Piper PA-28-161, Maintenance Manual

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PIPER AIRCRAFT, INC.
PA-28-161, WARRIOR III
MAINTENANCE MANUAL
PAGE 4
Nov 30/06
5D6
74-20-00
D. Assembly
(1) Cut a piece of harness wire to length required. Do not stretch wire when measuring it.
(2) On magneto end, make a final mark one inch from wire end. Another mark must be made
0.9375 inch from spark plug end of wire.
(3) Flare out shielding, then without allowing any shielding to fold under, insert Slick T-112 or
M-1743 stripping tool under braided shielding. (Refer to Figure 1.)
(4) Make sure stripping tool is inserted past cutting mark, and cut shielding with a sharp knife
using a rolling motion. Remove shielding and stripping tool. Do not cut silicone insulation.
(Refer to Figure 2.)
(5) Cut exposed insulation 0.125 inch back from end and roll insulation clockwise to remove. Do
not use a pulling motion when removing insulation. Trim end of coiled conductor to make a
clear hole for inserting stud. (Refer to Figure 3.)
(6) Using T-111 or M-1742 pin vise, insert T-110 or M-1741 drill (#72 drill), drill out silicone rubber
from inside coiled conductor approximately 0.5 inch deep. (Refer to Figure 4.)
(7) On spark plug end of wire install M-1673 nut followed by M-1671 female taper hex ferrule.
(Refer to Figure 5.)
(8) After installation of nut and ferrule, bend and rotate silicone insulation as per Figure 6 to flare
out shielding so drive ferrule can be inserted. Do not cut silicone insulation with sharp braiding
while wire is being rotated.
CAUTION: DO NOT REUSE THE M-1458 DRIVE FERRULE.
(9) On spark plug end of wire install M-1458 male tapered drive ferrule over silicone insulation and
under shielding to within 0.0625 inch from flange of ferrule. Make sure that shielding is away
from ferrule flange then slide ferrule M-1671 over the M-1458 drive ferrule until tight. (Refer to
Figure 7.)
(10) For spark plug end, mount M-1747 drive plate in a bench vise. Set hex ferrule in drive plate
slot. Drive M-1458 drive ferrule flush against the hex ferrule using the M-1744 drive tool. (Refer
to Figure 8.) Or, press into place using T-109 pressing tool.
(11) For magneto end of wire, insert wire through hole in M-1568 harness cap so shielding is
through hole as shown in Figure 9.
(12) Install an M-1458 male tapered drive ferrule over insulation and under shielding as in step 9,
then drive ferrule into M-1568 harness cap using M-1744 drive tool, similar to step 10. (Refer to
Figure 10.) Or, press into place using T-109 pressing tool.
(13) Clamp threaded end of M-1498 electrode screw in T-111 or M-1742 pin vise. Insert tapered pin
of electrode screw into center of coiled conductor by turning pin vise counterclockwise and
pushing at same time until screw is flush with insulation. This is done at both ends of the wire
assembly. (Refer to Figure 11.)
(14) On magneto end of wire, place M-3168 insulator sleeve over silicone insulation. On spark plug
end of wire, use M-1677 insulator sleeve. (Refer to Figure 12.)
(15) Turn M-2929 spring clockwise on electrode screw three full turns until end is flush with first
large coil of spring. This applies to both ends of wire. (Refer to Figure 13.)