Operating instructions
Table Of Contents
- 1 Introduction
- 2 General Description
- 3 Special Tools and Equipment
- 4 Disassembly
- 5 Cleaning, Repair and Replacement
- 6 Inspection
- Definitions
- Magnetic Particle Inspection
- Critical New Part Dimensions
- Fluorescent Particle Inspection
- Dimensional Inspection
- Protective Coatings
- Crankcase Inspection
- Crankshaft Inspection
- Camshaft Inspection
- Connecting Rod Inspection
- Gear Inspection
- Piston Inspection
- Cylinder Inspection
- Inspection Chart
- Crankcase Stud Heights
- Mag Particle Inspection Procedures
- Table of Limits
- Torque Specifications
- General Torques
- Table of Limits Chart
- 7 Assembly of Subassemblies
- 8 Final Assembly and Test
- 9 IO-520-M
- 10 IO-520-BB, CB and MB

6-14
SUBASSEMBLY
AND PART
INSPECT NATURE OF INSPECTION
SPECIAL
CONSIDERATIONS
Gears Shafts Measure diameters and
compare with bushing
diameters
Refer to Table of limits
Gear Teeth Scoring, burning or wear
enough to alter tooth profile.
Ball Bearing Balls, Cage Surface roughness, out-of-
round, excessive depth and
looseness
Adapter Cover All Areas Cracks, scratches on
machined surfaces, damaged
mounting holes.
Shaft Bearing Look for scoring.
Bore Measure Diameter.
Oil Seal See that old seal was
removed without damage to
casting.
ALTERNATOR
Hub Assembly Permold Crankcase Only.
Hub All Areas Scored or under bearing
surfaces.
Refer to Table of Limits.
Spring Damaged or broken.
Gear Look for chipped, cracked and
broken teeth, scoring, burning
and wear enough to alter tooth
profile.
Gear Bushing Measure bore diameter. Refer to Table of Limits.
Thrust Washer Thickness, excessive wear.
INDUCTION SYSTEM
Intake Manifold Flanges Check for warping by placing
flanges on surface plate.
Look for cracks.
Tubes Look for dents, out-of-round
ends, cracks.
Plug Bosses Damaged threads, cracks
around bosses.
Clamps Shape Look for distortion such as
out-of-roundness and lugs
converging.
FUEL INJECTION SYSTEM
Fuel Pump Adapter All Areas Cracks, damaged mounting
holes, inspect tapped holes.
Measure bore diameter.