SECTION IX

IO-520-M

The IO-520-M is similar to the other Permold engines Those systems which are unique to the IO-52D-M, the
covered in Sections I thru VIII except that the air Induction System and the Fuel Injection System are
throttle body is air frame mounted. covered on the following pages.

The instructions contained in Sections I thru VIII 9-1. INDUCTION SYSTEM.(See Figure 9-1).
pertaining to the Permold engine design, together with
the parts catalog, will provide adequate instructions a. Loosen hose clamps (7) or clamp assemblies (8) on
for the overhaul of the IO-520-M engine. hoses (9). Remove attaching parts (4,5,6) and remove
elbows (2,3 and 10).

FIGURE 9-1. INDUCTION SYSTEM

1. Gasket, Intake Manifold Flange 14. Bracket, Balance Tube
2. Tube Assembly, Intake Manifold, Cyl.1 ,2,3,4,5 15. Clamp, Balance Tube to Bracket
3. Tube Assembly, Intake Manifold, Cyl.6 16. Tube Assembly, Balance
4. Washer Plain 17. Washer
5. Washer, Lock 18. Bolt, 15/16-18 X 1-1/8 Inch Long
6. Screw, 1/4-20 x 7/8 Inch Long 19. Plug, Pipe
7. Clamp, Hose 20. Bracket, Crankcase-to-Riser
8. Clamp Assembly, Hose 21. Screw, 5/1&18 X 2.00 Inch Long
9. Hose, Intake Manifold 22. Spacer
10. Tube Elbow 23. Washer
11. Plug, Pipe 24. Nut
12. Riser 25. Flexible Duct
13. Stud, 1/4 X 1-1 13/32 Inch Long

9-1
b. Remove attaching parts (17,18) Clamp (16) and on proper bank of cylinders and adjust each tube so it
remove balance tube (16) and bracket (14). seats squarely on cylinder port. Attach each intake
flange to its cylinder with attaching parts 5,6).
c. Remove attaching parts (21 thru 24) and re move Position clamp on two center hoses on each side of
bracket (20). Remove clamp (26) and separate riser tube beads and tighten.
(12) and flexible coupling (25).
e. Push hose clamp assembly (8) on each rear elbow
9-2. INSPECTION. (10) and work hose (9) over bead. Install riser (12) in
hoses and position hose clamp assembly so beads are
a. Inspect intake tubes for distortion, cracks and out-
inside of clamps. Tighten clamps.
of-roundness.
f. Install bracket (20) on riser stud (13) and secure
b. Inspect stud in riser for straightness and thread
with attaching parts (23, 24). Secure bracket to sump
damage. Stud height should be 1.04 inches.
with spacer (22) and bolt (21).
9-3. REASSEMBLY.
g. Install clamp (15) and bracket (14) on balance tube
a. Push a new hose (9) on either side of center intake (16). Push tube ends into connecting hoses installed
tube (2). Slide one hose clamp (7) to a position on front intake tubes. Position bracket and secure to
midway on overlapping portion. Turn each clamp so sump with attaching parts (17, 18). Position clamp
that a screwdriver can be aligned with its screw yet assembly (8) over tube beads and tighten.
clear of stand when tube is installed. Tighten screw
h. Secure flexible coupling (25) to riser with clamp
only enough to hold hose in position.
(26).
b. Place a hose clamp on each end of cylinder intake
9-4 FUEL INJECTION SYSTEM (See Figure
tube (2,3) so it faces center tube. Push end tubes into
9-2).
hose previously installed on center intake tubes.
Work hose clamps over ends of hoses, but not past a. Instructions relative to the removal, inspection,
bead. Do not tighten at this time. repair, replacement and reassembly of the fuel
injection system is the same as those in Sections 1 thru
c. Push a hose (9) on each front intake tube (3) and
8 with the exception that the air throttle body and
hose (9) on each rear intake tube (10). Locate clamp
control assembly and connecting hoses are to be
assemblies (8) so tube beads are inside of clamps and
installed after the engine is installed in the airframe.
tighten clamps.
b. If it is necessary to replace fittings, they are to be
d. Lay a new gasket (1) on intake flange of each
oriented according to figures 9-3, 9-4 and 9-5.
cylinder. Position each assembly of tubes and hoses

9-2
 FIGURE 9-2. FUEL INJECTION SYSTEM.

1. Gasket, Fuel Pump to Crankcase 19. Spring

2. Coupling 20. Control Assembly
3. Fuel Pump 21. Washer Tab
4. Washer, Holding 22. Bolt
5. Washer, Lock 23. Lever
6. Nut 24. Rod Assembly
7. Throttle Assembly 25. Nut
8. Bushing 26. Spring
9. Collar 27. Rod End
10. Pin 28. Nut, Self Locking
11. Washer, Wave 29. Washer, Wave
12. Washer, Plain 30. Washer, Plain
13. Lever Assembly 31. Pin, Cotter
14. Bushing 32. Fuel Manifold Valve Assembly
15. Shaft, Throttle Plate 33. Tube Assembly
16. Plate, Throttle 34. Nozzle Assembly
17. Screw 35. Bracket, Fuel Discharge Tube
18. Screw, Adjusting 36. Clamp, Tube-to-Bracket

9-3
 FIGURE 9-3. FUEL PUMP AND VAPOR SEPARATOR FITTING LOCATIONS

A B C D E

MIXTURE VAPOR
INLET AND OUTLET RETURN RETURN DRAIN
ANGLE° AND AND AND ANGLE° AND
ANGLE° ANGLE° ANGLE°

IO-520-M 90° ELBOW 90° 90° ELBOW 310° 45° ELBOW 250° 90° ELBOW 270° 45° ELBOW 240°
45° ELBOW 270°

9-4
 FIGURE 9-4. FUEL CONTROL VALVE FITTING LOCATIONS

A B C D E

TO TO
MANIFOLD FUEL RETURN PRESSURE FUEL INLET MANIFOLD
VALVE TO TANK TAP VALVE

IO-520-M PLUG 90° ELBOW 240° 90° ELBOW 235° 90° ELBOW 150° 90° ELBOW 260°

9-5
 FIGURE 9-5. FUEL MANIFOLD VALVE FITTING LOCATIONS

ENGINE FITTING FITTING FITTING

MODEL “A” NUMBER “B” NUMBER “C” NUMBER

IO-520-M 90° ELBOW 90° NIPPLE 0° 45° ELBOW 270°

9-6
 TABLE XIX. TEST OPERATING LIMITS

FEATURE IO-520-M

Maximum takeoff power 285

Maximum continuous power 285
Full throttle speed (RPM) 2700-2750
Idling speed (RPM) 575-625
Fuel grade (Octane) 100LL/100
Fuel consumption at full throttle (Lbs./Hr. 139-147
Fuel pump pressure at full throttle (psi) 29.5-33.5
Fuel pump pressure at idle (psi) 6.0-7.0
Metered fuel pressure at full throttle (psi) 17.6-19.2
Metered fuel pressure at idle (psi) 3.5-4.0
Engine intake air temperature Ambient
Engine intake air pressure (Max.) (In. H2O) 1.0
Manifold pressure at full throttle (In. Hg) 28.75
Manifold pressure at idle (I n. Hg) 18.5 Max.
Oil Grade Above 40° F. SAE 50
Below 40° F. SAE 30 or
10W30
Oil consumption at max. continuous
power (Lbs./Hr.) 3
Oil temperature (desired range) 150-200° F.
Oil temperature (Max.) 240°F.
Oil pressure at full throttle (psi max.)
(oil temperature 175-185°F.) 30-60
Oil pressure at idle (psi min.)
(oil temperature 140-150°F.) 10
Ignition timing Left Magneto (BTC) 22°
(±1°) Right Magneto (BTC) 22°
Magneto drop at 2100 RPM (Max.) (RPM) 150
Magneto Spread 50
Cylinder head temperature (Max.) with
bayonet thermocouple 460°F.
*Crankcase pressure (Max.) (In. H2O) 4.0

9-7
 TABLE XX. STANDARD ACCEPTANCE TEST
PROPELLER STAND
Note: Engine oil pressure must be supplied to propeller transfer collar during all testing.
Period Time – Minutes RPM

1 5 1200

2 5 1600

3 10 2450

4 15 Rated RPM (adjust engine – fuel flow,

pr., ect.,) (Reduce RPM for
adjustments).

5 10 Engine Parameter checks (fuel inj., Oil

pr., temp. etc., - see applicable data)
2100 mag check (3.(b)).

6 10 2450

7 5 Idle RPM (cooling period - 300° max.

60 Total Minutes
Inspect engine and apply corrosion prevention treatment in accordance with TCM Service Bulletin M74-9.

START OIL CONSUMPTION DETERMINATION

Period Time – Minutes RPM
1 5 1200
2 5 1600
3 10 2450
4 15 Rated RPM (adjust engine – fuel flow,
pr., ect.,) (Reduce RPM for
adjustments).
5 10 Engine Parameter checks (fuel inj., Oil
pr., temp. etc., - see applicable data).
2100 mag check (3.(b)).

6 5 Idle RPM (cooling period - 300°

Max. C.H.T. before shut-down).
Stop engine, drain oil, weigh oil in for oil consumption determination.
7 5 Warm up to rated RPM (minimum
1200 RPM).
8 30 2450 (3.(c)).
9 5 600 Idle (cooling period - 300° Max.
C.H.T. before shut-down).
80 Total Minutes
Stop engine, drain and weigh oil and record. (3. (d)). Inspect engine and apply corrosion prevention
treatment in accordance with TCM Service Bulletin M74-9.

9-8