float mechanism located in a float chamber having ample fuel capacity to operate in all ordinary maneuvers is used. This float mechanism is adjusted a the factory to ‘obtain the proper fuel level, and Tequires mo adjustment in service unless it is necessary after a Tong period of service to install new paris, For information concerning the proper level see the section of these instruction pertaining to “Overhaul.” (2) MAIN” METERING SYSTEM: The metering system Used in the carburetor is of the plain tube type with an air bleed to the main discharge nozzle, ‘Phe main discharge nozzle is tocated at the center of the venturi and ig. screwed into a boss projecting into the air intake, The main air bleeder is screwed into the air bleed arm which is held in place by the main discharge nozzle, The actual metering of the fuel is accomplished by the mainmetering jet which 1s assembled in the bottom, of the float chamber ina ehanuel ‘through whieh the gas flows to the main discharge nozale, The size of the main metering Jet affects “the fuel consumption at all speeds from approximately 1000 RPM to full throttle speed, (3) MIXTURE CONTROL: The altitude or mixture control is of the back suction type which may be used to Jean out the mixture by placing a portion of the ven— turl suction on the fuel im the float chamber so that it ‘opposes the suction in the venturs en the main discharge nozzie, This control consists of a venturi suction ehan= nel {rom above the mixture conteol plates tothe throt= tle bore at the upper edge of the venturi, a manually operated valve, and the necessary passages to the float chamber ‘and venting system. ‘The valve con- sists of a lower and upper valve plate, the former fastened in place and the latter free to’ move, When the control is in the full rich position, holes ia both the upper and lower plates mate and alz is allowed to 63