SERVICE TABLE OF LIMITS AND TORQUE VALUE RECOMMENDATIONS

SERVICE TABLE OF LIMITS AND TORQUE VALUE RECOMMENDATIONS NOTICE The basic Table of Limits, SSP-1776 has been completely revised and reissued herewith as SSP-1776-5. It is made up of the following four parts, each part contains five sections. PART I DIRECT DRIVE ENGINES (Including VO and IVO-360) PART II INTEGRAL ACCESSORY DRIVE ENGINES PART III GEARED ENGINES PART IV VERTICAL ENGINES (Excluding VO and IVO-360) SECTION I 500 SERIES CRANKCASE, CRANKSHAFT & CAMSHAFT SECTION II 600 SERIES CYLINDERS SECTION III 700 SERIES GEAR TRAIN SECTION IV 800 SERIES BACKLASH (GEAR TRAIN) SECTION V 900 SERIES TORQUE AND SPRINGS This publication supersedes and replaces the previous publication SSP-1776-4. To make sure that SSP-1776-5 will receive the attention of maintenance personnel, a complete set of pages for the book is sent to all registered owners of Overhaul Manuals. These recipients should remove all previous Table of Limits material from the Overhaul Manual and discard. SSP-1776-5 April 13, 2020* * - Indicates cut-off date for data retrieved prior to publication. ©2020 by Lycoming “All Rights Reserved” This page intentionally left blank. INTRODUCTION SERVICE TABLE OF LIMITS This Table of Limits is provided to serve as a guide to all service and maintenance personnel engaged in the repair and overhaul of Lycoming Aircraft Engines. Much of the material herein contained is subject to revision; therefore, if any doubt exists regarding a specific limit or the incorporation of limits shown, an inquiry should be addressed to the Lycoming factory for clarification. DEFINITIONS Ref. (1st column) The numbers in the first column headed “Ref.” are shown as a reference number to locate the area described in the “Nomenclature” column. This number will be found in a diagram at the end of each section indicating a typical section where the limit is applicable. Chart (2nd column) The letter in this column is used as a symbol to designate engine models to which the specific limits are applicable. A list of the letter and the engines to which it refers is shown on the following page. Nomenclature (3rd column) This is a brief description of the parts or fits specified in the adjacent columns and indicated in the diagram at end of each section. Dimensions (4th and 5th columns) The dimensions shown in column 4 are the minimum and maximum dimensions for the part as manufactured. The dimensions shown in column 5 indicate the limit that must not be exceeded. Unless it can be restored to serviceable size, any part that exceeds this dimension must not be rebuilt into an engine. Clearance (6th and 7th columns) Like the dimensions shown in the 4th and 5th columns, the clearance represents the fit between the two mating surfaces as controlled during manufacture and as a limit for permissible wear. Clearances may sometimes be found to disagree with limits for mating parts; for example, maximum diameter of cylinder minus minimum diameter of piston exceeds limit for piston and barrel clearance. In such instances, the specified maximum clearance must not be exceeded. In some instances, where a parts revision has caused a dimensional or tolerance change, the superseded dimensional data has been deleted from the list; provided compliance with the change is mandatory. This manual contains torque values specifications for various type of hardware used on Lycoming Engines. The importance of correct torque application cannot be overemphasized. Under-torque can cause premature wear of nuts and bolts, as well as the parts they secure. Over-torque can cause wear or premature failure of a bolt or nut from overstress on threaded areas REQUIRED PRACTICES NOTE: Make sure that the torque applied is for the size of the bolt shank not the wrench size. NOTE: Do not exceed the maximum torque plus the friction drag. If the hole and nut castellation do not align, change washer or nut and try again. Exceeding the maximum recommended torque is not recommended. • Calibrate the torque wrench at least once a year, or immediately after it has been abused or dropped, to ensure continued accuracy. • Be sure the bolt and nut threads are clean and dry, unless otherwise specified by the manufacturer. • Apply a smooth even pull when applying torque pressure. If chattering or a jerking motion occurs during the final torque, back off the nut and retorque. • When installing a castle nut, start alignment with the cotter pin hole at the minimum recommended torque plus friction drag torque. If special adapters are used which will change the effective length of the torque wrench, the final torque indication or wrench setting must be adjusted accordingly. Identify the correct torque wrench indication or setting with the adapter installed. Refer to AC 43.13- 1B for details. i Introduction Drag Torque VARIABLE AFFECTING TORQUE. Several variables must be taken into consideration when determining the amount of torque to apply to a given fastener. Standard torque charts are developed for dry, un-plated conditions. Surface variables to be taken into account for each specific application include thread roughness, lubrication, hardening, scale, paint, and plating. Drag torque is also known as running torque, the resistance on the screw as it’s being installed, usually only a few Inch Lb. Drag torque is the natural friction between a fastener and its nut, nut plate, etc. NOTE: When specific torque values are included in a technical manual for a specific item, those values shall be used. This means that friction drag torque was already included for known conditions. • Run the nut down to near contact with the washer or bearing surface and check the friction drag torque required to turn the nut. • Add the friction drag torque to the desired torque. This is referred to as “final torque,” which should register on the indicator or setting for a snap-over type torque wrench. • Final torque = friction drag torque + desired torque. Letters of the alphabet and numbers are used as symbols throughout the Table of Limits to represent specific interpretations and to designate engine models. Letters in parenthesis refer to dimensional characteristics; letters without parentheses indicate engine models. They are listed below with the separate definitions. (A) These fits are either shrink fits controlled by machining, fits that may readily be adjusted, or fits where wear does not normally occur. In each case, the fit must be held to manufacturing tolerance. (B) Side clearance of wedge type rings must be measured with face of ring flush with piston. (D) These dimensions shown are measured at the bottom of the piston skirt at right angles to the piston pin. (E) Permissible wear on crankshaft (rod and main bearing journals) to be minus .0015 on diameter. (L) Loose fit; wherein a definite clearance is mentioned between the mating surfaces. (T) Tight fit; shrink or interference fit. (WD) Wide Deck Crankcase. The illustrations shown are typical of the referenced limit or fit described in the Table and in no instance are these illustrations intended to represent a specific part or engine model unless specified. Also, the terms used to designate cylinder, piston and ring materials such as “nitride, chrome, half-wedge” are more fully explained in the latest revision of Service Instruction No. 1037. Introduction ii SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES CHART MODELS CHART MODELS A O-235-C, -E, -H S7 HIO-360-D A1 O-235-F, -G, -J,-K, -L, -M, -N, -P S8 HIO-360-B B O-290 S9 HIO-360-C B1 O-290-D2 S10 HIO-360-A (S/N with suffix A) BD O-320-H (76 Series) S11 HIO-390-A G O, IO, LIO, AEIO-320 IO-, AEIO-390-A G1 O, IO-320 With Gov. at Front IO-390-C, -D (O-320-E1F, -E1J, -D1F & IO-320-D1B) S12 HIO-360-F1AD G2 AIO-320 S13 HIO-360-A (S/N without suffix A) J O-340 S14 HIO-360-E BE O, LO-360-E (76 Series) D O-435-A Y VO, IVO-360 T O, IO, LIO, AEIO, TIO, LTO-540 S O, IO, LIO, HIO, LHIO, TO, TIO, AEIO-360 T1 O-540-G, -H &IO-540-N, -R S1 TO-360 T2 (Large Mains – Parallel Valve) S2 AIO-360 IO-540-A, -B, -E, -G, -P (Angle Valve) S3 TIO-360 T3 IO-540-K, -M, -S; TIO, LTIO-540-A, -F, S4 O-360-A With Gov. at Front -J, -N, -R (Large Mains – Angle Valve) (O-360-A1H, -A1LD) IO, AEIO-580-B1A S5 IO, LIO-360-A, -C (Angle Valve) TEO-540 S6 IO, LIO-360-A, -C With Gov. at Front T4 TIO-540-C, -E, -G, -H (IO, LIO-360-C1E6 & IO-360-A1D6) AF IO-720 NOTE: In “Chart” column, a number appearing after a letter indicates an exception to the basic model. For example, A1 (O-235-F. –G, -J, -K, -L, -M, -N –P) is an exception to the basic model A (O-235-C, -E, -H) When referencing any section in this Table of Limits for a dimension or clearance, if the there is no specific A1 row for a particular reference number, the A limits also apply to the A1 engine models. SECTION I 500 SERIES CRANKCASE, CRANKSHAFT & CAMSHAFT SECTION II 600 SERIES CYLINDERS SECTION III 700 SERIES GEAR TRAIN SECTION IV 800 SERIES BACKLASH (GEAR TRAIN) SECTION V 900 SERIES TORQUE AND SPRINGS (A) These fits are either shrink fits controlled by machining, fits that may readily be adjusted, or fits where wear does not normally occur. In each case, the fit must be held to manufacturing tolerance. (B) Side clearance on piston rings must be measured with face of ring flush with piston. (D) The dimensions shown are measured at the bottom of the piston skirt at right angles to the piston pin. (E) Permissible wear of the crankshaft (rod and main bearing journals) to be minus 0.0015 on the diameter. (L) Loose fit; wherein a definite clearance is mentioned between the mating surfaces. (T) Tight fit; shrink or interference fit. (WD) Wide Deck Crankcase. SSP-1776-5-PT1 April 13, 2020* * - Indicates cut-off date for data retrieved prior to publication This Page Intentionally Left Blank TECHNICAL PUBLICATION REVISION REVISION NO. PUBLICATION PUBLICATION NO. PUBLICATION DATE SSP-1776-5-PT1 Service Table of Limits SSP-1776 October 28, 2013 PREVIOUS REVISIONS CURRENT REVISION* March 2014 1-1 July 2014 1-10 February 2016 Title Page, 1-1, 1-2, 1-3, 1-8, 1-9, 1-10, 1-11, 1-12 • Added S11 designation to Chart for IO-, AEIO-390-A engine models • Revised tappet information for Reference number 511 and 512 • Updated piston and cylinder barrel information for: o IO, AEIO-390-A o TIO-540-C, -E, -G, -H; IO o AEIO-580-B1A September 2016 Title Page, 1-8, 1-30 • Added engine model IO-390-C to Chart • Added engine model IO-390-C to Piston Application Table • Added S11 designation to Reference #823, backlash clearance for front governor engines April 2018 Title Page, 1-1, 1-3, 1-7, 1-8, 1-9, 1-10, 1-11, 1-34, 1-35, 1-36, 1-37 • Added HIO-360-F1AD, HIO-390-A, and TEO-540 to Chart • Added S12 designation for HIO-360-F1AD to tables where applicable • Revised Ref. number 512 (Tappet Plunger Assembly and Body) for clarity • Revised Piston Application Table to list only piston part numbers • Added NOTE to refer to the latest revision of Service Instruction No. SI-1037 for engine model and piston part number applicability • Deleted obsolete part numbers and Notes associated with those part numbers in Piston Application Table • Deleted NOTES that reference S.I. 1243 in Piston Application Table • Updated Lycoming P/N and Vendor P/N for one of the V- band couplings for Ref. number 921. • Added Ref. number 933 to Section V table and figure for torque value for brass union nut on stainless steel injector fuel line (Both Ends) • Deleted obsolete part numbers for Ref. numbers 950 and 951 April 2020 Title Page, 1-1, 1-7, 1-8, 1-9, 1-10, 1-11, 1-34, 1-36 • Added Serial Number identification for Chart number S10 - HIO-360-A • Added new engine model listing for IO-390-D to Chart reference number S11 • Added new Chart reference number S13 for HIO-360-A engines without S/N suffix A • Deleted HIO-360-E from Chart reference S9 • Added new Chart reference number S14 for HIO-360-E • Added new reference numbers S13 and S14 as applicable in Sections I, II, and V • Revised burnishing instructions for connecting rod bushing in reference number 600 • Revised the Mfr. Min. & Max. Clearance for Piston Ring Gap (Compression) Nitrided Cylinders (Choke Barrels) and Piston Ring Gap (Oil) in reference number 607 * Revisions are indicated with a vertical bar to the left of the revised item. ©2020 by Avco Corporation. All Rights Reserved Lycoming Engines is a division of Avco Corporation This Page Intentionally Left Blank SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 500 A All Main Bearings and Crankshaft .0025L .0055L .0060L B-D-G-J-S-T-Y-BD-BE-AF Main Bearings and Crankshaft (Thin Wall Bearing - .09 Wall Approx.) .0015L .0045L .0060L B-G-J-S-T-Y-AF Main Bearings and Crankshaft (Thick Wall Bearing - .16 Wall Approx.) .0011L .0041L .0050L A Diameter of Main Bearing Journal on Crankshaft 2.3735 2.375 (E) B-D-G-J-S-T-Y-BD-BE Diameter of Main Bearing Journal on Crankshaft (2-3/8 in. Main) 2.3745 2.376 (E) S1-S11-S12-T1-T3-AF Diameter of Main Bearing Journal on Crankshaft (2-5/8 in. Main) 2.6245 2.626 (E) S8-S10-S13 Diameter of Front Main Bearing Journal on Crankshaft (2-3/8 in. Main) 2.3750 2.3760 (E) S1-S11-S12-T1-T3-AF Diameter of Front Main Bearing Journal on Crankshaft (2-5/8 in. Main) 2.6245 2.6255 (E) 500 A-B-B1-D-G*-BD-BE Crankcase Bearing Bore Diameter (All) (Thin Wall Bearing) (2-3/8 in. Main) 2.566 2.567 2.5685 G**-J-S-T-Y Crankcase Bearing Bore Diameter (All Except Front) (Thick Wall Bearing) (2-3/8 in. Main) 2.6865 2.6875 2.6890 T1-T3-AF Crankcase Bearing Bore Diameter (Front Only) (Thin Wall Bearing) (2-5/8 in. Main) 2.816 2.817 2.8185 T1-T3-AF Crankcase Bearing Bore Diameter (All Except Front) (Thick Wall Bearing) (2-5/8 in. Main) 2.9365 2.9375 2.9390 S1-S12-T-AF Crankcase Bearing Bore Diameter (All) (Thin Wall Bearing) (2-5/8 in. Main) 2.816 2.817 2.8185 G**-J-S-T-Y *O-320-A, -E Narrow Deck, **O-320-A, -E Wide Deck Crankcase Bearing Bore Diameter (Front Only) (Thin Wall Bearing) (2-3/8 in. Main) 2.566 2.567 2.5685 501 ALL Connecting Rod Bearing and Crankshaft .0008L .0038L .0050L A-B-D-G-J-S-T-Y-BD Diameter of Connecting Rod Journal on Crankshaft (2-1/8 in.) 2.1235 2.125 (E) S-T-AF Diameter of Connecting Rod Journal on Crankshaft (2-1/4 in.) 2.2485 2.250 (E) A-B-D-G-J-S-T-Y-BD-BE Connecting Rod Bearing Bore Diameter (2-1/8 in.) (Measured At Axis 30O on Each Side) 2.2870 2.2875 Revised April 2020 1-1 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 501 S-T-AF Connecting Rod Bearing Bore Diameter (2-1/4 in.) (Measured At Axis 30O on Each Side) 2.4205 2.4210 502 ALL Connecting Rod - Side Clearance .004L .010L .016L 503 ALL Connecting Rod - Alignment .010 in 10 Inches 504 ALL Connecting Rod – Twist .012 in 10 Inches 505 Crankshaft Run-Out at Center Main Bearing 4 CYLINDER Mounted on No. 1 and 4 Journals Max. Run-Out No. 2 Journal .002 .002 Mounted on No. 1 and 4 Journals Max. Run-Out No. 3 Journal .005 .0075 Mounted on No. 2 and 4 Journals Max. Run-Out No. 3 Journal .003 .0045 6 CYLINDER Mounted on No. 2 and 5 Journals Max. Run-Out No. 1 Journal .002 .002 Mounted on No. 2 and 5 Journals Max. Run-Out No. 3 Journal .005 .0075 Mounted on No. 2 and 4 Journals Max. Run-Out No. 3 Journal .003 .0045 Mounted on No. 3 and 5 Journals Max. Run-Out No. 4 Journal .003 .0045 8 CYLINDER Mounted on No. 2 and 6 Journals Max. Run-Out No. 1 Journal .002 .002 Mounted on No. 2 and 4 Journals Max. Run-out No. 3 Journal .003 .0045 Mounted on No. 3 and 5 Journals Max. Run-Out No. 4 Journal .003 .0045 Mounted on No. 4 and 6 Journals Max. Run-Out No. 5 Journal .003 .0045 Mounted on No. 2 and 6 Journals Max. Run-Out No. 3, 4 and 5 Journals .005 .0075 506 ALL Crankshaft and Crankcase Front End Clearance .009L .016L .026L 507 ALL Clearance – Front Face of Crankshaft Oil Slinger to Front Face of Recess in Crankcase (Crankshaft Against Thrust Face) .002 .007L (A) SSP-1776-5-PT1 1-2 Revised February 2016 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 508 ALL Crankshaft – Prop. Flange Run-Out .002 .005 509 ALL Starter Ring Gear and Support .014T .022T (A) 510 A-B-D-G-J-S-T-Y-AF-BD-BE Crankshaft Timing Gear and Crankshaft .0005T .0010L (A) 511 A-B-D-G-J-S-T-Y-AF Tappet Body and Crankcase .0010L .0033L .004L BD-BE Tappet Body and Crankcase .0010L .0030L .004L A-B (Solid Tappets) O.D. of Tappet .6232 .6240 .6229 B1-D-G-J-S-T-Y-AF (Flat Tappets) O.D. of Tappet .7169 .7177 .7166 B1-D-G-J-S-T-Y-AF (Roller Tappets) O.D. of Tappet .8420 .8428 .8417 BD-BE O.D. of Tappet .8740 .8745 .8737 A-B (Solid Tappets) I.D. Tappet Bore in Crankcase .6250 .6263 .6266 B1-D-G-J-S-T-Y (Flat Tappets) I.D. Tappet Bore in Crankcase .7187 .7200 .7203 B1-D-G-J-S-T-Y-AF (Roller Tappets) I.D. Tappet Bore in Crankcase .8437 .8445 .8448 BD-BE I.D. Tappet Bore in Crankcase (Small Bore Tappet) .8755 .8773 .8776 BD-BE I.D. Tappet Bore in Crankcase (Large Bore Tappet) .9545 .9555 512 All Models Using Roller Tappets Tappet Plunger Assembly and Body – (Roller Tappets) .0010L .0047L .0067L All Models Using Straight Body Tappets Tappet Plunger Assembly and Body – (Straight Body Tappets) .0010L .0047L .0067L All Models Using Hyperbolic Tappets Tappet Plunger Assembly and Body – (Hyperbolic Tappets) .0010L .0067L .0087L 513 ALL Tappet Socket and Body (Hyperbolic Flat and Roller Tappets) .002L .007L .009L 514 ALL Camshaft and Crankcase .002L .004L .006L 515 ALL Camshaft – End Clearance .002L .009L .015L 516 ALL Camshaft Run-Out at Center Bearing Journal .000 .001 .006 517 All Models Using Counterweights Counterweight Bushing and Crankshaft .0013T .0026T (A) 518 All Models Using Counterweights Counterweight Roller – End Clearance .007L .025L .038L 519 All Models Using Counterweights Counterweight and Crankshaft – Side Clearance* .003L .013L .017L *Measure below roller next to flat. Revised April 2018 1-3 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 520 All Models Using Counterweights Counterweight Bore and Washer O.D. .0002L .0030L (A) 521 All Models Using Counterweights I.D. of Counterweight Bushing .7485 .7505 .7512 522 All (AS APPLICABLE) O.D. of Counterweight Roller (See latest revision of Service Instruction No. 1012) 523 D Thrust Bearing and Propeller Shaft .0000 .0012L .002L 524 D Thrust Bearing and Thrust Bearing Cap Clamp Fit (Shim to this Fit) .003T .005T (A) 525 D Thrust Bearing Tilt .027 Tilt 526 D Crankshaft Run-Out – Rear Cone Location .003 527 D Crankshaft Run-Out – Front Cone Location .007 528 D Thrust Bearing and Thrust Bearing Cage .0016L .0034L .0045L Longitudinal Section Thru Engines SSP-1776-5-PT1 1-4 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Crankcase, Crankshaft, Camshaft and Related Parts 1-5 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION II – CYLINDERS Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 600 ALL Connecting Rod and Connecting Rod Bushing Bushing P/N LW-13923 to be burnished in place Bushing P/N 01K28983 is not burnished in place ALL Finished I.D. of Connecting Rod Bushing 1.1254 1.1262 601 A-B-D-G-J-BD Length Between Connecting Rod Bearing Centers 6.4985 6.5015 S-T-Y-AF-BE Length Between Connecting Rod Bearing Centers 6.7485 6.7515 602 ALL Connecting Rod Bushing and Piston Pin .0008L .0021L .0025L 603 ALL Piston Pin and Piston .0003L .0014L .0018L ALL Diameter of Piston Pin Hole in Piston 1.1249 1.1254 ALL Diameter of Piston Pin 1.1241 1.1246 604 A-G-J-S-T-AF-BD-BE Piston and Piston Pin Plug .0002L .0010L .002L A-G-J-S-T-AF-BD-BE *Diameter of Piston Pin Plug 1.1242 1.1247 605 B-D-G-J-S-T-Y-AF Piston Pin and Piston Pin Plug (Optional) .0005L .0025L .005L G-J-S-T-Y-AF *Diameter of Piston Pin Plug .5655 .5665 B-D Diameter of Piston Pin Plug (Thin Wall Pin) .8405 .8415 *See latest edition of Service Instruction No. SI-1267. 606 A-B Piston Ring and Piston – Side Clearance (Top Ring Comp.) (Plain) Full Wedge .000 .004L .006L (B) B-D Piston Ring and Piston – Side Clearance (Top Ring Comp.) (Chrome) Full Wedge .0025L .0065L .008L (B) G-J-S-T-Y-AF-BD-BE Piston Ring and Piston – Side Clearance (Top Ring Comp.) Half Wedge .0025L .0055L .008L (B) 606 B Piston Ring and Piston – Side Clearance (2nd Ring Comp.) (Chrome) Full Wedge .0025L .0065L .008L (B) A-B-D-G-J-S-T-Y-AF-BD-BE Piston Ring and Piston – Side Clearance (2nd Ring Comp.) Full or Half Wedge .000 .004L .006L (B) J Piston Ring and Piston – Side Clearance (3rd Ring Comp.) Half Wedge .000 .004L .006L (B) 606 ALL Piston Ring and Piston – Side Clearance (Oil Regulating) .002L .004L .006L (B) A Piston Ring and Piston – Side Clearance (Bottom) .003L .0055L .007L(B) SSP-1776-5-PT1 1-6 Revised April 2020 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION II – CYLINDERS Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 607 ALL Piston Ring Gap (Compression) Plain and Chrome Cylinders (Straight Barrels) .020 .030 .047 ALL Piston Ring Gap (Compression) Nitrided Cylinders (Choke Barrels) .045 .065 .067 ALL Piston Ring Gap (Oil) .015 .040 .047 A-T2 Piston Ring Gap (Oil Scraper) (All Barrels) .015 .030 .047 For Choke Barrels – Ring gap is measured within 4 inches from bottom. Ring gap at top of travel must not be less than .0075. For All Other Barrels – Ring gap is measured at top limit of ring travel. 608 608 609 610 Piston Specifications Piston Number Min. Piston Dia. Cylinder Barrel Maximum Diameter Max. Clearance Piston Skirt & Cyl. Top Bottom 14B23917 4.3470 4.3555 4.3795 .021L 14B23918* 4.3290 4.3605 4.3805 .018L 14B23919 4.3470 4.3555 4.3795 .021L 14C28324 4.8395 4.8590 4.8805 .018L 14D21953-S 5.0790 5.1090 5.1305 .018L 14D23907 5.0790 5.1090 5.1305 .018L 14D23908* 5.0790 5.1090 5.1305 .018 14D23909* 5.0790 5.1090 5.1305 .018 14D23910* 5.0790 5.1090 5.1305 .018 14D23912* 5.0790 5.1090 5.1305 .018 14D23913 5.0790 5.1090 5.1305 .018L 14D23914* 5.0790 5.1090 5.1305 .018L 14D23915 5.0790 5.1090 5.1305 .018L 14D23916 5.0790 5.1090 5.1305 .018L 14D28056 5.0790 5.1090 5.1305 .018L 14E23911* 5.2720 5.3020 5.3235 .018L 70396† 4.8290 4.8620 4.8805 .018L 75984-S 4.8395 4.8590 4.8805 .018L LW-10208-S 5.0790 5.1090 5.1305 .018L NOTES: Refer to the latest revision of Service Instruction No. SI-1037 for a listing of engine models and piston part numbers applicable for each engine model. To find the average diameter of cylinder in an area 4” above bottom of barrel: First, measure diameter at right angles from plane in which valves are located. Second, measure diameter through the plane in which valves are located. Add both diameters; this sum, divided by 2, represents the average diameter of the cylinder. * - High Compression. † - Piston no longer available from Lycoming Engines. Maximum taper and out-of-round for cylinder in service is .0045 inch. To find the average out-of-round, measure diameter of cylinder in an area 4” above bottom of barrel: First, measure diameter at right angles from plane in which valves are located. Second, measure diameter through the plane in which valves are located. Difference between diameters must not exceed .0045 inch. Revised April 2020 1-7 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION II – CYLINDERS Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 611 A Exhaust Valve Seat and Cylinder Head .0065T .010T (A) B-D-G-J-S-T-Y-BD-BE Exhaust Valve Seat and Cylinder Head .0045T .008T (A) S1-S2-S3-S5-S6-S7-S9-S10- S11-S12-S13-S14-T2-T3-AF Exhaust Valve Seat and Cylinder Head .0075T .011T (A) A O.D. Exhaust Seat 2.0025 2.004 B-D-G-J-S-T-Y-BD-BE O.D. Exhaust Seat 1.7395 1.741 S1-S2-S3-S5-S6-S7-S9-S10- S11-S12-S13-S14-T2-T3-AF O.D. Exhaust Seat 1.9355 1.937 A I.D. Exhaust Seat Hole in Cylinder Head 1.994 1.996 B-D-G-J-S-T-Y-BD-BE I.D. Exhaust Seat Hole in Cylinder Head 1.733 1.735 611 S1-S2-S3-S5-S6-S7-S9-S10- S11-S12-S13-S14-T2-T3-AF Exhaust Seat Hole in Cylinder Head 1.926 1.928 612 A Intake Valve Seat and Cylinder Head .0070T .0105T (A) B-D-G-J-S-T-Y-AF-BD-BE Intake Valve Seat and Cylinder Head .0066T .010T (A) A O.D. Intake Seat 2.0965 2.0975 A1-B-D O.D. Intake Seat 1.9265 1.928 B1-C-J-S-T-Y-BD-BE O.D. Intake Seat 2.0815 2.083 S1-S2-S3-S5-S6-S7-S9-S10- S11-S12-S13-S14-T2-T3-AF O.D. Intake Seat 2.2885 2.290 A I.D. Intake Seat Hole in Cylinder Head 2.087 2.089 A1-B-D I.D. Intake Seat Hole in Cylinder Head 1.918 1.920 B1-G-J-S-T-Y-BD-BE I.D. Intake Seat Hole in Cylinder Head 2.073 2.076 S1-S2-S3-S5-S6-S7-S9-S10- S11-S12-S13-S14-T2-T3-AF I.D. Intake Seat Hole in Cylinder Head 2.280 2.282 613 ALL Exhaust Valve Guide in Cylinder Head .001T .0025T (A) 613 A-B-D-J O.D. Exhaust Valve Guide .5933 .5938 Y O.D. Exhaust Valve Guide .6267 .6272 G-J-S-T-AF-BD-BE O.D. Exhaust Valve Guide .6633 .6638 S1 O.D. Exhaust Valve Guide .6953 .6958 SSP-1776-5-PT1 1-8 Revised April 2020 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION II –CYLINDERS Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 613 A-B-D-G-J I.D. Exhaust Valve Guide Hole in Cylinder Head .5913 .5923 Y I.D. Exhaust Valve Guide Hole in Cylinder Head .6247 .6257 G-J-S-T-AF-BD I.D. Exhaust Valve Guide Hole in Cylinder Head .6613 .6623 S1 I.D. Exhaust Valve Guide Hole in Cylinder Head .6933 .6943 614 ALL Intake Valve Guide and Cylinder Head .0010T .0025T ALL O.D. Intake Valve Guide .5933 .5938 ALL I.D. Intake Valve Guide Hole in Cylinder Head .5913 .5923 615 A-B-D Exhaust Valve Stem and Valve Guide .0020L .0038L (A) A1-G-J-S-T-BD-BE Exhaust Valve Stem and Valve Guide (Parallel Valve Heads) .0040L .0060L (A) Y Exhaust Valve Stem and Valve Guide .0035L .0053L (A) S1-S2-S3-S5-S6-S11-S12-T2- T3-AF Exhaust Valve Stem and Valve Guide (Angle Valve Heads) .0037L .0050L (A) S7-S9-S10-S13-S14 Exhaust Valve Stem and Valve Guide (Angle Valve Heads - Helicopter) .0035L .0055L (A) A-B-D O.D. Exhaust Valve Stem .4012 .4020 A1 O.D. Exhaust Valve Stem .4320 .4333 G-J-Y O.D. Exhaust Valve Stem .4332 .4340 G-J-S-T-BD-BE O.D. Exhaust Valve Stem (Parallel Valve Heads) .4932 .4945 .4915 S1-S2-S3-S5-S6-S7-S9-S10- S11-S12-S13-S14-T2-T3-AF O.D. Exhaust Valve Stem (Angle Valve Heads) .4955 .4965 .4937 A-B-D Finished I.D. Exhaust Valve Guide .4040 .4050 A1-G-J Finished I.D. Exhaust Valve Guide .4370 .4380 Y Finished I.D. Exhaust Valve Guide .4375 .4385 Revised April 2020 1-9 SSP-1776-5-PT1 Service allowable limits of .4937 or .4915 is applicable only to inconel or nimonic valves SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION II – CYLINDERS Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 615 G-J-S-T-BD-BE Finished I.D. Exhaust Valve Guide (Parallel Valve Heads) .4985 .4995 S1-S2-S3-S5-S6-S11-S12-S13- S14-T2-T3-AF Finished I.D. Exhaust Valve Guide (Angle Valve Heads) .4995 .5005 S7-S9-S10 Finished I.D. Exhaust Valve Guide (Angle Valve Heads – Helicopter) .5000 .5010 ½ inch diameter exhaust valves may have exhaust valve guides that are .003 in. over the maximum inside diameter limit, anytime up to 300 hours of service. After 300 hours of service, inside diameter of exhaust valve guide may increase .001 in. during each 100 hours of operation up to the recommended overhaul time for the engine, or not to exceed .015 inch over the basic I.D. See latest edition of Service Instruction No. 1009 for recommended overhaul time. 616 ALL Intake Valve Stem and Valve Guide .0010L .0028L .006L ALL O.D. Intake Valve Stem .4022 .4030 .4010 616 ALL Finished I.D. Intake Valve Guide .4040 .4050 617 ALL Intake and Exhaust Valve and Valve Cap Clearance (Rotator Type Small Dia. Head) .000 .004L 006L 618 A-B Solid Tappet Clearance (After Engine in Run) .006 .012 A Dry Tappet Clearance (Steel Push Rods) .002 .008 D-G-J-S-T-Y-AF-BD-BE Dry Tappet Clearance .028 .080 619 A Valve Rocker Shaft and Cylinder Head (No Bushing) .0001L .0013L .0025L 619 B-D-J-S-T-Y Valve Rocker Shaft and Valve Rocker Bushing (Parallel Valve Heads) .0001L .0013L .0025L S1-S2-S3-S5-S6-S7-S9-S10- S11-S12-S13-S14-T2-T3-AF Valve Rocker Shaft and Valve Rocker Bushing (Angle Valve Heads) .0001L .0013L .0025L 619 A Finished I.D. of Valve Rocker Shaft Bores in Cylinder Head (No Bushings) .6246 .6261 .6270 619 B-D-G-J-S-T-Y Finished I.D. of Valve Rocker Shaft (Bushing) in Cylinder Head (Parallel Valve Heads) .6246 .6261 .6270 S1-S2-S3-S5-S6-S7-S9-S10- S11-S12-S13-S14-T2-T3-AF Finished I.D. of Valve Rocker Shaft (Bushing) in Cylinder Head (Angle Valve Heads) .6246 .6261 .6270 620 ALL Valve Rocker Shaft and Valve Rocker Bushing .0007L .0017L .004L ALL Finished I.D. of Rocker Arm Bushing .6252 .6263 .6270 ALL O.D. of Valve Rocker Shaft .6241 .6245 .6231 SSP-1776-5-PT1 1-10 Revised April 2020 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION II – CYLINDERS Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 621 ALL Valve Rocker Bushing and Valve Rocker Bushing Must Be Burnished In Place 622 ALL Valve Rocker Shaft Bushing and Cylinder Head .0022T .0038T (A) ALL Valve Rocker Shaft Bushing Hole in Cylinder Head .7380 .7388 623 A-B-D-G-J-S-T-Y Valve Rocker and Cylinder Head - Side Clearance (Parallel Valve Heads) .005L .013L .016L S1-S2-S3-S5-S6-S7-S9-S10- S11-S12-S13-S14-T2-T3-AF Valve Rocker and Cylinder Head – Side Clearance (Angle Valve Heads) .002L .020L .024L 624 A-B-J Push Rod and Ball End .0005T .0025T (A) 625 A Intake and Exhaust Valve Guide Height .705 .725 ALL Intake Valve Guide Height (Parallel Valve Heads) .705 .725 ALL EXCEPT O-235 Exhaust Valve Guide height (Parallel Valve Heads) .765 .785 ALL Intake and Exhaust Valve Guide height (Angle Valve Heads) .914 .954 Revised April 2020 1-11 SSP-1776-5-PT1 MEASURE VALVE GUIDE HEIGHT FROM THE VALVE SPRING SEAT COUNTERBORE IN THE CYLINDER HEAD TO THE TOP OF VALVE GUIDE. SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION II – CYLINDERS Cylinder, Piston and Valve Components SSP-1776-5-PT1 1-12 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION II – CYLINDERS Cylinder, Piston and Valve Components 1-13 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION III – GEAR TRAIN Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. OIL PUMP 700 ALL Oil Pump Drive Shaft and Oil Pump Body or Cover .0010L .0025L .004L 701 A-B-D-G-J-S-T-AF Oil Pump Drive Shaft and Accessory Housing .0015L .0030L .006L Y Oil Pump Drive Shaft and Accessory Case .0015L .0030L .006L BD-BE Oil Pump Drive Shaft and Crankcase .0010L .0025L .004L 702 S-T-AF (DUAL MAGNETO) Oil Pump Drive Shaft – End Clearance .015L .050L .065L BD-BE Oil Pump Drive Shaft – End Clearance .017L .037L .047L 703 A-B-D-G-J-S-T-Y-AF Oil Pump Impellers – Diameter Clearance .002L .006L .008L BD-BE Oil Pump Impellers – Diameter Clearance .0035L .0075L .009L 704 ALL (EXCEPT BD-BE) Oil Pump Impellers – Side Clearance .002L .0045L .005L BD-BE Oil Pump Impellers – Side Clearance .003L .005L .006L AS APPLICABLE Width of Oil Pump Impellers .622 .624 .621 AS APPLICABLE Width of Oil Pump Impellers .747 .749 .746 AS APPLICABLE Width of Oil Pump Impellers .995 .997 .994 BD-BE Width of Oil Pump Impellers .622 .623 .620 705 S-T-AF (DUAL MAGNETO) Oil Pump Impeller and Idler Shaft .0010L .0025L .004L A-B-D-G-J-S-T-Y-AF Oil Pump Impeller and Idler Shaft (Alum. and Sinterbond) .001T .003T (A) BD-BE Oil Pump Impeller and Idler Shaft .002T .004T (A) 706 A-B-D-G-J-S-T-Y-AF Oil Pump Idler Shaft and Oil Pump Body .0005L .0020L .003L BD-BE Oil Pump Idler Shaft and Oil Pump Body .0010L .0025L .003L S-T-AF (DUAL MAGNETO) Oil Pump Idler Shaft and Oil Pump Body .0000 .0015T (A) 707 A-B-D-G-J-S-T-Y-AF Oil Pump Idler Shaft and Accessory Housing .0010L .0025L .0035L BD-BE Oil Pump Idler Shaft and Crankcase .0010L .0025L .0035L 708 G2-S2 Scavenge Pump Drive Shaft and Adapter .0010L .0025L .004L 709 G2-S2 Scavenge Pump – End Clearance .000 .045L .060L SSP-1776-5-PT1 1-14 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION III – GEAR TRAIN Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. SCAVENGE PUMP 710 G2-S2 Scavenge Pump Impellers – Diameter Clearance .007L .011L .014L 711 G2-S2 Scavenge Pump Impellers – Side Clearance .003L .005L .006L G2-S2 Width of Impellers 1.496 1.498 1.495 712 G2-S2 Scavenge Pump Impellers and Idler Shaft .0010L .0025L .004L 713 G2-S2 Scavenge Pump Body and Idler Shaft .0000 .0015T (A) 714 S-T4-AF (WIDE DECK) Turbocharger Scavenge Pump Drive and Adapter .0010L .0025L .004L 715 S-T4-AF (WIDE DECK) Turbocharger Scavenge Pump Shaft and Adapter .0010L .0020L .0035L 716 S-T4-AF (WIDE DECK) Gerotor Pump – Rotor – Side Clearance .0015L .003L .004L 717 S-T4-AF (WIDE DECK) Gerotor Pump Housing and Adapter .0005L .0020L (A) 718 S-T4-AF (WIDE DECK) Turbocharger Scavenge Pump – End Clearance .0055L .0365L .0415L T4 (DUAL MAGNETO) Turbocharger Scavenge Pump – End Clearance .0105L .0395L .0445L FUEL PUMP 719 A-B-D-G-J-S-T AC Fuel Pump Plunger and Accessory Housing .0015L .003L .005L 720 J-S-T-AF Crankshaft Idler Gear and Crankshaft Idler Gear Shaft .001L .003L .005L 721 S-T-AF (DUAL MAGNETO) Crankshaft Idler Gear Shaft and Accessory Housing .0020L .0035L .0065L S-T-AF (DUAL MAGNETO) Crankshaft Idler Gear Shaft and Crankcase .0020L .0035L .0065L 722 S-T-AF AN Fuel Pump Idler Gear and Shaft .001L .003L .005L 723 S-T-AF (DUAL MAGNETO) AN Fuel Pump Idler Shaft and Accessory Housing and Crankcase .0020L .0035L .0065L S-T-AF (DUAL MAGNETO) AN Fuel Pump Idler Shaft and Crankcase .0020L .0035L .0065L 724 A-B Crankshaft Idler Gear – End Clearance .003L .043L .058L G-J-S-Y Crankshaft Idler Gear – End Clearance .005L .040L .055L T-AF Crankshaft Idler Gear – End Clearance .007L .037L .052L S (DUAL MAGNETO) Crankshaft Idler Gear – End Clearance .020L .030L .040L T-AF (DUAL MAGNETO) Crankshaft Idler Gear – End Clearance .015L .038L .046L 1-15 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION III – GEAR TRAIN Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. FUEL PUMP (CONT.) 725 S AN Fuel Pump Idler Gear – End Clearance .010L .045L .055L T-AF AN Fuel Pump Idler Gear – End Clearance .002L .018L .024L S-T-AF (DUAL MAGNETO) AN Fuel Pump Idler Gear – End Clearance .015L .038L .045L 726 S-T-Y-AF AN Fuel Pump Drive Shaft Gear and Adapter .0010L .0025L .004L 727 S AN Fuel Pump Drive Shaft Gear – End Clearance .035L .069L .079L T-AF AN Fuel Pump Drive Shaft Gear – End Clearance .044L .081L .091L T-AF (DUAL MAGNETO) AN Fuel Pump Drive Shaft Gear – End Clearance .035L .073L .083L Y AN Fuel Pump Drive Shaft Gear – End Clearance .000L .067L .075L GOVERNOR & HYDRAULIC PUMP 728 T-AF (NARROW DECK) Front Governor Drive Idler Shaft (Both Ends) and Crankcase .0010L .0025L .004L 729 G1-G2-S2-S4-S6-T-AF (WIDE DECK) Front Governor Idler Gear and Shaft .0010L .0025L .004L 730 BD-BE Front Governor Drive Gear and Crankcase .0010L .0025L .004L BD-BE Front Governor Drive Gear and Camshaft .0005L .0025L .004L 731 G1-G2-S-T-AF Front Governor Gear and Crankcase .0010L .0025L .004L BD Front Governor Gear and Crankcase .0010L .0030L .004L 732 G1-G2-S-T-AF Front Governor Gear – End Clearance .008L .016L .021L BD-BE Front Governor Gear – End Clearance .0045L .0165L .021L 733 G-J-S Rear Governor Gear and Adapter .0010L .0025L .005L G-S (DUAL MAGNETO) Rear Governor Gear and Accessory Housing .0010L .0025L .005L 734 G-J-S Rear Governor Gear – End Clearance .002L .024L .034L G-S (DUAL MAGNETO) Rear Governor Gear – End Clearance .002L .037L .044L 735 T-AF Hydraulic Pump Gear and Adapter .0010L .0025L .004L T-AF (DUAL MAGNETO) Hydraulic Pump Gear and Accessory Housing .0010L .0025L .004L 736 T-AF Hydraulic Pump Gear – End Clearance .010L .066L .076L T-AF (DUAL MAGNETO) Hydraulic Pump Gear – End Clearance .007L .032L .039L SSP-1776-5-PT1 1-16 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION III – GEAR TRAIN Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. VACUUM & TACHOMETER 737 A-B-G-J-S-T-Y-AF Vacuum Pump Gear and Adapter .0010L .0030L .0045L 737 S-T-AF (DUAL MAGNETO) Vacuum Pump Gear and Accessory Housing .0010L .0025L .004L 737 D Vacuum Pump Gear and Accessory Housing .0010L .0025L .006L 738 A-B-G-J-S-T-AF Vacuum Pump Gear – End Clearance .010L .057L .075L D Vacuum Pump Gear – End Clearance .003L .020L .030L Y Vacuum Pump Gear – End Clearance .000 .067L .075L S (DUAL MAGNETO) Vacuum Pump Gear – End Clearance .012L .044L .055L T-AF (DUAL MAGNETO) Vacuum Pump Gear – End Clearance .017L .039L .050L 739 A-B-Y Tachometer Drive Shaft and Adapter .0015L .0035L .006L BD-BE Tachometer Drive Shaft and Adapter .0010L .0050L .0065L 739 D-G-J-S-T-AF Tachometer Drive Shaft and Accessory Housing .0015L .0035L .006L 740 G-J-S (DUAL DRIVE) Vacuum Pump Gear and Adapter .0010L .0025L .004L 741 G-J-S (DUAL DRIVE) Vacuum Pump Gear – End Clearance .000 .017L .027L 742 G-J-S (DUAL DRIVE) Idler Gear and Shaft .0010L .0030L .005L 743 G-J-S (DUAL DRIVE) Idler Gear – End Clearance .021L .041L .060L 744 G-J-S (DUAL DRIVE) Propeller Governor Gear and Adapter .0013L .0028L .005L G-J-S (DUAL DRIVE) Hydraulic Pump Gear and Adapter .0013L .0028L .005L 745 G-J-S (DUAL DRIVE) Propeller Governor or Hydraulic Pump – End Clearance .000 .054L .074L MAGNETO, GENERATOR, STARTER 746 T Magneto Bearing and Gear .0005T .0001L .0005L 746 D Magneto Bearing and Gear .0008T .0001L .0005L 747 T Magneto Bearing and Crankcase .0002T .0007L (A) 747 D Magneto Drive Bearing and Adapter .0006T .0008T (A) 748 S7 Magneto Bearing and Gear .0001T .0010T (A) 1-17 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION III – GEAR TRAIN – Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. MAGNETO, GENERATOR, STARTER (CONT.) 749 S7 Magneto Bearing and Adapter .000 .0012L .0015L 750 S-T-AF (DUAL MAGNETO) Magneto Drive Gear and Crankcase .0010L .0025L .003L 751 S-T-AF (DUAL MAGNETO) Magneto Drive Gear – End Clearance .005L .073L .083L 752 AF Magneto Drive Gear and Shaft .001L .003L .005L 753 BD-BE Magneto Drive Gear and Crankcase Bushing .001L .003L .005L 754 Y Magneto Shaft Gear and Magneto Case .001L .003L .005L 755 Y Magneto Shaft Gear and Support Assembly .001L .003L .005L 756 Y Magneto Shaft Gear and Accessory Drive Shaft Gear – End Play .0075L .0125L .015L 757 Y Accessory Drive Shaft Gear and Support Assembly .001L .003L .005L 758 S Magneto Gear and Bushing (S4LN-21 and S4LN-1227) .0005L .0020L .0035L T Magneto Gear and Bushing (S6LN-21 & S6LN-1227) .0015L .0035L .0055L T-AF (DUAL MAGNETO) Magneto Gear and Bushing .0015L .0035L .0055L 7095 BD-BE Bushing – Magneto Drive and Crankcase .0025T .0045T (A) 759 D Generator Gear Bushing and Generator Gear .0020T .0035T (A) 760 D Generator Gear Bushing and Generator Drive Coupling Adapter .001L .0028L .005L 761 D Bendix Drive Gear Bushing and Crankcase .0005T .0025T (A) 762 D Bendix Drive Gear and Bendix Drive Gear Bushing .0010L .0025L .005L 763 D Bendix Drive Shaft and Bendix Drive Housing .003L .005L .010L 764 D Bendix Drive Shaft – End Clearance .000 .0059L .080L SSP-1776-5-PT1 1-18 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION III – GEAR TRAIN Oil Pumps 1-19 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION III – GEAR TRAIN Scavenge Pumps SSP-1776-5-PT1 1-20 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION III – GEAR TRAIN Fuel Pumps 1-21 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION III – GEAR TRAIN Front Governor SSP-1776-5-PT1 1-22 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION III – GEAR TRAIN Rear Governor and Hydraulic Pumps 1-23 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION III – GEAR TRAIN Tachometer Drives, Vacuum and Hydraulic Pump Drives SSP-1776-5-PT1 1-24 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION III – GEAR TRAIN Accessory Drives: Magnetos Generator and Starters 1-25 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION III – GEAR TRAIN Accessory Drives: Magnetos SSP-1776-5-PT1 1-26 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION III – GEAR TRAIN Generator and Bendix Drive 1-27 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION IV – BACKLASH Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 800 A-B-G-J-S-T-Y-AF Camshaft and Vacuum Pump – Backlash .004 .015 .020 801 BD-BE Camshaft and Vacuum and Oil Pump Drive – Backlash .006 .014 .020 802 Y Camshaft and Fuel Pump – Backlash .004 .015 .020 803 A-B-G-J-S-T-Y-AF Camshaft and Crankshaft Idler – Backlash .004 .015 .020 804 A-B-G-J-S-T-Y-AF Crankshaft and Crankshaft Idler – Backlash .004 .015 .020 805 A-B-G-J-S-T-AF Magneto Drive and Crankshaft Idler – Backlash .004 .015 .020 806 BD-BE Magneto Drive and Crankshaft Gear – Backlash .006 .014 .020 807 BD-BE Crankshaft Gear and Vacuum and Oil Pump Drive – Backlash .006 .014 .020 808 A-B-D-G-J-S-T-Y-AF Oil Pump Impellers – Backlash .008 .015 .020 BD-BE Oil Pump Impellers – Backlash .008 .012 .020 809 S-T-AF (DUAL MAGNETO) Oil Pump Drive and Crankshaft Idler – Backlash .004 .015 .020 810 Y Magneto and Magneto Shaft Gear – Backlash .004 .015 .020 811 Y Accessory Drive Shaft Gear and Magneto Driven Shaft Gear – Backlash .003 .005 .012 812 Y Crankshaft Gear and Accessory Drive Shaft Gear – Spline Backlash .002 .005 .015 813 G-J-S (DUAL DRIVE) Camshaft and Propeller Governor or Hydraulic Pump – Backlash .004 .015 .020 814 G-J-S (DUAL DRIVE) Governor or Hydraulic Pump Drive and Drive Gear – Spline Backlash .0013 .0073 .010 815 G-J-S (DUAL DRIVE) Governor or Hydraulic Pump and Idler – Backlash .004 .015 .020 816 G-J-S (DUAL DRIVE) Vacuum Pump and Idler – Backlash .004 .015 .020 817 S-T-AF AN Fuel Pump Idler and Crankshaft Idler – Backlash .004 .015 .020 818 S-T-AF AN Fuel Pump Idler and Fuel Pump Drive – Backlash .004 .015 .020 819 S-T-AF (DUAL MAGNETO) Crankshaft Gear and AN Fuel Pump Idler – Backlash .004 .015 .020 820 T-AF Hydraulic Pump and Crankshaft Idler – Backlash .004 .015 .020 SSP-1776-5-PT1 1-28 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION IV – BACKLASH Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 821 G-J-S Propeller Governor Drive and Crankshaft Idler – Backlash (Rear Governor) .004 .015 .020 822 G1-G2-S2-S4-S6-T-AF Propeller Governor Idler and Camshaft – Backlash (Front Governor) .004 .015 .020 823 G1-G2-S2-S4-S6-S11-T-AF Propeller Governor Drive and Idler – Backlash (Bevel Gears) (Front Governor) .004 .008 .015 824 BD-BE Propeller Governor Drive and Camshaft – Backlash (Bevel Gears) (Front Governor) .003 .011 .015 825 D Crankshaft Timing Gear and Camshaft Gear – Backlash .004 .015 .020 826 D Camshaft Gear and Generator Gear – Backlash .004 .015 .020 827 D Crankshaft Gear and Generator Gear – Backlash .004 .015 .020 828 D Magneto Coupling Spline – Backlash .001 .005 .0075 829 D Vacuum Pump Gear and Vacuum Pump Drive Gear – Backlash .004 .015 .020 830 D Starter Drive and Bendix Drive Gear – Backlash .004 .015 .020 831 D Bendix Drive Shaft Spline and Bendix Drive Gear Spline – Backlash .001 .006 .015 832 S Injector Pump Idler Gear and Injector Pump Drive Shaft Gear – Backlash .004 .015 .020 1-29 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION IV – BACKLASH Backlash (Accessory Drives) SSP-1776-5-PT1 1-30 Revised September 2016 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION IV – BACKLASH Backlash (Accessory Drives) 1-31 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION IV – BACKLASH Backlash (Accessory Drives) SSP-1776-5-PT1 1-32 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION IV – BACKLASH Backlash (Accessory Drives) 1-33 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION V – SPECIAL TORQUE REQUIREMENTS Ref. Chart Thread Size Nomenclature Torque Limits 900 A-B-D-G-S-T-Y-BD-BE 3/8-24 Connecting Rod Nuts 480 in.-lbs J 3/8-24 Connecting Rod Nuts 360 in.-lbs S1-S3-S5-S6-S7-S9-S11-S12- S14-T3-AF 3/8-24 Connecting Rod Bolts – Tighten to this Length 2-255 – 2.256 901 BD-BE 9/16-18 Oil Pump Shaft Nut 660 in.-lbs 902 BD-BE 5/16-24 Rocker Stud Nut 150 in.-lbs. 903 ALL (AS APPLICABLE) (EXCEPT S7) 3/8-24 Magneto Nut (To attach drive member to magneto) – Bendix – Sintered Bushing – Gray 120-150 in.-lbs. ALL (AS APPLICABLE) 3/8-24 Magneto Nut (To attach drive member to magneto) – Bendix – Steel Bushing 170-300 in.-lbs. A-G-S 3/8-24 Magneto Nut (To attach drive member to magneto) – Slick 120-300 in.-lbs. S7 1/2-20 Magneto Nut (To attach drive member to magneto) 170-300 in.-lbs. 904 ALL 10-32 Magneto Plate Screws (To attach ignition cable outlet plate to magneto) 15 in.-lbs. 905 ALL (using a silicone gasket) 1/4-20 Rocker Box Screws 35 in.-lbs. ALL (using a cork gasket) 1/4-20 Rocker Box Screws 50 in.-lbs. 906 ALL 5/16-18 Exhaust Port Studs 40 in.-lbs. min. 907 ALL 18MM Spark Plugs 420 in.-lbs. 908 ALL 1/8-27 NPT Fuel Pump Vent Fitting (Approximately two turns beyond finger tight) 96 in.-lbs. 909 ALL 5/8-32 Alternator Pulley Nut 450 in.-lbs. 910 ALL 1/4-28 Alternator Output Terminal Nut 85 in.-lbs. 911 ALL 10-32 Alternator Auxiliary Terminal Nut 30 in.-lbs. 912 ALL 5/16-24 Starter Terminal Nut 24 in.-lbs. 913 ALL (AS APPLICABLE) 1/16-27 NPT Piston Cooling Nozzle in Crankcase 100 in.-lbs. 914 Y-S-T-AF 1/8-27 NPT Injector Nozzle in Cylinder Head 60 in.-lbs. 915 ALL (AS APPLICABLE) 3/4-16 Oil Filter Bolt (AC Can and Element Type) 300 in.-lbs ALL (AS APPLICABLE) 13/16-16 Oil Filter (Throw-Away Type) 240 in.-lbs. ALL (AS APPLICABLE) 3/4-16 Converter Stud 720 in.-lbs..) 916 ALL (AS APPLICABLE) 3/4-18 NPT Carburetor Drain Plug 144 in.-lbs. 917 ALL (AS APPLICABLE) 1.00-14 Oil Cooler Bypass Valve 300 in.-lbs. SSP-1776-5-PT1 1-34 Revised April 2020 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION V – SPECIAL TORQUE REQUIREMENTS (CONT.) New Ref. Chart Thread Size Nomenclature Torque Limits 918 ALL (AS APPLICABLE) 1-1/4-12 Oil Pressure Relief Valve 300 in.-lbs. 919 ALL 1/4 Hex Head and Below Hose Clamps (Worm Type) 20 in.-lbs. 5/16 Hex. Head and Above Hose Clamps (Worm Type) (Metal to metal: example: heat shield to exhaust pipe) 45 in.-lbs. 5/16 Hex. Head and Above Hose Clamps (Worm Type) 30 – 35 in.-lbs. 920 ALL Cylinder Head Drain Back Hose Clamps 10 in.-lbs. 921 S-T Exhaust V-Band Coupling Torque Data Coupling Size Tube OD Lycoming Part Number Vendor Part Number T-Bolt Split Type Locknut Torque In.-Lbs. 1/4 In. Drilled Hex Nut With Safety Wire Torque In.-Lbs. 1.75 in. LW-12093-4 MVT69183-175 65 75 2.00 in. LW-12093-5 MVT69183-200 85 75 2.25 in. LW-12093-6 MVT69183-225 85 75 2.25 in. LW-12125-3 MVT69197-225 85 3.69 in. LW-13464 U4204-55-369M 70 3.69 in. LW-15768 NH1004420-10 70 922 ALL Turbocharger V-Band Torque Data Turbocharger Model No. V-Clamp Part No. V-Clamp Diameter Torque In.-Lbs. TO-473* 400500-600 6.00 in. 40 – 80 TEO659* 400500-685 6.85 in. 40 – 50 THO8A60* 400500-775 7.75 in. 40 – 60 THO8A69* 400500-775 7.75 in. 40 – 60 301E10-2** TC-6-15 6.50 in. 15 – 20 * - AiResearch turbocharger. ** - Rajay turbocharger. See latest revision of Service Instruction No. 1238 for assembly procedure. 927 Chart Thread Size Nomenclature Torque Limits ALL DUAL MAG. MODELS 1/2-20 Crankshaft Gear Bolt 660 in.-lbs. BD 1/4 Crankshaft Gear Bolts 96 – 120 in.-lbs. 928 ALL 3/8-16 Cylinder Hold Down Studs (Crankcase Driving Torque) 100 in.-lbs. 7/16-14 Cylinder Hold Down Studs (Crankcase Driving Torque) 200 in.-lbs. 1/2-13 Cylinder Hold Down Studs (Crankcase Driving Torque) 250 in.-lbs. 929 A-B-D-BD-BE-J- G-Y-S-T-AF 3/8 Cylinder Hold Down Nuts 300 in.-lbs. A1 7/16 Cylinder Hold Down Nuts 420 in.-lbs. B-D-BD-BE-J-G- Y-S-T-AF 1/2 Cylinder Hold Down Nuts 600 in.-lbs. Cylinder Hold Down and Crankcase Parting Flange Nuts’ Tightening Procedures – See latest revision of Service Instruction No. 1029 Revised April 2018 1-35 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION V – SPECIAL TORQUE REQUIREMENTS (CONT.) Ref. Chart Thread Size Nomenclature Torque Limits 930 ALL 3/8 Allen Head Screw (Diaphragm Fuel Pump) 225-250 in.-lbs. 931 A 9/16 Locking Nut (Valve Adjusting Screw) 450 in.-lbs. 932 ALL 5/16-18 Exhaust Transitions – Studs (Driving Torque) 100 in.-lbs. ALL 3/8-16 Exhaust Transitions – Studs (Driving Torque) 200 in.-lbs. 933 ALL 5/16-32 Brass union nut on stainless steel injector fuel line (Both Ends) 25-50 in.-lbs.* * It is also permissible to tighten the fuel line union nut finger tight, then continue tightening the nut with a wrench an additional 30 to 60 degrees (1/2 to 1 flat of the nut.) Torque in excess of 50 in.-lbs. can result in damage to the parts. SECTION V – SPRINGS Ref. Chart Nomenclature Lycoming Part No. Wire Dia. Length at Comp. Length COMP. LOAD Mfr. Min. Mfr. Min. Service Max. 950 A-B-D-G-J-S-T- Y-BD-BE Outer Valve Springs (Parallel) LW-11800 .177 1.30 in. 112 lb. 122 lb. 109 lb. min. S1-S2-S3-S5-S6- S7-S9-S10-S11- S12-S13-S14-T2- T3 Outer Valve Springs (Angle) LW-11796 .182 1.43 in. 116 lb. 124 lb. 113 lb. min. 951 A-B-D-G-J-S-T- Y-BD-BE Auxiliary Valve Spring (Parallel) LW-11795 .135 1.17 in. 61 lb. 67 lb. 58 lb. min. S1-S2-S3-S5-S6- S7-S9-S10-S11- S12-S13-S14-T2- T3-AF Auxiliary Valve Spring (Angle) LW-11797 .142 1.33 in. 75 lb. 83 lb. 72 lb. min. 952 ALL (AS APPLICABLE) Oil Pressure Relief Valve Spring Lycoming Part Numbers Identification Dye Free Length 61084 None 2.18 .054 1.30 in. 8.5 lb. 9.5 lb. 8.3 lb. min. LW-18085 Purple/White 1.93 .067 1.44 in. 14.50 lb. 15.23 lb. 13.8 lb. min. 68668 Purple 2.04 .054 1.30 in. 7.1 lb. 7.8 lb. 6.9 lb. min. 77467 Yellow 1.90 .054 1.30 in. 6.4 lb. 7.1 lb. 6.2 lb. min. LW-11713 White 2.12 .059 1.44 in. 10.79 lb. 11.92 lb. 10.5 lb. min. 953 A-B-G-J-S-T-Y- AF Oil Cooler Bypass Spring .0465 1.94 in. 6.50 lb. 7.25 lb. 6.41 lb. min. 954 BD-BE Oil Filter Bypass Spring .047 1.00 in. 3.05 lb. 3.55 lb. 3.0 lb. min. 955 D Magneto Coupling Spring .091 .603 in. 20 lb. 22 lb. 19 lb. min. SSP-1776-5-PT1 1-36 Revised April 2020 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION V SPECIAL TORQUE REQUIREMENTS Revised April 2018 1-37 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION V – SPECIAL TORQUE REQUIREMENTS Engine Accessories and Hardware SSP-1776-5-PT1 1-38 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION V – SPECIAL TORQUE REQUIREMENTS Engine Accessories and Hardware 1-39 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS PART I – DIRECT DRIVE ENGINES SECTION V – SPECIAL TORQUE REQUIREMENTS Engine Springs and Hardware SSP-1776-5-PT1 1-40 SERVICE TABLE OF LIMITS STANDARD TORQUE UNLESS OTHERWISE LISTED Torque limits for propeller attaching bolts to be supplied by propeller aircraft manufacturer. NOTE: Refer to Table VIII for torque value conversions (In. Lb. or Ft. Lb. to Nm). TABLE I TABLE II BOLTS, SCREW AND NUTS PIPE PLUGS Thread Torque Thread Torque Thread Torque In. Lb. Ft. Lb. In. Lb. Ft. Lb. In.-Lbs. 8 20 to 22 ----- 7/16 600 to 660 50 to 55 1/16-27 NPT 40 to 44 10 49 to 54 ----- 1/2 900 to 984 75 to 82 1/8-27 NPT 40 to 44 1/4 96 to 106 ----- 9/16 1320 to 1452 110 to 121 1/4-18 NPT 85 to 94 5/16 204 to 228 17 to 19 5/8 1800 to 1980 150 to 165 3/8-18 NPT 110 to 121 3/8 360 to 396 30 to 33 3/4 3240 to 3564 270 to 297 1/2-14 NPT 160 to 176 THIN NUTS (1/2 DIA. OF BOLT) – 1/2 LISTED TORQUE 3/4-14 NPT 230 to 252 1-11-1/2 NPT 315 to 347 TABLE III TABLE IV CRUSH TYPE GASKETS FLEXIBLE TUBE CONNECTIONS (SEALASTIC OR EQUIVALENT FITTINGS) Thread Pitch on Part to be Tightened ANGLE OF TURN Tube Size Thread Torque In.-Lbs. Threads Per Inch Aluminum Copper Aluminum Alloy Steel 8 135° 67° (-3) 3/16 3/8 - 24 30 to 50 70 to 80 10 135° 67° (-4) 1/4 7/16 - 20 40 to 65 90 to 100 12 180° 90° (-5) 5/16 1/2 - 20 60 to 80 135 to 150 14 180° 90° (-6) 3/8 9/16-18 75 to 125 270 to 300 16 270° 135° (-8) 1/2 3/4-16 150 to 250 450 to 500 18 270° 135° (-10) 5/8 7/8 - 14 200 to 350 650 to 700 20 270° 135° 24 360° 180° TABLE V 28 360° 180° STUDS MIN. DRIVING TORQUE NOTE: Install all crush type gaskets except the self centering type, with the unbroken surface against the flange of the plug or part being tightened against the seal. Turn the part until the sealing surfaces are in contact and then tighten to the angle of turn listed for the appropriate thread size. NOTE: Lubricate Threads Unless Otherwise Specified. Threads Torque In.-Lbs. 1/4-20 15 5/16-18 25 3/8-16 50 TABLE VI JAM NUT OR STRAIGHT THREAD O-RING BOSS Tube Size Thread Torque Ft. Lbs. -03 3/8 – 24 8 – 9 -04 7/16 – 20 13 – 15 -05 1/2 – 20 14 – 15 -06 9/16 – 18 23 – 24 -08 3/4 – 16 40 – 43 -10 7/8 – 14 43 – 48 -12 1-1/16 – 12 68 – 75 -14 1-3/16 – 12 83 – 90 -16 1-5/16 – 12 112 – 123 -20 1-5/8 – 12 146 – 161 -24 1-7/8 – 12 154 – 170 -32 2-1/2 – 12 218 – 240 1-41 SSP-1776-5-PT1 SERVICE TABLE OF LIMITS STANDARD TORQUE (CONT.) UNLESS OTHERWISE LISTED TABLE VII METAL TUBE FITTINGS Dash Nos. Ref. Tubing OD inches Wrench torque for tightening AN-818 Nut (pound inches) Minimum bend radii measured to tubing centerline. Dimension in inches Aluminum-alloy tubing Steel tubing Aluminum-alloy tubing (Flare MS33583) for use on oxygen lines only Minimum Maximum Minimum Maximum Minimum Maximum Alum. Alloy Steel -2 1/8 20 30 75 85 -- -- 3/8 -- -3 3/16 25 35 95 105 -- -- 7/16 21/32 -4 1/4 50 65 135 150 -- -- 9/16 7/8 -5 5/16 70 90 170 200 100 125 3/4 1-1/8 -6 3/8 110 130 270 300 200 250 15/16 1-5/16 -8 1/2 230 260 450 500 300 400 1-1/4 1-3/4 -10 5/8 330 360 650 700 -- -- 1-1/2 2-3/16 -12 3/4 460 500 900 1000 -- -- 1-3/4 2-5/8 -16 1 500 700 1200 1400 -- -- 3 3-1/2 -20 1-1/4 800 900 1520 1680 -- -- 3-3/4 4-3/8 -24 1-1/2 800 900 1900 2100 -- -- 5 5-1/4 -28 1-3/4 -- -- -- -- -- -- -- -- -32 2 1800 2000 2660 2940 -- -- 8 7 TABLE VIII TORQUE CONVERSIONS In. Lb. Ft. Lb. Nm In. Lb. Ft. Lb. Nm In. Lb. Ft. Lb. Nm 5 0.42 0.56 100 8.33 11.30 1000 83.33 113.00 10 0.83 1.13 200 16.67 22.60 2000 166.70 226.00 20 1.67 2.26 300 25.00 53.90 3000 250.00 339.00 30 2.50 3.39 400 33.33 45.19 4000 333.30 451.90 40 3.33 4.52 500 41.67 56.49 5000 416.70 564.90 50 4.17 5.65 600 50.00 67.79 6000 500.00 677.90 SSP-1776-5-PT1 1-42 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES CHART MODELS AQ TIO-541 AZ TIGO-541 SECTION I 500 SERIES CRANKCASE, CRANKSHAFT & CAMSHAFT SECTION II 600 SERIES CYLINDERS SECTION III 700 SERIES GEAR TRAIN SECTION IV 800 SERIES BACKLASH (GEAR TRAIN) SECTION V 900 SERIES TORQUE AND SPRINGS (A) These fits are either shrink fits controlled by machining, fits that may readily be adjusted, or fits where wear does not normally occur. In each case, the fit must be held to manufacturing tolerance. (B) Side clearance on piston rings must be measured with face of ring flush with piston. (D) The dimensions shown are measured at the bottom of the piston skirt at right angles to the piston pin. (E) Permissible wear of the crankshaft (rod and main bearing journals) to be minus 0.0015 on the diameter. (L) Loose fit; wherein a definite clearance is mentioned between the mating surfaces. (T) Tight fit; shrink or interference fit. (WD) Wide Deck Crankcase. SSP-1776-5-PT2 April 13, 2020* * - Indicates cut-off date for data retrieved prior to publication. ©2020 by Lycoming “All Rights Reserved” This Page Intentionally Left Blank TECHNICAL PUBLICATION REVISION REVISION NO. PUBLICATION PUBLICATION NO. PUBLICATION DATE SSP-1776-5-PT2 Service Table of Limits SSP-1776 October 28, 2013 PREVIOUS REVISIONS CURRENT REVISION* April 2018 2-8, 2-23, 2-24, 2-25, 2-26, 2-27, 2-28, 2-29 • Deleted NOTES that reference S.I. 1243 in Piston Application Table • Added pages and figures for all 900 Series reference numbers in Section V April 2020 2-7 • Revised burnishing instructions for connecting rod bushing in reference number 600 • Revised the Mfr. Min. & Max. Clearance for Piston Ring Gap (Compression) Nitrided Cylinders (Choke Barrels) and Piston Ring Gap (Oil) in reference number 607 * Revisions are indicated with a vertical bar to the left of the revised item. ©2020 by Avco Corporation. All Rights Reserved Lycoming Engines is a division of Avco Corporation This Page Intentionally Left Blank SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 500 AQ Main Bearings and Crankshaft (Except Front) .0011L .0041L .0050L AZ Main Bearings and Crankshaft .0011L .0041L .0050L AQ Front Main Bearings and Crankshaft .0021L .0046L .0050L AQ-AZ Diameter of Main Bearing Journal on Crankshaft (2-5/8 Main) 2.6245 2.626 (E) AQ Diameter of Front Main Bearing Journal on Crankshaft (2-5/8 Main) 2.6240 2.6250 (E) AQ-AZ Crankcase Bearing Bore Diameter 2.9365 2.9375 2.9390 501 AQ-AZ Connecting Rod Bearing and Crankshaft .0008L .0038L .0050L AZ Diameter of Connecting Rod Journal on Crankshaft (2-1/8) 2.1235 2.125 (E) AQ Diameter of Connecting Rod Journal on Crankshaft (2-1/4) 2.2485 2.250 (E) AZ Connecting Rod Bearing Bore Diameter (2-1/8) (Measure at Axis 30° on each side) 2.2870 2.2875 AQ Connecting Rod Bearing Bore Diameter (2-1/4) (Measure at Axis 30° on each side) 2.4205 2.4210 502 AQ-AZ Connecting Rod – Side Clearance .004L .010L .016L 503 AQ-AZ Connecting Rod – Alignment .010 in 10 Inches 504 AQ-AZ Connecting Rod – Twist .012 in 10 Inches 505 Crankshaft Run-Out at Center Main Bearings AZ Mounted on No. 1 and 4 Journals Max. Run-Out No. 2 and 3 Journals .005 .0075 Mounted on No. 1 and 3 Journals Max. Run-Out No. 2 Journal .003 .0045 Mounted on No. 2 and 4 Journals Max. Run-Out No. 3 Journal .003 .0045 AQ Mounted on No. 2 and 5 Journals Max. Run-Out No. 1 Journal .002 .002 Mounted on No. 2 and 5 Journals Max. Run-Out No. 3 Journal .005 .0075 Mounted on No. 2 and 4 Journals Max. Run-Out No. 3 Journal .003 .0045 2-1 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 506 AQ (CONT.) Mounted on No. 3 and 5 Journals Max. Run-Out No. 4 Journal .003 .0045 AQ-AZ Crankshaft and Crankcase – Front End Clearance .005L .016L .026L 507 AQ Clearance – Front Face of Crankshaft Oil Slinger to Front Face of Recess in Crankcase (Crankshaft Against Thrust Face) .002 .007 (A) 508 AQ-AZ Crankshaft Propeller Flange Run-Out .005 509 AQ Starter Ring Gear and Support .014T .022T (A) 510 AQ-AZ Crankshaft Timing Gear and Crankshaft .002L .0005L (A) 511 AQ-AZ Tappet Body and Crankcase .0010L .0030L .004L AQ-AZ O.D. of Tappet .9990 .9995 .9987 AQ-AZ I.D. Tappet Bore in Crankcase 1.0005 1.0018 1.0021 514 AQ-AZ Camshaft and Crankcase .002L .004L .006L 515 AQ-AZ Camshaft – End Clearance .002L .004L .015L 516 AQ-AZ Camshaft Run-Out at Center Bearing Journal .000 .001 .006 517 AQ-AZ Counterweight Bushing and Crankshaft .0013T .0026T (A) 518 AQ-AZ Counterweight Roller – End Clearance .003L .025L .038L 519 AQ-AZ Counterweight and Crankshaft – Side Clearance (Measure Below Roller Next to Flat) .003L .013L .017L 520 AQ-AZ Counterweight Bore and Washer O.D. .0002L .0030L (A) 521 AQ-AZ I.D. Counterweight Bushing .7485 .7505 .7512 AZ I.D. Counterweight Bushing (2nd order) 1.030 1.032 1.0327 522 AQ-AZ O.D. of Counterweight Roller (See latest revision of Service Instruction No. 1012) 523 AZ Thrust Bearing and Propeller Shaft .0001L .0012L .002L 524 AZ Propeller Shaft and Rear Bearing .0015L .0030L .0040L SSP-1776-5-PT2 2-2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 524 AZ Propeller Shaft Bearing Bore Diameter 2.1865 2.1875 2.1885 525 AZ Thrust Bearing and Crankcase .0006L .0010T (A) 526 AZ Thrust Bearing and Thrust Bearing Cap Clamp Fit (Shim to this Fit) .003T .005T (A) 527 AZ Thrust Bearing Tilt at 4 Foot .027 Tilt 528 AZ Thrust Bearing End Play .006 .008 .010 529 AZ Crankshaft and Crankshaft Front Bearing .0002T .0015T (A) Section Thru Prop. Shaft, Crankshaft and Front Bearings 2-3 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Connecting Rod, Counterweights and Related Parts SSP-1776-5-PT2 2-4 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Longitudinal Section Thru Engine 2-5 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Connecting Rod Bearing, Tappet Body and Crankcase SSP-1776-5-PT2 2-6 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION II – CYLINDERS Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 600 AQ-AZ Connecting Rod and Connecting Rod Bushing Bushing P/N LW-13923 to be burnished in place Bushing P/N 01K28983 is not burnished in place AQ-AZ Finished I.D. of Connecting Rod Bushing 1.1254 1.1262 601 AQ-AZ Length Between Connecting Rod Bearing Centers 6.7485 6.7515 602 AQ-AZ Connecting Rod Bushing and Piston Pin .0008L .0021L .0025L 603 AQ-AZ Piston Pin and Piston .0003L .0014L .0018L AQ-AZ Diameter of Piston Pin Hole in Piston 1.1249 1.1254 AQ-AZ Diameter of Piston Pin 1.1241 1.1246 604 AQ-AZ Piston and Piston Pin Plug .0002L .0010L .002L AQ-AZ *Diameter of Piston Pin Plug 1.1242 1.1247 605 AQ-AZ Piston Pin and Piston Pin Plug – Nitrided and Chrome Cylinders .0005L .0025L .005L AQ-AZ *Diameter of Piston Pin Plug .5655 .5665 * See latest revision of Service Instruction No. 1267. 606 AQ-AZ Piston Ring and Piston – Side Clearance (Top Ring Comp.) .0025L .0055L .008L (B) AQ-AZ Piston Ring and Piston – Side Clearance (2nd Ring Comp.) .000L .004L .006L (B) AQ-AZ Piston Ring and Piston - Side Clearance (Oil Regulating) .002L .004L .006L (B) 607 AQ-AZ Piston Ring Gap (Compression) Chrome Cylinders (Straight Barrels) .020 .030 .047 AQ-AZ Piston Ring Gap (Compression) Nitrided and Chrome Cylinders (Choke Barrels) .045 .065 .067 AQ-AZ Piston Ring Gap (Oil Regulating) (All Barrels) .015 .040 .047 For Choke Barrels – Ring gap is measured within 4 inches from bottom. Ring gap at top of travel must not be less than .0075. For All Other Barrels – Ring gap is measured at top limit of ring travel. Revised April 2020 2-7 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION II – CYLINDERS Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. Engine and Piston Application Min. Piston Diameter Type of Piston Cylinder Barrel Max. Clearance Piston Skirt & Cyl. Engine Chart Code Letter Piston Number Top Bottom Type of Surface Maximum Diameter 608 608 609 610 AQ-AZ 76966, LW-10545 5.0790 5.1090 Forged-Cam N-C 5.1305 .018L NOTES: To find the average diameter of cylinder in an area 4” above bottom of barrel: First, measure diameter at right angles from plane in which valves are located. Second, measure diameter through the plane in which valves are located. Add both diameters; this sum, divided by 2, represents the average diameter of the cylinder. *=High Compression. Cylinder Barrel: N=nitride hardened, C=chrome plated. Maximum taper and out-of-round permitted for cylinder in service is .0045 inch. To find the average out-of-round, measure diameter of cylinder in an area 4” above bottom of barrel: First, measure diameter at right angles from plane in which valves are located. Second, measure diameter through the plane in which valves are located. Difference between diameters must not exceed .0045 inch. Piston diameter at top is measured at top ring land (between top and second compression ring grooves) at right angle to piston pin hole; diameter at bottom of piston is measured at the bottom of the piston skirt at right angles to the piston pin. Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 611 AQ-AZ Exhaust Valve Seat and Cylinder Head .0075T .011T (A) AQ-AZ O.D. Exhaust Seat 1.9355 1.937 AQ-AZ I.D. Exhaust Seat Hole in Cylinder Head 1.926 1.928 612 AQ-AZ Intake Valve Seat Hole in Cylinder Head .0065T .010T (A) AQ-AZ O.D. Intake Seat 2.2885 2.290 AQ-AZ I.D. Intake Seat Hole in Cylinder Head 2.280 2.282 613 AQ-AZ Exhaust Valve Guide and Cylinder Head .0011T .0030T (A) AQ-AZ O.D. Exhaust Valve Guide .6954 .6963 AQ-AZ I.D. Exhaust Valve Guide Hole in Cylinder Head .6933 .6943 SSP-1776-5-PT2 2-8 Revised April 2018 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION II – CYLINDERS Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 614 AQ-AZ Intake Valve Guide and Cylinder Head .0010T .0025T AQ-AZ O.D. Intake Valve Guide .5933 .5938 AQ-AZ I.D. Intake Valve Guide Hole in Cylinder Head .5913 .5923 615 AQ-AZ Exhaust Valve Stem and Valve Guide .0037L .0050L (A) AQ-AZ O.D. Exhaust Valve Stem .4955 .4965 .4937 AQ-AZ Finished I.D. Exhaust Valve Guide .4995 .5005 1/2 inch diameter exhaust valves may have exhaust valve guides that are .003 in. over the maximum inside diameter limit, anytime up to 300 hours of service. After 300 hours of service, inside diameter of exhaust valve guide may increase .001 in. during each 100 hours of operation up to the recommended overhaul time for the engine, or not to exceed .015 inch over the basic I.D. See latest revision of Service Instruction No. 1009 for recommended overhaul time. 616 AQ-AZ Intake Valve Stem and Valve Guide .0010L .0028L .006L AQ-AZ O.D. Intake Valve Stem .4022 .4030 .4010 AQ-AZ Finished I.D. Intake Valve Guide .4040 .4050 617 AQ-AZ Intake and Exhaust Valve and Valve Cap – Clearance (Rotator Type with Small Diameter Head) .000 .004L .005L 618 AQ-AZ Dry Tappet Clearance .040 .105 619 AQ-AZ Valve Rocker Shaft and Valve Rocker Bushing .0001L .0013L .0025L AQ-AZ Finished I.D. of Valve Rocker Shaft (Bushing) in Cylinder Head .6246 .6261 .6270 620 AQ-AZ Valve Rocker Shaft and Valve Rocker Bushing .0007L .0017L .004L AQ-AZ Finished I.D. of Rocker Arm Bushing .6252 .6263 .6270 AQ-AZ O.D. Valve Rocker Shaft .6241 .6245 .6231 621 AQ-AZ Valve Rocker Bushing and Valve Rocker Bushing Must Be Burnished in Place 622 AQ-AZ Valve Rocker Shaft Bushing and Cylinder Head .0022T .0038T (A) AQ-AZ Valve Rocker Shaft Bushing Hole in Cylinder Head .7380 .7388 623 AQ-AZ Valve Rocker and Cylinder Head – Side Clearance .002L .020L .024L 2-9 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION II – CYLINDERS Cylinder, Piston and Valve Components SSP-1776-5-PT2 2-10 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION III – GEAR TRAIN Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. OIL PUMP 700 AQ-AZ Oil Pump Drive Shaft and Oil Pump Body .0010L .0030L .004L 701 AQ-AZ Oil Pump Drive Shaft and Oil Pump Cover .0035L .0050L .0065L 703 AQ-AZ Oil Pump Impellers – Diameter Clearance .002L .005L .008L 704 AQ-AZ Oil Pump Impellers – Side Clearance .002L .0045L .005L Width of Oil Pump Impellers 1.372 1.374 1.371 705 AQ-AZ Oil Pump Driven Impellers and Idler Shaft .0005L .002L .004L FUEL PUMP 722 AQ-AZ Fuel Pump Idler Gear and Shaft .001L .003L .005L 725 AQ-AZ Fuel Pump Idler Gear – End Clearance .002L .028L .038L 726 AQ-AZ Fuel Pump Drive Shaft Gear and Crankcase .0010L .0025L .004L 727 AQ-AZ Fuel Pump Drive Shaft Gear – End Clearance .0015L .0385L .0485L GOVERNOR & TACHOMETER 728 AQ Front Governor Drive Idler Shaft (Both Ends) and Crankcase .0010L .0025L .004L 731 AQ-AZ Governor Driven Gear and Crankcase .0010L .0025L .004L 732 AQ-AZ Propeller Governor Drive Gear – End Clearance .008L .016L .021L 739 AZ Tachometer Drive Shaft and Adapter .0015L .0035L .006L VACUUM PUMP & HYDRAULIC PUMP 759 AQ-AZ Vacuum and Hydraulic Pump Drive Shaft Gear and Crankcase .0010L .0025L .006L 760 AQ-AZ Vacuum and Hydraulic Pump Drive Shaft Gear – End Clearance .018L .028L .035L MAGNETO 761 AQ-AZ Magneto Coupling and Crankcase .0010L .0030L .004L 762 AQ-AZ Magneto Drive Shaft Gear and Crankcase .0010L .0030L .004L 2-11 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION III – GEAR TRAIN Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. ACCESSORY DRIVE, COMPRESSOR, BREATHER, PROPELLER SHAFT, ALTERNATOR, & STARTER 763 AQ-AZ Accessory Drive Gear Intermediate and Crankcase (2 Places) .0010L .0030L .005L 764 AQ-AZ Accessory Drive Gear – End Clearance .016L .018L .020L 765 AQ-AZ Accessory Drive Gear and Crankcase .0010L .0030L .005L 766 AQ-AZ Compressor Drive Shaft and Compressor Drive Adapter .0010L .0030L .005L 767 AQ-AZ Compressor Drive Shaft – End Clearance .0005 .0295 .040 768 AQ-AZ Breather Slinger Gear and Shaft .0021L .0035L .005L 769 AQ-AZ Breather Slinger Gear – End Clearance .008 .017 .025 770 AZ Propeller Shaft Drive Gear and Bearings .0025L .0050L .0060L 771 AZ Propeller Shaft Drive Gear – End Play .005 .015 .022 772 AZ Propeller Shaft and Rear Bearing .0015L .0030L .0040L 773 AZ Alternator Driven Gear and Adapter Bushing .0025L .0045L .0065L 774 AZ Starter Drive and Alternator Drive Gear – End Play .004 .008 .011 775 AZ Starter Driven Gear and Adapter Bushing .0015L .0030L .005L 776 AZ Starter Drive Shaft (Slip Coupling) and Crankcase .0015L .0040L .007L 777 AZ Starter Idler Gear and Idler Gear Bearing .0005L .0020L .005L SSP-1776-5-PT2 2-12 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION III – GEAR TRAIN Propeller Shaft Drive Gear 2-13 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION III – GEAR TRAIN Alternator, Starter and Propeller Shaft SSP-1776-5-PT2 2-14 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION III – GEAR TRAIN Fuel Pump, Magneto, Vacuum and Hydraulic Pump 2-15 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION III – GEAR TRAIN Governor, Fuel Pump and Breather Gear SSP-1776-5-PT2 2-16 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION III – GEAR TRAIN Oil Pump, Tachometer and Compressor 2-17 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION IV – BACKLASH Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 808 AQ-AZ Oil Pump Impellers – Backlash .008 .013 .020 822 AQ Propeller Governor Idler and Camshaft – Backlash .005 .015 .020 823 AQ-AZ Propeller Governor Drive and Idler – Backlash .004 .008 .015 825 AQ-AZ Crankshaft Timing Gear and Camshaft – Backlash .005 .015 .020 826 AQ-AZ Accessory Drive and Accessory Drive Intermediate .004L .006L .010L 827 AQ-AZ Accessory Drive Gear Intermediate and Idler – Spline Backlash .002 .005 .007 828 AQ-AZ Accessory Idler and Vacuum and Hydraulic Pump Gear – Backlash .004 .011 .016 829 AZ Propeller Shaft – Reduction Gear Total Backlash at 4 Foot Radius .38 .75 .90 830 AZ Starter (Bendix – Slip Coupling) and Starter Drive Gear – Backlash .016 .031 .045 831 AQ-AZ Accessory Idler and Magneto Drive Shaftgear – Backlash .005 .015 .020 832 AZ Starter Drive Gear and Starter and Alternator Drive Shaft Gear – Backlash .004 .008 .015 833 AZ Alternator Drive Gear and Starter and Alternator Drive Shaftgear – Backlash .003 .008 .012 834 AQ-AZ Fuel Pump Idler Gear and Vacuum and Hydraulic Pump Drive Gear – Backlash .002 .015 .020 835 AQ-AZ Fuel Pump Idler Gear and Fuel Pump Drive – Backlash .0006 .0160 .021 836 AQ-AZ Magneto Drive Shaft Gear and Magneto Coupling – Spline Backlash .0010 .0045 .0075 837 AQ-AZ Accessory Drive Gear and Compressor Drive Shaft – Spline Backlash .0040 .0076 .014 838 AQ-AZ Crankshaft Gear and Accessory Drive Shaftgear – Spline Backlash .0040 .0076 .014 839 AQ Breather Slinger Gear and Accessory Idler – Backlash .005 .015 .020 840 AZ Front Crankshaft Spline Bushing and Alternator and Starter Shaft Gear – Spline Backlash .001 .005 .006 SSP-1776-5-PT2 2-18 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION IV – BACKLASH Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 841 AZ Propeller Shaft Drive Gear and Alternator and Starter Shaft Gear – Spline Backlash .001 .004 .006 842 AZ Propeller Shaft Drive Gear and Driven Gear – Backlash .008 .014 .016 843 AZ Starter Slip Coupling Gear and Starter Idler – Backlash .0002 .0045 .0075 844 AZ Bendix Starter Motor Shaft Gear and Idler – Backlash .0002 .0045 .0075 845 AZ Propeller Shaft Spline and Propeller Shaft Driven Gear – Spline Backlash .008 .011 .015 (When Measured at O.D. of Propeller Gear) .020 .028 .036 Accessory Drives 2-19 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION IV – BACKLASH Accessory Drives SSP-1776-5-PT2 2-20 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION V – SPECIAL TORQUE REQUIREMENTS Ref. Chart Thread Size Nomenclature Torque Limits 900 AQ-AZ 3/8-24 Connecting Rod Nuts – Tighten to Length 2.255-2.256 903 AQ-AZ 3/8-24 Magneto – Nut (To attach drive member to magneto) 300 in. lbs. 904 AQ-AZ 10-32 Magneto – Plate Screws 15 in. lbs. 905 AQ-AZ (using a silicone gasket) 1/4-20 Rocker Box Screws 35 in.-lbs. AQ-AZ (using a cork gasket) 1/4-20 Rocker Box Screws 50 in. lbs. 907 AQ-AZ 18MM Spark Plugs 420 in. lbs. 909 AQ Alternator Pulley Nut 450 in. lbs. AZ Alternator Quill Shaft Nut 474 in. lbs. 910 AQ-AZ 1/4-28 Alternator Output Terminal Nut 85 in. lbs. 911 AQ-AZ 10-32 Alternator Auxiliary Nut 30 in. lbs. 912 AQ-AZ 5/16-24 Starter Terminal Nut 2 in. lbs. 913 AQ-AZ 1/16-27 NPT Piston Cooling Nozzle in Crankcase 100 in. lbs. 915 AQ-AZ 3/4-16 Oil Filter Bolt (AC Can and Element Type) 300 in. lbs. AQ-AZ 13/16-16 Oil Filter (Throw away type) 240 in. lbs. AQ-AZ 3/4-16 Converter Stud 720 in. lbs. 917 AQ-AZ 1.00-14 Oil Cooler Bypass Valve 300 in. lbs. 918 AQ-AZ 1-1/4-12 Oil Pressure Relief Valve 300 in. lbs. 919 AQ-AZ Hose Clamps 45 in. lbs. 921 AQ-AZ Exhaust V-Band Coupling Torque Data Coupling Size Tube OD Lycoming Part No. Vendor Part No. T-Bolt Split Type Locknut Torque In. Lbs. 1/4 In. Drilled Hex Nut with Safety Wire Torque In. Lbs. 2.00 in. LW-12093-5 MVT69183-200 85 75 2.25 in. LW-12093-6 MVT-69183-225 85 75 2.25 in. LW-12125-3 MVT-69197-225 85 922 AZ Turbocharger V-Band Torque Data Turbocharger Model No. V-Clamp Part No. V-Clamp Diameter Torque In. Lbs. T18A21* 400500-925 9.25 in. 40-60 * - AiResearch turbocharger. See latest revision of Service Instruction No. 1238 for assembly procedure. 923 AZ 2-1/16-12 Propeller Shaft Lock Nut 1000 ft. lbs. 924 AQ-AZ 7/16-20 Fuel Injector Nozzles (In Induction Housing) 210 in. lbs. 925 AQ-AZ 3/4-16 Compressor Drive Pulley Nut 240 in. lbs. 926 AZ 5/8-18 Starter Drive Shaft Gear Nut 900 in. lbs. 927 AQ-AZ 1/4 Bolts – Crankshaft Gear 96-120 in. lbs. 928 AQ-AZ 3/8-16 Cylinder Hold Down Studs (Crankcase Driving Torque) 100 in. lbs. 1/2-13 Cylinder Hold Down Studs (Cr ankcase Driving Torque) 250 in. lbs. 929 AQ-AZ 3/8 Cylinder Hold Down Nuts 300 in. lbs. 1/2 Cylinder Hold Down Nuts 600 in. lbs. Cylinder Hold Down Nut Tightening Procedure – See latest revision of Service Instruction No. 1029. 932 AQ-AZ 5/16-18 Exhaust Transitions – Studs (Driving Torque) 100 in. lbs. 3/8-16 Exhaust Transitions – Studs (Driving Torque) 200 in. lbs. 2-21 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION V – SPRINGS Ref. Chart Nomenclature Lyc. Part No. Wire Dia. Length at Comp. Length COMP. LOAD Mfr. Min. Mfr. Max. Service Max. 950 AQ-AZ Outer Valve Spring LW-11798 76351 .192 .177 1.610 in. 1.610 in. 136 lb. 136 lb. 144 lb. 144 lb. 133 lb. min. 951 AQ-AZ Auxiliary Valve Spring LW-11799 76352 .148 .142 1.48 in. 1.48 in. 86 lb. 86 lb. 94 lb. 94 lb. 83 lb. min. 952 AQ-AZ Oil Pressure Relief Valve Spring Lycoming Part Numbers Identification Dye Free Length 68668 Purple 2.04 .054 1.30 in. 7.1 lb. 7.8 lb. 7.1 lb. min. LW-11713 White 2.12 .059 1.44 in. 10.79 lb. 11.92 lb. 10.5 lb. min. LW-11138 None 2.64 .051 1.44 in. 8.55 lb. 9.45 lb. 8.3 lb. min. 955 AQ-AZ Fuel Drain Check Valve Spring .047 .75 in. 5.50 lb. 6.50 lb. 5.35 lb. min. 956 AQ-AZ Oil Filter Relief Valve Spring .054 1.93 in. 3.05 lb. 3.55 lb. 3.00 lb. min. 957 AZ Shroud Tube Spring .105 2.09 in. 14 lb. 16 lb. 13 lb. min. 958 AQ-AZ Pressurizing Valve Spring .032 .455-.485 .65 lb. .75 lb. .63 lb. min. 959 AZ Spring Between Crankshaft and Starter and Alternator Drive Gear .13 1.40 in. 48 lb. 52 lb. 46 lb. min. 960 AZ Alternator Drive Coupling Spring .047 .83 in. 10 lb. 11 lb. 9 lb. min. SSP-1776-5-PT2 2-22 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION V – SPECIAL TORQUE REQUIREMENTS Engine Accessories and Hardware Added April 2018 2-23 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION V – SPECIAL TORQUE REQUIREMENTS Engine Accessories and Hardware SSP-1776-5-PT2 2-24 Added April 2018 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION V – SPECIAL TORQUE REQUIREMENTS Engine Accessories and Hardware Added April 2018 2-25 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION V – SPECIAL TORQUE REQUIREMENTS Engine Accessories and Hardware SSP-1776-5-PT2 2-26 Added April 2018 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION V – SPECIAL TORQUE REQUIREMENTS Engine Accessories and Hardware Added April 2018 2-27 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION V – SPECIAL TORQUE REQUIREMENTS Engine Accessories and Hardware SSP-1776-5-PT2 2-28 Added April 2018 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES SECTION V – SPECIAL TORQUE REQUIREMENTS Engine Accessories and Hardware Added April 2018 2-29 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART II – INTEGRAL ACCESSORY DRIVE ENGINES STANDARD TORQUE UNLESS OTHERWISE LISTED Torque limits for propeller attaching bolts to be supplied by propeller aircraft manufacturer. NOTE: Refer to Table VIII for torque value conversions (In. Lb. or Ft. Lb. to Nm). TABLE I TABLE II BOLTS, SCREW AND NUTS PIPE PLUGS Thread Torque Thread Torque Thread Torque In. Lb. Ft. Lb. In. Lb. Ft. Lb. In. Lbs. 8 20 to 22 ----- 7/16 600 to 660 50 to 55 1/16-27 NPT 40 to 44 10 49 to 54 ----- 1/2 900 to 984 75 to 82 1/8-27 NPT 40 to 44 1/4 96 to 106 ----- 9/16 1320 to 1452 110 to 121 1/4-18 NPT 85 to 94 5/16 204 to 228 17 to 19 5/8 1800 to 1980 150 to 165 3/8-18 NPT 110 to 121 3/8 360 to 396 30 to 33 3/4 3240 to 3564 270 to 297 1/2-14 NPT 160 to 176 THIN NUTS (1/2 DIA. OF BOLT) – 1/2 LISTED TORQUE 3/4-14 NPT 230 to 252 1-11-1/2 NPT 315 to 347 TABLE III TABLE IV CRUSH TYPE GASKETS FLEXIBLE TUBE CONNECTIONS (SEALASTIC OR EQUIVALENT FITTINGS) Thread Pitch on Part to be Tightened ANGLE OF TURN Tube Size Thread Torque In. Lbs. Threads Per Inch Aluminum Copper Aluminum Alloy Steel 8 135° 67° (-3) 3/16 3/8 - 24 30 to 50 70 to 80 10 135° 67° (-4) 1/4 7/16 - 20 40 to 65 90 to 100 12 180° 90° (-5) 5/16 1/2 - 20 60 to 80 135 to 150 14 180° 90° (-6) 3/8 9/16-18 75 to 125 270 to 300 16 270° 135° (-8) 1/2 3/4-16 150 to 250 450 to 500 18 270° 135° (-10) 5/8 7/8 - 14 200 to 350 650 to 700 20 270° 135° 24 360° 180° TABLE V 28 360° 180° STUDS MIN. DRIVING TORQUE NOTE: Install all crush type gaskets except the self centering type, with the unbroken surface against the flange of the plug or part being tightened against the seal. Turn the part until the sealing surfaces are in contact and then tighten to the angle of turn listed for the appropriate thread size. NOTE: Lubricate Threads Unless Otherwise Specified. Threads Torque In. Lbs. 1/4-20 15 5/16-18 25 3/8-16 50 TABLE VI JAM NUT OR STRAIGHT THREAD O-RING BOSS Tube Size Thread Torque Ft. Lbs. -03 3/8 – 24 8 – 9 -04 7/16 – 20 13 – 15 -05 1/2 – 20 14 – 15 -06 9/16 – 18 23 – 24 -08 3/4 – 16 40 – 43 -10 7/8 – 14 43 – 48 -12 1-1/16 – 12 68 – 75 -14 1-3/16 – 12 83 – 90 -16 1-5/16 – 12 112 – 123 -20 1-5/8 – 12 146 – 161 -24 1-7/8 – 12 154 – 170 -32 2-1/2 – 12 218 – 240 SSP-1776-5-PT2 2-30 SERVICE TABLE OF LIMITS STANDARD TORQUE (CONT.) UNLESS OTHERWISE LISTED TABLE VII METAL TUBE FITTINGS Dash Nos. Ref. Tubing OD inches Wrench torque for tightening AN-818 Nut (pound inches) Minimum bend radii measured to tubing centerline. Dimension in inches Aluminum-alloy tubing Steel tubing Aluminum-alloy tubing (Flare MS33583) for use on oxygen lines only Minimum Maximum Minimum Maximum Minimum Maximum Alum. Alloy Steel -2 1/8 20 30 75 85 -- -- 3/8 -- -3 3/16 25 35 95 105 -- -- 7/16 21/32 -4 1/4 50 65 135 150 -- -- 9/16 7/8 -5 5/16 70 90 170 200 100 125 3/4 1-1/8 -6 3/8 110 130 270 300 200 250 15/16 1-5/16 -8 1/2 230 260 450 500 300 400 1-1/4 1-3/4 -10 5/8 330 360 650 700 -- -- 1-1/2 2-3/16 -12 3/4 460 500 900 1000 -- -- 1-3/4 2-5/8 -16 1 500 700 1200 1400 -- -- 3 3-1/2 -20 1-1/4 800 900 1520 1680 -- -- 3-3/4 4-3/8 -24 1-1/2 800 900 1900 2100 -- -- 5 5-1/4 -28 1-3/4 -- -- -- -- -- -- -- -- -32 2 1800 2000 2660 2940 -- -- 8 7 TABLE VIII TORQUE CONVERSIONS In. Lb. Ft. Lb. Nm In. Lb. Ft. Lb. Nm In. Lb. Ft. Lb. Nm 5 0.42 0.56 100 8.33 11.30 1000 83.33 113.00 10 0.83 1.13 200 16.67 22.60 2000 166.70 226.00 20 1.67 2.26 300 25.00 53.90 3000 250.00 339.00 30 2.50 3.39 400 33.33 45.19 4000 333.30 451.90 40 3.33 4.52 500 41.67 56.49 5000 416.70 564.90 50 4.17 5.65 600 50.00 67.79 6000 500.00 677.90 2-31 SSP-1776-5-PT2 SERVICE TABLE OF LIMITS PART III – GEARED ENGINES CHART MODELS E GO-435 ALL E1 GO-435-C2B2, -C2B2-6 H GO-480, IGO-480 ALL H1 GO-480-B H2 GO-480-F1A6, -F2A6, -F4A6, -G2D6, -G2F6 H3 GO-480-G1H6, -G1D6 H4 GO-480-D1A (Crosswise Accessory Housing) H5 GO-480-G1B6 (Crosswise Accessory Housing) P GSO-480, IGSO-480 P1 IGSO-480 AB IGSO-540 AC IGO-540 NOTE In “Chart” column, a number appearing after a letter shows exception to basic model. SECTION I 500 SERIES CRANKCASE, CRANKSHAFT & CAMSHAFT SECTION II 600 SERIES CYLINDERS SECTION III 700 & 7000 SERIES GEAR TRAIN SECTION IV 800 SEREIS BACKLASH (GEAR TRAIN) SECTION V 900 SERIES TORQUE & SPRINGS (A) These fits are either shrunk fits controlled by machining, fits that may readily be adjusted, or fits where wear does not normally occur. In each case, the fit must be held to manufacturing tolerance. (B) Side clearance on piston rings must be measured with face of ring flush with piston. (C) Replacements to correct these items must be made to give uniform backlash within 0.001 between the stationary gear and pinions, and within 0.001 between the pinions and the ring gear. (D) These dimensions shown are measured at bottom of piston skirt at right angles to piston pin. (E) Permissible wear of the crankshaft (rod and main bearing journals) to be minus 0.0015 on the diameter. (L) Loose fit; wherein a definite clearance is mentioned between the mating surfaces. (T) Tight fit; shrink or interference fit. SSP-1776-5-PT3 April 13, 2020* * - Indicates cut-off date for data retrieved prior to publication. ©2020 by Lycoming “All Rights Reserved” This Page Intentionally Left Blank TECHNICAL PUBLICATION REVISION REVISION NO. PUBLICATION PUBLICATION NO. PUBLICATION DATE SSP-1776-5-PT3 Service Table of Limits SSP-1776 October 28, 2013 PREVIOUS REVISIONS CURRENT REVISION* April 2018 3-9, 3-47, 3-53 • Deleted NOTES that reference S.I. 1243 in Piston Application Table • Added Ref. number 930 to Section V table and figure for torque value for brass union nut on stainless steel injector fuel lines and primer lines (Both Ends) April 2020 3-8 • Revised burnishing instructions for connecting rod bushing in reference number 600 • Revised the Mfr. Min. & Max. Clearance for Piston Ring Gap (Compression) Nitrided Cylinders (Choke Barrels) and Piston Ring Gap (Oil) in reference number 607 * Revisions are indicated with a vertical bar to the left of the revised item. ©2020 by Avco Corporation. All Rights Reserved Lycoming Engines is a division of Avco Corporation This Page Intentionally Left Blank SERVICE TABLE OF LIMITS PART III – GEARED ENGINES SECTION I – CRANKCASE, CRANKSHAFT AND CAMSHAFT Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 500 E-H1-H2-H4 All Main Bearings and Crankshaft .0015L .0045L .0060L H3-H5-P-AB-AC Main Bearings and Crankshaft (Except Front) .0011L .0041L .0050L H3-H5-P-AB-AC Front Main Bearings and Crankshaft .0011L .0041L .0050L E-H-P Diameter of Main Bearing Journal on Crankshaft 2.3745 2.376 (E) E-H1-H2-H4 Crankcase Bearing Bore Diameters (All) 2.566 2.567 2.5685 H3-H5-P-AB-AC Crankcase Bearing Bore Diameters (All) 2.6865 2.6875 2.6890 501 ALL Connecting Rod Bearings and Crankshaft .0008L .0038L .0050L ALL Diameter of Connecting Rod Journal on Crankshaft (2-1/8 in.) 2.1235 2.125 (E) ALL Connecting Rod Bearing Bore Diameter (Measured at axis 30° on each side) 2.2870 2.2875 502 ALL Connecting Rod Side Clearance .004L .010L .016L 503 ALL Connecting Rod Alignment .010 in 10 Inches 504 ALL Connecting Rod Twist .012 in 10 Inches 505 ALL Crankshaft Run-Out at Center Main Bearings Mounted on No. 1 and 4 Journals Max. Run-Out No. 2 and 3 Journals .005 .0075 Mounted on No. 1 and 3 Journals Max. Run-Out No. 2 Journal .003 .0045 Mounted on No. 2 and 4 Journals Max. Run-Out No. 3 Journal .003 .0045 506 ALL Crankshaft and Crankcase Front End Clearance .006L .015L .025L 510 E-H1-H2-H3 Crankshaft Timing Gear and Crankshaft .0015L .0005T (A) H4-H5-P-AB-AC Crankshaft Timing Gear and Crankshaft .0000 .0015T (A) 511 ALL Tappet Body and Crankcase .0010L .0033L .004L ALL O.D. of Tappet .7169 .7177 .7166 ALL I.D. Tappet Bore in Crankcase .7187 .7200 .7203 3-1 SSP-1776-5-PT3 SERVICE TABLE OF LIMITS PART III – GEARED ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 512 ALL Tappet Plunger Assembly and Body (Hyperbolic) .0010L .0067L .0087L 513 ALL Tappet Socket and Body (Hyperbolic) .002L .007L .009L 514 ALL Camshaft and Crankcase .002L .004L .006L 515 ALL Camshaft – End Clearance .002L .009L .015L 516 ALL Camshaft Run-Out at Center Bearing Journal .000 .001 .006 517 ALL Counterweight Bushing and Crankshaft .0013T .0026T (A) 518 ALL Counterweight Roller – End Clearance .007L .025L .038L 519 ALL Counterweight and Crankshaft – Side Clearance* .003L .013L .017L * - Measure below roller next to flat. 520 ALL Counterweight Bore and Washer O.D. .0002L .0030L (A) 521 ALL I.D. of Counterweight Bushing .7485 .7505 .7512 522 ALL O.D. of Counterweight Roller (P/N 69433) (See latest revision of Service Instruction No. 1012) .5045 .5050 AC O.D. of Counterweight Roller (P/N 73287) (See latest revision of Service Instruction No. 1012) .5189 .5194 ALL O.D. of Counterweight Roller (P/N 70416) (See latest revision of Service Instruction No. 1012) .6945 .6950 523 ALL Thrust Bearing and Propeller Shaft .0000 .0012L .002L 526 ALL Thrust Bearing and Thrust Bearing Cap Clamp Fit (Shim to this fit) .003T .005T (A) 527 ALL Thrust Bearing Tilt .027 Tilt 528 ALL Thrust Bearing – End Play .006 .008 .010 530 ALL Propeller Shaft Run-Out (Rear Cone Location) .003 531 ALL Propeller Shaft Run-Out (Front Cone Location) (Propeller Shaft Installed) .007 532 E-H1-H2-H3 Starter Jaw and Crankshaft .0005L .0040L (A) 533 ALL Thrust Bearing and Reduction Gear Housing .0006L .0024L .0035L SSP-1776-5-PT3 3-2 SERVICE TABLE OF LIMITS PART III – GEARED ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 534 ALL Crankshaft and Crankcase Front Bushing .0010T .0025T (A) 535 ALL Pinion – End Clearance .011 .016 .030 536 ALL Pinion Shaft and Cage (See latest revision of Service Instruction No. 1236) .0001T .0005T ALL Pinion Shaft and Cage (See latest revision of Service Instruction No. 1114) Select for Hand Push Fit (C) .002 537 ALL Propeller Shaft and Crankshaft Bushing .0020L .0035L .005L ALL I.D. Propeller Shaft Bushing in Crankshaft 1.251 1.2525 1.253 This Diameter must be concentric with Front Main Bearing within .003 in. TIR. 538 ALL Stationary Gear and Plate – End Clearance .000 .004 .007 539 ALL Ring Gear and Drive Plate – End Clearance .000 .004 .007 540 P-AB-AC Reduction Gear Governor and Magneto Housing and Reduction Gear Housing Sleeve .004T .006T (A) 541 H4-H5-P-AB-AC Rear Crankshaft Spline Bushing and Crankshaft .0002T .0015T (A) 3-3 SSP-1776-5-PT3 SERVICE TABLE OF LIMITS PART III – GEARED ENGINES SECTION I – CRANKCASE, CRANKSHAFT AND CAMSHAFT Crankcase, Crankshaft, Bearings, Camshaft, Tappets and Counterweights SSP-1776-5-PT3 3-4 SERVICE TABLE OF LIMITS PART III – GEARED ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Longitudinal Section Thru Engine, Camshaft, Tappet Body and Crankshaft 3-5 SSP-1776-5-PT3 SERVICE TABLE OF LIMITS PART III – GEARED ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Reduction Gear and Related Parts SSP-1776-5-PT3 3-6 SERVICE TABLE OF LIMITS PART III – GEARED ENGINES SECTION I – CRANKCASE, CRANKSHAFT, CAMSHAFT Starter Jaw and Crankshaft 3-7 SSP-1776-5-PT3 SERVICE TABLE OF LIMITS PART III – GEARED ENGINES SECTION II – CYLINDERS Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 600 ALL Connecting Rod and Connecting Rod Bushing Bushing P/N LW-13923 to be burnished in place Bushing P/N 01K28983 is not burnished in place Finished I.D. of Connecting Rod Bushing 1.1254 1.1262 601 E-H-P Length Between Connecting Rod Bearing Centers 6.4985 6.5015 AB-AC Length Between Connecting Rod Bearing Centers 6.4785 6.7515 602 ALL Connecting Rod Bushing and Piston Pin .0008L .0021L .0025L 603 ALL Piston Pin and Piston .0003L .0014L .0018L ALL Diameter of Piston Pin Hole in Piston 1.1249 1.1254 ALL Diameter of Piston Pin 1.1241 1.1246 604 H-P-AB-AC Piston and Piston Pin Plug .0002L .0010L .002L H-P-AB-AC *Diameter of Piston Pin Plug 1.1242 1.1247 605 ALL Piston Pin and Piston Pin Plug (Optional) .0005L .0025L .005L H-P-AB-AC *Diameter of Piston Pin Plug .5655 .5665 E Diameter of Piston Pin Plug (Thin Wall Pin) .8405 .8415 *See latest revision of Service Instruction No. 1267. 606 ALL Piston Ring and Piston – Side Clearance (Top Ring Comp.) Half Wedge .0025L .0055L .008L (B) ALL Piston Ring and Piston – Side Clearance (2nd Ring Comp.) Full or Half Wedge .000 .004L .006L (B) ALL (AS APPLICABLE) Piston Ring and Piston – Side Clearance (3rd Ring Comp.) Half Wedge .000 .004L .006L (B) ALL Piston Ring and Piston – Side Clearance (Oil Regulating) .002L .004L .006L (B) ALL (AS APPLICABLE) Piston Ring and Piston – Side Clearance (Oil Scraper) .003L .0055L .007L (B) 607 ALL Piston Ring Gap (Comp.) Plain and Chrome Cylinders (Straight Barrels) .020 .030 .047 ALL Piston Ring Gap (Comp.) Nitrided and Chrome Cylinders (Choke Barrels) .045 .065 .067 ALL Piston Ring Gap (Oil Regulating) (All Barrels) .015 .040 .047 SSP-1776-5-PT3 3-8 Revised April 2020 SERVICE TABLE OF LIMITS PART III – GEARED ENGINES SECTION II – CYLINDERS Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 607 ALL (AS APPLICABLE) Piston Ring Gap (Oil Scraper) (All Barrels) .015 .030 .047 For Choke Barrels – Ring gap is measured within 4 inches from bottom. Ring gap at top of travel must not be less than .0075. For All Other Barrels – Ring gap is measured at top limit of ring travel. Engine and Piston Application Min. Piston Diameter Type of Piston Cylinder Barrel Max. Clearance Piston Skirt & Cyl. Engine Chart Code Letter Piston Number Top Bottom Type of Surface Maximum Diameter 608 608 609 610 E E E E 67266, 71553 4.8395 4.8540 Forged-Round P 4.8805 .018L 73620, 73628 4.8395 4.8540 Forged-Round N 4.8805 .018L 67266, 71553, 73620, 73628, 73932 4.8395 4.8540 Forged-Round C 4.8805 .0225L 75984 4.8395 4.8590 Forged-Cam C-N 4.8805 .018L H-P H-P 69236 5.0905 5.1040 Forged-Cam P-C 5.1305 .0225L 71545, 71608* 5.0905 5.1025 Forged-Round C 5.1305 .024L H-P-AB-AC 71940, 72249*, 72578, 73947*, 73976 5.0905 5.1040 Forged-Round C 5.1305 .0225L H-AC 71940, 72249*, 73947*, 73976 5.0905 5.1040 Forged-Round N 5.1305 .023L H-P-AB 74242, 75617* 5.0790 5.1090 Forged-Cam C 5.1305 .018L H-P-AB-AC 74242, 76258* 5.0790 5.1090 Forged-Cam N 5.1305 .018L AC 75617*, 76258* 5.0790 5.1090 Forged-Cam C-N 5.1305 .018L H-P-AB-AC 73264*, 75961, 76966, 78203*, 78762, LW-10207*, LW-10208, LW-10545 5.0790 5.1090 Forged-Cam C-N 5.1305 .018L NOTES: To find the average diameter of cylinder in an area 4” above bottom of barrel: First, measure diameter at right angles from plane in which valves are located. Second, measure diameter through the plane in which valves are located. Add both diameters; this sum, divided by 2, represents the average diameter of the cylinder. *=High Compression. Cylinder Barrel: N=nitride hardened, C=chrome plated. Maximum taper and out-of-round permitted for cylinder in service is .0045 inch. To find the average out-of-round, measure diameter of cylinder in an area 4” above bottom of barrel: First, measure diameter at right angles from plane in which valves are located. Second, measure diameter through the plane in which valves are located. Difference between diameters must not exceed .0045 inch. Piston diameter at top is measured at top ring land (between top and second compression ring grooves) at right angle to piston pin hole; diameter at bottom of piston is measured at the bottom of the piston skirt at right angles to the piston pin. Revised April 2018 3-9 SSP-1776-5-PT3 SERVICE TABLE OF LIMITS PART III – GEARED ENGINES SECTION II – CYLINDERS Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 611 ALL Exhaust Valve Seat and Cylinder Head .0075T .011T (A) ALL O.D. Exhaust Seat 1.9355 1.937 ALL I.D. Exhaust Seat Hole in Cylinder Head 1.926 1.928 612 ALL Intake Valve Seat and Cylinder Head .0065T .010T (A) E-H-P O.D. Intake Seat 2.1675 2.169 AB-AC O.D. Intake Seat 2.2885 2.290 E-H-P I.D. Intake Seat Hole in Cylinder Head 2.159 2.161 AB-AC I.D. Intake Seat Hole in Cylinder Head 2.280 2.282 613 ALL Exhaust Valve Guide and Cylinder Head .001T .0025T (A) ALL O.D. Exhaust Valve Guide .6633 .6638 ALL I.D. Exhaust Valve Guide Hole in Cylinder Head .6613 .6623 614 ALL Intake Valve Guide and Cylinder Head .001T .0025T (A) ALL O.D. Intake Valve Guide .5933 .5938 ALL I.D. Intake Valve Guide Hole in Cylinder Head .5913 .5923 615 ALL Exhaust Valve Stem and Valve Guide .0037L .0050L ALL O.D. Exhaust Valve Stem .4957 .4965 .4937 Service allowable limits of .4937 is applicable only to inconel or nimonic valves. ALL Finished I.D. Exhaust Valve Guide .4995 .5005 ½ inch diameter exhaust valves may have exhaust valve guides that are .003 inch over the maximum inside diameter limit, anytime up to 300 hours of service. After 300 hours of service, inside diameter of exhaust valve guide may increase .001 inch during each 100 hours of operation up to the recommended overhaul time for the engine, or not to exceed .015 inch over the basic I.D. See latest revision of Service Instruction No. 1009 for recommended overhaul time. 616 ALL Intake Valve Stem and Valve Guide .0010L .0028L .006L ALL O.D. Intake Valve Stem .4022 .4030 .4010 ALL Finished I.D. Intake Valve Guide .4040 .4050 SSP-1776-5-PT3 3-10 SERVICE TABLE OF LIMITS PART III – GEARED ENGINES SECTION II – CYLINDERS Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. 617 ALL Valve and Valve Cap Clearance .000 .004L .005L 618 ALL Dry Tappet Clearance .028 .080 619 ALL Valve Rocker Shaft and Valve Rocker Bushing .0001L .0013L .0025L ALL Finished I.D. of Valve Rocker Shaft (Bushing) in Cylinder Head .6246 .6261 .6270 620 ALL Valve Rocker Shaft and Valve Rocker Bushing .0007L .0017L .004L ALL O.D. Valve Rocker Shaft .6241 .6245 .6231 ALL Finished I.D. of Rocker Arm Bushing .6252 .6263 .6270 621 ALL Valve Rocker Bushing and Valve Rocker Bushing Must Be Burnished In Place 622 ALL Valve Rocker Shaft Bushing and Cylinder Head .0022T .0038T (A) ALL Valve Rocker Shaft Bushing and Hole in Cylinder Head .7380 .7388 623 ALL Valve Rocker and Cylinder Head – Side Clearance .002L .020L .024L 625 ALL Intake and Exhaust Valve Guide Height .914 .954 MEASURE VALVE GUIDE HEIGHT FROM THE VALVE SPRING SEAT COUNTERBORE IN THE CYLINDER HEAD TO THE TOP OF VALVE GUIDE. 3-11 SSP-1776-5-PT3 SERVICE TABLE OF LIMITS PART III – GEARED ENGINES SECTION II – CYLINDERS Cylinder, Piston, Connecting Rod and Valve Components SSP-1776-5-PT3 3-12 SERVICE TABLE OF LIMITS PART III – GEARED ENGINES SECTION III – GEAR TRAIN Ref. Chart Nomenclature Dimensions Clearances Mfr. Min. & Max. Service Max. Mfr. Min. & Max. Service Max. OIL PUMP & SCAVENGE PUMP 700 E-H1-H2-H3 Oil Pump Drive Gear and Oil Pump Body .0010L .0025L .004L 701 E-H1-H2-H3 Oil Pump Drive Gear and Accessory Housing .0015L .0030L .006L 702 E-H1-H2-H3 Oil Pump Drive Gear – End Clearance .008L .042L .060L H4-H5-P-AB-AC Oil Pump and Scavenge P