652 Oliver Street
PA 17701 U.S.A.
PUBLICATION 76 Series Engine Overhaul Manual PUBLICATION NO. 60294-9 PUBLICATION DATE August 1980
REVISION NO. 60294-9-2
The page(s) furnished herewith are intended to replace the corresponding page(s) of the publication indicated above. This revisionconsists of: Previous revisions to this publication February, 1992 i June 1996 i
Approved by F.A.A.
3rd Printing Part No. 60294-g August 1996
652 Oliver Street Williamsport, PA 17701 U.S.A. 717/323-6181
TO THE OWNER OF THIS MANUAL THIS MANUAL HAS BEEN DESIGNED TOPERMIT ADDITION OF NEW AND REVISED PAGES, AS REQUIRED FOR COVERAGE OF NEW ENGINE MODELS, NEW SHOP PROCEDURES, AND PROCESSES. NEW AND REVISED PAGES WILL BE FURNISHED TO OWNERS OF THIS MANUAL WHO FILL OUT THE REGISTRATION CARD AND RETURN IT TO LYCOMING. THE PRICE OF THE MANUAL INCLUDES THE COST OF MAILING ALL REVISED AND NEW PAGES FOR THIS MANUAL TO THE ADDRESS SHOWN ON THE CARD FOR A PERIOD OFTHREE (3)YEARS. REGISTERED OWNERS OF THE MANUAL WILL BE NOTIFIED OF ANY CHANGE IN REVISION POLICY OR COST OF REVISIONS.
SERVICE BULLETINS, LETTERS AND INSTRUCTIONS
Although the information contained in this manual is up-to-date at time of publication, users are urged to keep abreast of later information through Lycoming Service Bulletins, Instructions and Service Letters which are available fromall Lycoming distributors or from the factory by subscription. Consult the latest edition of Service Letter No. L114 for subscription information.
The illustrations, pictures and drawings shown in this publication are typical of the subject matter they portray; in no instance are they to be interpreted as examples of any specific engine, equipment or part thereof.
TABLE OF CONTENTS SECTION 1. 2. INTRODUCTION GENERAL DESCRIPTION 2-1 2-1 2-1 2-2 2-2 2-2 2-2 2-2 2-2 2-2 Disassembly Cleaning Inspection Cylinder Pistons Valve Rockers Push Rods Valves Hydraulic Lifter Valve Springs Repair and Replacement Spark Plug Inserts Valve Seat Valve Refacing Valve Guide Nitrided Cylinder Barrels ChromePlated Cylinder Barrels Valve Repairs Warped Exhaust Flanges Reassembly Assembly of Pistons Assembly of Cylinders Installation of Cylinder and Pistons Intercylinder Baffles 6. OIL SUMP AND FUEL INDUCTION General Disassembly Intake Pipes Carburetor Oil Suction Screen Oil Sump Cleaning Oil Sump Carburetor Inspection Oil Suction Screen Carburetor Repair and Replacement Carburetor Reassembly Intake PipesOil Suction Screen 7. CRANKCASE, CRANKSHAFT RECIPROCATING PARTS General Disassembly Oil Pump and Vacuum Pump Starter Ring Gear Support Tachometer Governor Drive Crankcase Camshaft Crankshaft Counterweights Cleaning Inspection Bearing Crankcase Visual Dimensional Crankshaft Visual Dimensional & 7-1 7-1 7-1 7-1 7-1 7-1 7-2 7-2 7-4 7-4 6-1 6-1 6-1 6-1 6-1 6-1 6-1 6-1 6-1 6-2 6-2 6-2 5-1 5-3 5-4 5-55-5 5-5 5-5 5-6 5-7 5-7 PAGE 1-1 SECTION 5. CYLINDERS, (CONT). PISTONS AND VALVE TRAIN
Cylinders Valve Operating Mechanism Crankcase Crankshaft Counterweight Connecting Rods Pistons Lurication System Cooling System Induction System Ignition System 3. GENERAL OVERHAUL PROCEDURES
5-9 5-9 5-10 5-10 5-10 5-10 5-10 5-11 5-11 5-12
General Cleaning Degreasing Removal of Hard CarbonInspection General Bearing Surface Gears Corrosion Screwed Fittings Magnetic Corrosion Prevention Repair and Replacement Damaged Parts Painted Parts Replacement of Studs Corrosion Prevention Reassembly Corrosion Prevention Pre-Lubrication of Parts Oilite Bearing Table of Limits Oil Seal and Gaskets Arbitary Replacement of Parts 4. IGNITION SYSTEM
3-1 3-1 3-1 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-3...