TEXTRON LYCOMING OPERATOR'S MANUAL
SECTION 5
0-540
& 10-540 SERIES
a. Removal of CylinderAssembly -
(1) Remove exhaust manifold and cooling baffles.
(2) Remove rocker box drain tube, intake pipe, baffle and any clips
that might interfere with the removal of the cylinder.
(3) Disconnect ignition cables and remove the bottom spark plug.
(4) Remove rocker box cover and rotate crankshaft until piston is
approximately at top center of the compression stroke. This is indi-
cated by a positive
pressure inside of cylinder
tending to push
thumb off of bottom
spark plug
hole.
(5)
Slide valve rocker shafts from
cylinder head and remove
the
valve rockers. Valve rocker shafts can be removed at the cylinder
is removed from the engine.
Remove rotator cap
from exhaust
valve stem.
(6) Remove
push rods by grasping ball
end and pulling rod out
of
shroud tube.
Detach shroud tube spring
and lock plate and pull
shroud tubes
through holes in cylinder
head.
NOTE
The hydraulic tappets,
push rods, rocker arms
and valves must
be assembled in the same
location from which they
were re-
moved.
(7) Remove
cylinder base nuts and
hold down plugs (where
employed), then
remove cylinder by pulling
directly away from
crankcase.
Be careful not to allow
the piston to drop against the
crankcase,
as the piston leaves
the cylinder.
b.
Remove of Piston
from Connecting
Rod -
Remove the
piston pin
plugs.
Insert piston
pin puller (P/N
64843) through
piston pin,
as-
semble
puller nut; then
proceed to remove
piston
pin. Do not allow
connecting
rod to rest on the cylinder
bore of the crankcase.
Support
the connecting
rod
with heavy rubber
band, discarded
cylinder
base
oil ring seal,
or any other non-marring
method.
c. Remove
of Hydraulic
Tappet Sockets
and Plunger
Assemblies -
It
will be necessary
to remove
and bleed the hydraulic
tappet
plunger as-
sembly
so that dry tappet
clearance can
be checked
when the cylinder
assembly is
reinstalled. This
is accomplished
in the following
manner:
5-12
Revised
January 1999
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