Operating instructions

8-10 MARCH 1982
8-17. OIL COOLER -TYPICAL OF SANDCAST
CRANKCASE (See Figure 4-11).
a. Install new gasket (11) on crankcase studs. Install
oil cooler end plate (9) on crankcase. Secure with five
sets of attaching parts (6, 7, 8).
b. Install new gasket (5) and oil cooler (4) on oil
cooler end plate. Secure with twelve sets of attaching
parts (1,2, 3).
8-18. OIL COOLER -TYPICAL ON PERMOLD
CRANKCASE (See Figure 4-12).
a. Install baffle support assembly (15) on crankcase
through bolts.
b. Install gaskets (10, IO-520-C) or (9 and 11, IO-
520-B). Mount oil cooler on mounting legs (IO-520-
C) or crankcase (IO-520-B). Secure with attaching
parts (1 through 6).
c. Install oil temperature control valve (12).
8-19. VALVE MECHANISM (See Figure 4-20 and
Figure 2-6).
a. Turn engine upside down.
b. Lubricate exterior surface of each tappet just prior
to installation. Apply oil to socket, but not into body
oil holes. Install all tappets.
c. To install each pushrod housing (14) compress
spring (15) and place packing (17) between two steel
washers (16) on that end of housing. Insert this end of
housing into crankcase guide until other end and its
seal ring can be aligned with cylinder head opening.
Move assembly outward until packing (17) has
entered cylinder hole. Release spring slowly until it is
free and remove compressor.
d. Install six pushrod housings nearest to engine
mount brackets first, since compressor must lie close
to horizontal in order to clear crankcase flange.
e. Before installing valve-actuating parts on each
cylinder, turn crankshaft until cam lobes for that pair
of tappets are pointed to the opposite side of the
engine.
f. Install lubricated pushrods (13) and seat them in
tappet sockets. Install proper rocker assembly (9, 10,
11), thrust washers (12) and insert rocker shaft (8).
Install rocker shaft retaining screw (6) and washer (7)
and secure with safety wire.
g. Install all pushrods and rockers in other cylinders
in same manner. Install valve rocker covers (4),
gaskets (5) and secure with attaching parts (1, 2, 3).
8-20. OIL SUMP -STAMPED ALUMINUM
SHEET METAL (See Figure 4-9).
a. Place new gasket (12) on crankcase suction tube
pad and position suction tube assembly on crankcase.
b. Attach suction tube assembly (11) to crankcase
with two slotted screws (8) and two sets of screws and
washers (9, 10). Torque screws (9) to value given in
Table of Limits, Section VI. '
c. Install gasket (16) on suction tube (17). Insert
threaded end of tube through crankcase and oil pump.
Install new gasket (16) and nut (15) on protruding,
threaded end of suction tube. Install washer (14) and
screw (13). Secure screw to brace with lockwire.
Tighten nut to torque specified in Table of Limits,
Section VI (IO-520-C).
d. Spread a film of Tite-Seal compound on both sides
of the sump gasket (7) and position it on the
crankcase.
e. Lay sump on crankcase and install attaching parts
(3, 4, 5).
8-21. OIL SUMP -CAST ALUMINUM (See
Figure 4-10).
a. Install gasket (15) on suction tube assembly (16).
Insert threaded end of tube through crankcase and oil
pump. Install new gasket (15) and acorn nut (14) on
protruding, threaded end of suction tube. Secure
suction tube to crankcase with screw (13) and secure
with lockwire. Torque acorn nut to value specified in
Table of Limits, Section VI.
b. Spread a film of Tite-Seal compound on both sides
of gasket (12) and position it on crankcase.
c. Lay sump (10) on crankcase, and install attaching
parts (7, 8, 9).
d. Install mounting legs (6) and secure with attaching
parts (3, 4, 5).
8-22. INDUCTION SYSTEM, IO-520-A, B, C, F,
J, K, L (See Figure 4-6).
a. Push a new hose (15) on either end of center intake
tubes. Slide one hose clamp (14) to a position
midway on overlapping portion. Turn each clamp so
that a screwdriver can be aligned with its screw and
yet clear of stand when tube is installed. Tighten
screw only enough to hold hose in position.