Textron Lycoming IO-540 Series Operator's Manual page 97

TEXTRON LYCOMING OPERATOR'S MANUAL
0-540 & 10-540 SERIES SECTION 5
(1) Remove the hydraulic tappet push rod socket by inserting the foref-
inger into the concave end of the socket and withdrawing. If the socket
cannot be removed in this manner, it may be removed by grasping
the edge of the socket with a pair of needle nose pliers. However,
care must be exercised to avoid scratching the socket.
(2) To remove the hydraulic tappet plunger assembly, use the special
Textron Lycoming service tool. In the event that the tool is not
available, the hydraulic tappet plunger assembly may be removed by
a hook in the end of a short piece of lockwire, inserting the wire
so that the hook engages the spring of the plunger assembly. Draw
the plunger assembly out of the tappet body by gently pulling the wire.
CAUTION
Never use a magnet to remove hydraulic plunger assemblies from the
crankcase. This can cause the check ball to remain off its seat, rendering
the unit inoperative.
d. Assembly of Hydraulic Tappet Plunger Assemblies - To assemble the
unit, unseat the ball by inserting a thin clean wire through the oil inlet
hole. With the ball off its seat, insert the plunger and twist clockwise
so that the spring catches. All oil must be removed before the plunger
is inserted.
e. Assembly of Cylinder and Related Parts - Rotate the crankshaft so
that the connecting rod of the cylinder being assembled
is at the top
center of compression stroke. This can be checked by placing two fingers
on the intake and exhaust tappet bodies. Rock crankshaft back and forth
over top center. If the tappet bodies do not move the crankshaft is on
the compression stroke.
(1) Place each plunger assembly in its respective
tappet body and
assemble the socket on top of plunger assembly.
(2) Assemble piston with rings so that the number stamped on the
piston pin boss is toward the front of the engine. The piston pin should
be of a handpush fit. If difficulty is experienced in inserting the piston
pin, it is probably caused by carbon or burrs in the piston pin hole.
During assembly, always use a generous quantity of oil, both in the
piston pin hole and on the piston pin.
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