PIPER AIRCRAFT, INC.

PA-34-220T, SENECA IV / V
MAINTENANCE MANUAL

Distribution

1. Harness Assembly
A. Inspection
(1) Check the lead assemblies for nicks, cuts, mutilated braiding, badly worn section or any other
evidence of physical damage. Inspect the spark plug sleeves for chafing or tears and damaged
or stripped threads on coupling nuts. Check the compression spring to see if it is broken or
distorted. Inspect the grommet for tears. Check all the mounting brackets and clamps to see
that they are secure and not cracked.
(2) Should a harness problem be suspected, integrity of the harness wiring may be checked using
an ohmmeter, buzzer, or other suitable device such as the Bendix/ECD High Tension Lead
Tester Kits, P/N 11-8950 or 11-8950-1; check each lead for continuity. If continuity does not exist,
harness wire is broken and must be replaced.
(3) If an insulation failure is suspected, the condition of the insulation may be determined using the
Bendix 11-8950 and the 11-8950-1 High Tension Lead Tester Kits manufactured by the Electrical
Components Division, The Bendix Corporation, Sidney, New York.
(4) Test Unit Preparation:
(a) Install two C cells in the battery holder in accordance with correct position.
(b) Check that red and black leads are open-circuited.
(c) Depress PRESS-TO-TEST push-button switch.
(d) Ensure INDICATOR lamp flashes and GAP fires intermittently as long as PRESS-TO-TEST
switch is depressed.
(e) Interconnect both red and black high voltage leads and again depress PRESS-TO-TEST
switch. INDICATOR lamp only should flash. GAP does not fire.
(f) Disconnect black and red leads.
(5) Insulation Test:
(a) Attach clip of red high voltage test lead to ignition harness lead terminal.
(b) Attach black test lead clip to lead ferrule.
(c) Depress PRESS-TO-TEST push-button switch.
(d) Observe that INDICATOR lamp flashes and GAP fires intermittently as long as PRESS-TO-
TEST switch is held depressed.
(e) Whenever lNDICATOR lamp flashes and gap fails to fire, lead under test is defective.
(f) When testing leads which are installed on an engine, it may be found that distributed
capacitance causes the tester to reject good leads if the tester and red test lead are allowed
to lay in close physical contact with the engine parts. For best results, keep the tester and
the red high voltage lead well clear of the grounded metal parts of the engine.
(g) On some engines, leakage through the magneto distributor to the magneto coil may occur
if the distributor finger electrode is lined up with the lead under test. If this occurs, the tester
will indicate a rejection. Before final rejection of a lead which has one end connected to the
magneto, turn the engine slightly and repeat test to confirm the reading.
(6) A second acceptable method for performing an insulation check is with a high voltage, direct
current tester such as the TAKK Model 86 or 86A or an equivalent direct current tester capable
of delivering a test potential of 10,000 volts. Connect ground lead of high voltage tester to outer
shielding braid of a single lead. Connect plug terminal. Turn tester ON and apply 10,000 volts.
The insulation resistance should be 100 megohms minimum. Proceed to check other leads of
harness in the same manner.

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PA-34-220T, SENECA IV / V
MAINTENANCE MANUAL

B. Removal
(1) Disconnect the clamps that secure the wires to the engine and accessories.
(2) Loosen the coupling nuts at the spark plugs and remove the insulators from the spark plug
barrel well. Use caution when withdrawing the insulator so that the insulator spring will not be
damaged.
(3) Place a guard over the harness insulators.
(4) Remove the harness assembly terminal plate from the magneto.
(5) Remove the harness from the airplane.
C. Installation
Before installing the harness plate on the magneto, check the mating surfaces for cleanliness. Spray
the entire face of the grommet with a light coat of Plastic Mold Spray, SMOOTH Silicone Spray or
equivalent. This will prevent the harness grommet from sticking to the magneto distributor block.
(1) Place the harness terminal plate on the magneto and tighten the nuts around the plate
alternately to seat the cover squarely on the magneto.Torque the nuts to 18 to 22 inch-pounds.
(2) Route the ignition wires to their respective cylinders as shown in Figure 1.
(3) Clamp the harness assembly in position.
(4) Connect the leads to the spark plugs.
D. Maintenance

WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN

SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN
PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE
INTRODUCTION - supplementary publications.)
2. Spark Plugs
A. Removal
(1) Loosen the coupling nut on the harness lead and remove the terminal insulator from the spark
plug barrel well. (A crows foot adapter is needed to remove the lower spark plugs.)
NOTE: When withdrawing the ignition cable lead connection from the plug, care must be
taken to pull the lead straight out and in line with the centerline of the plug barrel;
otherwise, a side load will be applied which frequently results in damage to the barrel
insulator and connector. If the lead cannot be removed easily in this manner, the
resisting contact between the neoprene collar and the barrel insulator will be broken
by a rotary twisting of the collar. Avoid undue distortion of the collar and possible side
loading of the barrel insulator.
(2) Remove the spark plug from the engine. In the course of engine operation, carbon and other
combustion products will be deposited on the end of the spark plug and will penetrate the lower
threads to some degree. As a result, greater torque is frequently required for removing a plug
than for its installation. Accordingly, the torque limitations given do not apply to plug removal,
and sufficient torque must be used to unscrew the plug. The higher torque in removal is not
as detrimental as in installation, since it cannot stretch the threaded section. It does, however,
impose a shearing load on this section and may, if sufficiently severe, produce a failure in this
location.

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PA-34-220T, SENECA IV / V
MAINTENANCE MANUAL

Ignition Schematic
Figure 1

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PA-34-220T, SENECA IV / V
MAINTENANCE MANUAL

(3) Place spark plugs in a tray that will identify their position in the engine as soon as they are
removed.
(4) Removal of seized spark plugs in the cylinder may be accomplished by application of liquid
carbon dioxide by a conical metal funnel adapter with a hole at the apex just large enough to
accommodate the funnel of a C02 bottle. (See Figure 2.) When a seized spark plug cannot be
removed by normal means, the funnel adapter is placed over and around the spark plug. Place
the funnel of the C02 bottle inside the funnel adapter and release the carbon dioxide to chill and
contract the spark plug. Break the spark plug loose with a wrench. A warm cylinder head at the
time the carbon dioxide is applied will aid in the removal of an excessively seized plug.
(5) Do not allow foreign objects to enter the spark plug hole.
B. Installation
CAUTION: Do not install a spark plug that has been dropped.
Before installing spark plugs, ascertain that the threads within the cylinder are clean and not
damaged.
(1) Apply anti-seize compound sparingly on the threads and install gasket and spark plugs. Torque
300 to 360 inch-pounds.
CAUTION: Make certain the deep socket is properly seated on the spark
plug hexagon. the plug could be damaged if the wrench is off
center when pressure is applied.
(2) Carefully insert the terminal insulator in the spark plug and tighten the coupling unit.
C. Inspection and Cleaning
Good spark plug maintenance is necessary for engines to operate efficiently. Plugs should be as
clean as possible; mechanically sound; exhibit enough electrode for additional use; exhibit properly
gapped and contoured electrodes; and, pass necessary tests for electrical soundness. For further
information not included herein, contact the spark plug manufacturer for further information.
(1) Visually inspect each spark plug for the following non-repairable defects:
(a) Terminal barrel sleeve cracked.
(b) Badly battered or rounded shell hexagons.
(c) Threads at top of shielding badly nicked or corroded.
(d) Connector seat badly nicked or corroded.
(e) Chipped, cracked, or broken ceramic insulators in the firing end or shielding barrel.
(f) Badly eroded or disfigured electrodes. See Figure 3.
(2) Clean the spark plug as follows:
NOTE: Do not use carbon tetrachloride to degrease spark plugs except if using vapor degrease
method. Do not soak plugs in solvent and ensure solvent does not enter shielding barrel.
(a) Degrease the spark plugs as required. Refer to manufacturers information for specific
requirements.
(b) Dry plugs using clean, dry air. Heating in a small oven is often recommended to thoroughly
remove all traces of solvent.
NOTE: If any solvent or oil remains in the firing end, or connector well of the spark plug,
abrasive will pack between the shell and insulator, if abrasive blasting is used.

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PA-34-220T, SENECA IV / V
MAINTENANCE MANUAL

Removing Frozen Spark Plug

Figure 2

(c) Clean the firing end terminal well. There are different machines (vibrators, abraisive
blasters, etc.) and methods capable of accomplishing this task. Contact the manufacturer
if necessary to determine the appropriate procedures and materials. To prevent flashover,
all foreign matter, moisture, and stains should be removed from the terminal well insulator..
(d) Set electrode gaps as specified by the spark plug manufacturers specification.

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PA-34-220T, SENECA IV / V
MAINTENANCE MANUAL

FINE WIRE ELECTRODE MASSIVE ELECTRODE

NORMAL ELECTRODE CONDITION

INSULATOR TIP GRAY, TAN OR LIGHT BROWN
FEW COMBUSTION DEPOSITS
ELECTRODES NOT BURNED OR ERODED
PROPER TYPE AND HEAT RANGE PLUG FOR
ENGINE AND SERVICE.
SPARK PLUG SHOULD BE CLEANED, REGAPPED
AND TESTED BEFORE REINSTALLTION

NORMAL WORN-OUT CONDITION

ELECTRODES ERODED BY HIGH VOLTAGE

SPARKING AND BY CORROSIVE GASES
FORMED DURING COMBUSTION TO LESS THAN
1/2 ORIGINAL THICKNESS
MORE VOLTAGE NEEDED TO FIRE SPARK
PLUGS - OFTEN MORE THAN IGNITION
SYSTEM CAN PRODUCE.
REPLACE WITH NEW APPROVED AVIATION
SPARK PLUGS.

SEVERE WORN-OUT CONDITION

EXCESSIVELY ERODED CENTER AND GROUND

ELECTRODES PLUS EXTENSIVE NECKING OF
FINE WIRE GROUND ELECTRODES INDICATE
ABNORMAL ENGINE POWER OR PLUGS
LONG OVERDUE FOR REPLACEMENT.
DISCARD SPARK PLUGS AND CHECK HEAT
RANGE BEFORE INSTALLING NEW ONES.
REPLACE WITH NEW APPROVED AVIATION
SPARK PLUGS IN APPROPRIATE HEAT RANGE.

Spark Plug Inspection Criteria

Figure 3

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PA-34-220T, SENECA IV / V
MAINTENANCE MANUAL

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PA-34-220T, SENECA IV / V
MAINTENANCE MANUAL

End of Section

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