Continental SPARK IGNITED ENGINES MAINTENANCE MANUAL

STANDARD PRACTICE

MAINTENANCE

MANUAL

SPARK IGNITED ENGINES

Technical Portions Accepted by the Federal Aviation Administration

Publication M-0, Revision 1 CHANGE 3

2023 CONTINENTAL AEROSPACE TECHNOLOGIES, INC. JAN 2023

Supersedure Notice

This manual incorporates maintenance and service information contained in Continental Aerospace Technologies™ Service Documents common to the horizontally opposed, spark ignition, aviation gasoline (AvGas) engines conforming to Type Certificate held by Continental Motors, Inc. This document is supplemental to the Instructions for Continued Airworthiness provided in the manuals listed in Section 1-1.1. Instructions contained in the Service Documents listed in Section 1-2.4 are superseded by instructions in this manual upon release, except for those Mandatory Service Bulletins (MSBs) and Critical Service Bulletins (CSBs) linked to Airworthiness Directives.

Effective Changes for this Manual

0 ..... 15 September 2019

1 ...........1 February 2021

2 ............26 August 2021

3 ............ 6 January 2023

List of Effective Pages

Document Title: Standard Practice Maintenance Manual Publication Number: M-0 Initial Publication Date: 15 September 2019

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Published and printed in the U.S.A. by Continental Motors, Inc. dba Continental Aerospace Technologies

Available exclusively from the publisher: P.O. Box 90, Mobile, AL 36601

Copyright © 2019, 2021, 2023 Continental Aerospace Technologies, Inc. All rights reserved. This material may not be reprinted, republished, broadcast, or otherwise altered without the publisher's written permission. This manual is provided without express, statutory, or implied warranties. The publisher will not be held liable for any damages caused by or alleged to be caused by use, misuse, abuse, or misinterpretation of the contents. Content is subject to change without notice. Other products and companies mentioned herein may be trademarks of the respective owners.

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™

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Preface

This manual was developed in accordance with Title 14, Code of Federal Regulations (CFR) Part 33, §33.4 as the Instructions for Continued Airworthiness (ICA) for Standard Practices.

Continental Motors, Inc. provides ICAs based on the design, testing, and certification of engines and parts. Continental Motors, Inc. is the holder of the Type Certificate (TC) or Parts Manufacture Approval (PMA) issued by the Federal Aviation Administration (FAA). Instructions in Continental manuals, which include maintenance, repair limits, and overhaul instructions, are

applicable only to Continental Aerospace Technologies™ (Continental®) engines and parts.

Except for authorized owner preventive maintenance (defined in Title 14, Code of Federal Regulations (CFR) Part 43 §§43.3 and 43.13), Continental ICAs are written for exclusive use by FAA (or equivalent authority) licensed mechanics or FAA (or equivalent authority) certified repair station employees.

Information and instructions contained in this manual anticipate the user possesses and applies the knowledge, training, and experience commensurate with the requirements to meet the prerequisite FAA license and/or certification requirements. No other use is authorized. It is the responsibility of the owner to verify the mechanic or facility operating, maintaining, or servicing the engine uses the most current ICA, including manual change pages, service documents, and FAA Airworthiness Directives (ADs), to perform those functions.

Aftermarket parts installed on a Continental engine constitutes a deviation from type-design criteria. Continental has not participated in design, test, or certification of any aftermarket parts. Continental does not provide product manufacturing specifications to aftermarket parts manufacturers and accepts no liability for the suitability, durability, longevity, or safety of such parts installed on Continental engines. Installation of aftermarket parts on a Continental engine must be performed using ICAs prepared by the manufacturer and found acceptable by the FAA for the subject installation. Continental ICAs must not be used for such parts.

WARNING

Ensure you have the latest revision of this manual, any applicable change pages, FAA Airworthiness Directives and Continental service documents prior to commencing engine service, inspection, maintenance, or overhaul.

To facilitate the use of current data, Continental provides the latest information on the Continental web site (http://www.continental.aero). This information (applicable to current versions) includes an index of manuals, links to active service documents, FAA Airworthiness Directives, and other information applicable to the ICAs. Additionally, Continental technical publications (the current version in electronic or printed format) are available through our publications distributor, Aircraft Technical Publishers (ATP) (www.atp.com). Refer to “Related Publications” in Section 1-2.5. for additional information about service subscriptions and ATP contact information (see Table 1-2).

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Table of Contents

TABLE OF CONTENTS

Chapter 1. Introduction

1-1. Scope and Purpose of This Manual.............................................................................................. 1-1

1-1.1. Instructions for Continued Airworthiness........................................................................... 1-1

1-1.2. Advisories ........................................................................................................................... 1-3

1-1.3. Effectivity Symbols ............................................................................................................ 1-3

1-1.4. Using this Manual............................................................................................................... 1-4

1-1.5. Compliance......................................................................................................................... 1-6

1-1.6. Order of Precedence ........................................................................................................... 1-7

1-2. Publications .................................................................................................................................. 1-7

1-2.1. Publication Access.............................................................................................................. 1-7

1-2.2. Publication Changes ........................................................................................................... 1-7

1-2.3. Update/Change Distribution ...............................................................................................1-8

1-2.4. Service Documents ........................................................................................................... 1-10

1-2.4.1. Service Documents Incorporated in this Manual.................................................... 1-11

1-2.4.2. Service Documents Released After Publication ..................................................... 1-13

1-2.5. Related Publications ......................................................................................................... 1-15

1-2.5.1. Suggestions and Corrections................................................................................... 1-15

1-3. Contact Information ................................................................................................................... 1-16

1-4. Service Parts............................................................................................................................... 1-16

1-4.1. Service Part Applicability and Availability....................................................................... 1-16

1-4.2. Part Supersedure ............................................................................................................... 1-16

Chapter 2. Tools

2-1. Special Tools ................................................................................................................................ 2-1

2-1.1. Vendor Contact Information ...............................................................................................2-7

2-2. Mechanic’s Tools ....................................................................................................................... 2-24

Chapter 3. Lubricants, Sealants, and

Adhesives

3-1. Engine Oil Specifications............................................................................................................. 3-1

3-1.1. Oil Brand Selection ............................................................................................................ 3-1

3-2. Oil Change Intervals .................................................................................................................... 3-3

3-3. Additives ...................................................................................................................................... 3-3

3-4. Sealant, Lubricant, and Adhesive Applications............................................................................ 3-4

3-4.1. General Sealant Application Instructions ..........................................................................3-11

3-4.1.1. Four Cylinder Engine Crankcase Threading........................................................... 3-12

3-4.1.2. Six Cylinder Engine Crankcase Threading............................................................. 3-14

3-4.2. Scavenge Pump Body Sealant and Threading.................................................................. 3-18

3-4.3. Oil Pump Assembly Sealant and Threading ..................................................................... 3-19

3-4.4. Starter Adapter Assembly Sealant and Threading ............................................................ 3-23

3-4.5. Starter Adapter Accessory Drive Cover Sealant and Threading....................................... 3-24

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Chapter 4. Airworthiness Limitation Section

Chapter 5.Engine Removal & Installation

5-1. Engine Removal ........................................................................................................................... 5-1

5-1.1. Tools and Consumable Supplies ......................................................................................... 5-1

5-1.2. Engine Removal Procedure ................................................................................................5-1

5-2. Engine Installation........................................................................................................................ 5-2

5-2.1. Common Tools and Consumable Supplies .........................................................................5-2

5-2.2. Engine Receipt and Handling .............................................................................................5-3

5-2.3. Uncrating the Engine ..........................................................................................................5-3

5-2.4. Crating an Engine for Shipping .......................................................................................... 5-3

5-2.5. Acceptance Inspection ........................................................................................................ 5-3

5-2.6. Engine Transport................................................................................................................. 5-4

5-2.7. Engine Installation Procedures ...........................................................................................5-4

5-2.8. Engine Adjustments and Component Replacement by OEMs and STC Converters.......... 5-5

5-2.9. Engine Pre-oiling ................................................................................................................ 5-7

Chapter 6. Engine Inspection and Service

6-1. Engine Inspection Introduction ....................................................................................................6-1

6-2. Inspection and Maintenance Schedule ......................................................................................... 6-1

6-3. Time Between Overhaul............................................................................................................... 6-1

6-4. Scheduled Inspections .................................................................................................................. 6-5

6-4.1. One Time Post - Installation Inspections............................................................................6-6

6-4.2. 25-Hour Initial Operation Inspection..................................................................................6-6

6-4.3. 50-Hour Engine Inspection................................................................................................. 6-8

6-4.4. 100-Hour (Annual) Engine Inspection ............................................................................... 6-9

6-4.5. 500-Hour Engine Inspection............................................................................................. 6-11

6-4.6. Visual Inspection............................................................................................................... 6-12

6-4.7. Engine Operational Check ................................................................................................6-14

6-4.7.1. Fuel Injection System Specifications ......................................................................6-15

6-4.7.2. Maintenance Preflight Inspection............................................................................ 6-20

6-4.7.3. Oil Pump Operational Check .................................................................................. 6-22

6-4.7.4. Fuel System Operational Check.............................................................................. 6-23

6-4.7.5. Magneto RPM Drop Check..................................................................................... 6-31

6-4.7.6. Engine Shutdown .................................................................................................... 6-32

6-4.8. Engine Oil Servicing......................................................................................................... 6-33

6-4.8.1. Check and Replenish Engine Oil Level ..................................................................6-33

6-4.8.2. Oil Change and Filter/Screen Replacement ............................................................ 6-49

6-4.8.3. Check for Oil Leaks ................................................................................................ 6-52

6-4.8.4. Oil Sample Collection ............................................................................................. 6-52

6-4.8.5. Oil Trend Monitoring and Spectrographic Oil Analysis......................................... 6-53

6-4.9. Ignition System Maintenance ........................................................................................... 6-54

6-4.9.1. Ignition Timing ....................................................................................................... 6-54

6-4.9.2. Spark Plug Maintenance.......................................................................................... 6-62

6-4.9.3. Ignition Harness Maintenance.................................................................................6-66

6-4.10. Engine Adjustments........................................................................................................ 6-68

6-4.10.1. Oil Pressure Adjustment........................................................................................ 6-68

6-4.10.2. Fuel System Adjustment ....................................................................................... 6-70

6-4.10.3. Manifold Pressure Adjustment.............................................................................. 6-91

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6-4.10.4. Belt Tension Check and Adjustment .................................................................... 6-96

6-4.11. Cylinder Inspections..................................................................................................... 6-102

6-4.11.1. Cylinder Visual Inspection.................................................................................. 6-103

6-4.11.2. Differential Pressure Test.................................................................................... 6-105

6-4.11.3. Cylinder Borescope Inspection ........................................................................... 6-113

6-4.11.4. Cylinder to Crankcase Mounting Deck Inspection............................................. 6-117

6-4.11.5. Baffle Inspection ................................................................................................. 6-118

6-4.11.6. Cowling Inspection ............................................................................................. 6-122

6-4.12. Crankcase Inspection.................................................................................................... 6-122

6-4.12.1. Crankcase Critical Stress Areas .......................................................................... 6-125

6-4.13. Engine Mount Inspection.............................................................................................. 6-129

6-4.14. Induction System Inspection ........................................................................................ 6-129

6-4.15. Ignition System Inspection ........................................................................................... 6-131

6-4.15.1. Impulse Coupling Functional Check................................................................... 6-133

6-4.15.2. Starting Vibrator Functional Check .................................................................... 6-134

6-4.15.3. Magneto Drive Coupling Inspection................................................................... 6-134

6-4.16. Engine Gauge Inspection.............................................................................................. 6-135

6-4.17. Fuel System Inspection................................................................................................. 6-136

6-4.18. Throttle and Mixture Control Lever Inspection............................................................ 6-137

6-4.19. Engine Control Linkage Inspection.............................................................................. 6-139

6-4.20. Induction System Drain Inspection .............................................................................. 6-141

6-4.20.1. Induction System Drain Inspection (Naturally Aspirated Engines).................... 6-142

6-4.20.2. Induction System Drain Inspection (Turbocharged Engines)............................. 6-143

6-4.21. Turbocharger and Exhaust System Inspection.............................................................. 6-144

6-4.21.1. Turbocharger Oil Supply Check Valve Inspection ............................................. 6-149

6-4.22. Alternator Inspection .................................................................................................... 6-153

6-4.22.1. Alternator Drive Coupling Inspection ................................................................ 6-154

6-4.22.2. Alternator Drive Coupling Inspection ................................................................ 6-155

6-5. Unscheduled Maintenance ....................................................................................................... 6-158

6-5.1. Propeller Strike ............................................................................................................... 6-158

6-5.1.1. Propeller Strike Inspection.................................................................................... 6-158

6-5.2. Hydraulic Lock Inspection ............................................................................................. 6-159

6-5.3. Engine Overspeed Inspections........................................................................................ 6-160

6-5.3.1. Category I Overspeed Inspection.......................................................................... 6-161

6-5.3.2. Category II Overspeed Inspection......................................................................... 6-161

6-5.3.3. Category III Overspeed Inspection ....................................................................... 6-162

6-5.4. Turbocharger Overboost................................................................................................. 6-162

6-5.5. Lightning Strike Inspection ............................................................................................ 6-162

6-5.6. Contaminated Fuel System Inspection ........................................................................... 6-163

6-5.7. Foreign Object Contamination Inspection...................................................................... 6-163

6-5.8. Sticking or Stuck Valves................................................................................................. 6-164

6-6. Inspection Checklists ............................................................................................................... 6-166

Chapter 7. Engine Operation

7-1. Introduction .................................................................................................................................. 7-1

7-2. Flight Prerequisites....................................................................................................................... 7-1

7-2.1. Oil Change Interval ............................................................................................................ 7-1

7-2.2. Engine Fuel Requirements.................................................................................................. 7-2

7-2.3. Engine Operation after Cylinder Replacement and/or Major Overhaul............................. 7-6

7-2.4. Flight Check and Break-In ................................................................................................. 7-8

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7-2.4.1. Engine Break-In ........................................................................................................7-8

7-2.4.2. Flight Check .............................................................................................................. 7-9

7-3. Normal Operation.......................................................................................................................7-18

7-3.1. Pre-operational Requirements........................................................................................... 7-18

7-3.2. Engine Start....................................................................................................................... 7-19

7-3.2.1. Cold Start................................................................................................................. 7-20

7-3.2.2. Flooded Engine ....................................................................................................... 7-20

7-3.2.3. Hot Start .................................................................................................................. 7-21

7-3.3. Ground Run-up .................................................................................................................7-22

7-3.4. Engine Shutdown.............................................................................................................. 7-24

7-4. Engine Operation in Abnormal Environments ........................................................................... 7-25

7-4.1. Engine Operation in Extreme Cold................................................................................... 7-25

7-4.1.1. Engine Preheating ................................................................................................... 7-26

Chapter 8. Troubleshooting

8-1. General Troubleshooting.............................................................................................................. 8-2

8-1.1. General Troubleshooting for Engines equipped with a Carburetor.................................... 8-2

8-1.2. General Troubleshooting for Engines with Continental Continuous Flow Fuel Injection

Systems .........................................................................................................................................8-3

8-1.3. Engine Runs Rough ............................................................................................................ 8-4

8-1.3.1. Engine Runs Rough (equipped with Carburetor)...................................................... 8-4

8-1.3.2. Engine Runs Rough (equipped with Continental Continuous Flow Fuel Injection Sys-

tem).........................................................................................................................................8-5

8-1.4. Engine Will Not Run........................................................................................................... 8-6

8-1.5. Engine Indication Malfunctions.......................................................................................... 8-7

8-1.6. Engine Performance Malfunctions ..................................................................................... 8-8

8-2. Induction System.......................................................................................................................... 8-9

8-2.1. Engine Will Not Start.......................................................................................................... 8-9

8-2.2. Engine Will Not Run......................................................................................................... 8-10

8-2.3. Engine Lacks Power/Manifold Pressure Low (Naturally Aspirated Models) .................. 8-10

8-2.4. Engine Lacks Power/Manifold Pressure Low (Turbocharged Models)............................ 8-11

8-3. Continental Continuous Flow Fuel Injection System.................................................................8-12

8-3.1. Engine Will Not Start........................................................................................................ 8-12

8-3.2. Fluctuating or Erroneous Fuel Flow ................................................................................. 8-13

8-3.3. Poor Acceleration.............................................................................................................. 8-13

8-3.4. Fuel Injector Operational Check....................................................................................... 8-14

8-4. Charging System ........................................................................................................................8-16

8-5. Starting System...........................................................................................................................8-16

8-6. Ignition System........................................................................................................................... 8-17

8-6.1. Ignition Harness and Spark Plug Diagnostics................................................................... 8-18

8-7. Lubrication System.....................................................................................................................8-19

8-8. Engine Cylinders ........................................................................................................................ 8-21

8-9. Crankcase ................................................................................................................................... 8-23

8-9.1. Excess Crankcase Pressure ............................................................................................... 8-24

8-10. Turbocharger and Exhaust System ...........................................................................................8-25

8-10.1. Freeing Turbine Shafts Dragging or Frozen by Corrosion ............................................. 8-26

8-10.2. Oil Leaking from Turbocharger...................................................................................... 8-27

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Chapter 9. Engine Preservation and Storage

9-1. Preserving and Storing an Engine................................................................................................ 9-1

9-1.1. Engine Preservation Checklist............................................................................................9-1

9-1.2. New or Unused Engine Storage.......................................................................................... 9-1

9-1.3. Installed Engine, Temporary Storage ................................................................................. 9-1

9-1.4. Installed Engine, Indefinite Storage ................................................................................... 9-3

9-1.5. Crated Engine, Indefinite Storage ...................................................................................... 9-4

9-1.6. Return an Engine to Service after Storage.......................................................................... 9-6

9-2. Turbocharger Preservation and Storage ....................................................................................... 9-8

9-2.1. Short Term Storage (on shelf)............................................................................................. 9-8

9-2.2. Short Term Storage (on aircraft) .........................................................................................9-8

9-2.3. Long Term Storage (on shelf) .............................................................................................9-8

9-2.4. Long Term Storage (on aircraft) ......................................................................................... 9-8

9-2.5. Shelf Life ............................................................................................................................ 9-8

9-2.6. Turbocharger Pre-Lubrication (not installed) ..................................................................... 9-9

9-2.7. Turbocharger Pre-Lubrication (on aircraft) ........................................................................ 9-9

Chapter 10.Non-Overhaul Repair and

Replacement

10-1. Parts Replacement.................................................................................................................... 10-1

10-2. Fuel Injector Replacement ....................................................................................................... 10-3

10-2.1. Nozzle Identification ...................................................................................................... 10-3

10-2.2. Fuel Injector Removal (Turbocharged Engines) ............................................................ 10-4

10-2.3. Fuel Injector Installation (Turbocharged Engines)......................................................... 10-4

10-2.4. Fuel Injector Removal (Naturally Aspirated Engines) ................................................... 10-6

10-2.5. Fuel Injector Installation (Naturally Aspirated Engines)................................................ 10-6

10-3. Induction Drain Connector Replacement................................................................................. 10-8

10-3.1. Induction Drain Connector Removal and Cleaning ....................................................... 10-8

10-3.2. Induction Drain Connector Installation .......................................................................... 10-8

10-4. Alternator Replacement............................................................................................................ 10-9

10-4.1. Gear Driven Alternator Replacement, Forward Mount ................................................ 10-9

10-4.1.1. Gear Driven Alternator Removal ......................................................................... 10-9

10-4.1.2. Alternator Drive Coupling Removal .................................................................. 10-11

10-4.1.3. Alternator Drive Coupling Installation .............................................................. 10-11

10-4.1.4. Alternator Drive Coupling Slippage Inspection ................................................. 10-12

10-4.1.5. Gear Driven Alternator Installation ................................................................... 10-13

10-4.2. Gear Driven Alternator Replacement, Aft Mount ....................................................... 10-14

10-4.2.1. Gear Driven Alternator Removal ....................................................................... 10-14

10-4.2.2. Alternator Drive Hub Removal .......................................................................... 10-16

10-4.2.3. Alternator Drive Hub Installation ...................................................................... 10-16

10-4.2.4. Gear Driven Alternator Installation ................................................................... 10-18

10-4.3. Alternator Service Instructions ..................................................................................... 10-19

10-5. Magneto Replacement............................................................................................................ 10-21

10-5.1. Continental Magneto Removal..................................................................................... 10-21

10-5.2. Continental Magneto Installation ................................................................................. 10-22

10-5.3. Champion (Slick) Magneto Removal ........................................................................... 10-24

10-5.4. Champion (Slick) Magneto Installation ....................................................................... 10-25

10-5.5. Magneto Filter Replacement ........................................................................................ 10-27

10-5.5.1. Continental Magneto Filter Replacement ........................................................... 10-27

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10-5.5.2. Champion (Slick) Magneto Filter Replacement..................................................10-29

10-6. Cylinder Repairs..................................................................................................................... 10-31

10-6.1. Cylinder Replacement................................................................................................... 10-32

10-6.1.1. Cylinder Removal ............................................................................................... 10-32

10-6.1.2. Cylinder Installation............................................................................................ 10-34

10-6.1.3. Cylinder Torque .................................................................................................. 10-37

10-6.2. Cylinder Position Numbers........................................................................................... 10-38

10-6.3. Cylinder Head Repair ................................................................................................... 10-38

10-6.4. Cylinder Fin Tip Repair................................................................................................ 10-39

10-6.5. Cylinder Bore Inspection ..............................................................................................10-39

10-6.6. Cylinder Barrel Repair.................................................................................................. 10-39

10-6.7. Cylinder Bore Honing................................................................................................... 10-40

10-6.8. Cylinder Stud Replacement .......................................................................................... 10-41

10-6.9. Spark Plug Heli-coil Replacement................................................................................ 10-42

10-6.10. Cylinder Protective Coatings ...................................................................................... 10-43

10-6.11. Cylinder Bore and Piston Fit Specifications............................................................... 10-44

10-6.12. Legacy Product Replacement Valves.......................................................................... 10-53

10-7. Crankcase Repair.................................................................................................................... 10-56

10-8. Piston Replacement ................................................................................................................ 10-56

10-9. Crankshaft Repair................................................................................................................... 10-57

10-9.1. Crankshaft Counterweight Inspection and Repair ........................................................ 10-57

10-9.1.1. Crankshaft Counterweight Removal ................................................................... 10-76

10-9.1.2. Counterweight Identification............................................................................... 10-77

10-9.1.3. Crankshaft Counterweight Inspection................................................................. 10-82

10-9.1.4. Crankshaft Counterweight Bushing Bore Inspection.......................................... 10-83

10-9.1.5. Crankshaft Counterweight Bushing Replacement .............................................. 10-85

10-9.1.6. Crankshaft Hanger Blade Bushing Inspection ....................................................10-88

10-9.2. Oil Control Plug Replacement...................................................................................... 10-90

10-9.3. Crankshaft Plating Overhaul......................................................................................... 10-92

10-9.4. Connecting Rod Replacement ......................................................................................10-93

10-9.4.1. Connecting Rod Dimensional Inspection............................................................ 10-93

10-9.4.2. Connecting Rod Piston Pin Bushing Replacement ............................................. 10-98

10-9.4.3. Connecting Rod Piston Pin Bushing Boring..................................................... 10-100

10-10. Crankshaft Nose Oil Seal Replacement .............................................................................10-101

10-10.1. Solid Nose Oil Seal Removal ................................................................................... 10-101

10-10.2. Solid Nose Oil Seal Installation................................................................................ 10-102

10-10.3. Split Nose Oil Seal Removal .................................................................................... 10-104

10-10.4. Split Type Nose Oil Seal Installation ........................................................................ 10-104

10-11. Exhaust Flange to Cylinder Installation ............................................................................. 10-106

10-12. Lubrication System Maintenance....................................................................................... 10-108

10-12.1. Oil Filters Adapters................................................................................................... 10-108

10-12.2. Oil Filter Adapter Stud Replacement........................................................................ 10-110

10-12.3. Lubrication System Priming ..................................................................................... 10-112

10-12.3.1. Alternate Priming Method 1(470, 520, 550 engines only).............................. 10-112

10-12.3.2. Alternate Priming Method 2............................................................................ 10-112

10-13. Crankcase Breather System Maintenance .......................................................................... 10-114

Chapter 11. Non-Destructive Inspection

11-1. Visual Inspection ...................................................................................................................... 11-1

11-1.1. Gear Tooth Inspection..................................................................................................... 11-2

11-2. Fluorescent Penetrant Inspection.............................................................................................. 11-3

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11-3. Magnetic Particle Inspection.....................................................................................................11-4

11-3.1. Connecting Rod Magnetic Particle Inspection ................................................................11-6

11-4. Ultrasonic Inspection.................................................................................................................11-7

11-4.1. Ultrasonic Inspection Certification..................................................................................11-7

11-4.2. Crankshaft Ultrasonic Inspection ....................................................................................11-8

Chapter 12. Engine Cleaning

12-1. Engine and Component Cleaning............................................................................................. 12-1

12-1.1. Cylinder Cleaning........................................................................................................... 12-6

12-1.2. Piston Cleaning............................................................................................................... 12-7

12-1.3. Cleaning Exhaust Parts................................................................................................... 12-8

12-1.4. Cleaning Aluminum Alloy Parts..................................................................................... 12-8

12-2. Dry Blasting ............................................................................................................................. 12-9

12-3. Vapor Blasting .......................................................................................................................... 12-9

12-4. Protective Coatings ................................................................................................................ 12-10

12-4.1. Alodine.......................................................................................................................... 12-10

12-4.2. Aviation Oil................................................................................................................... 12-10

12-4.3. Paint ...............................................................................................................................12-11

Appendix A.Glossary

A-1. Abbreviations/Acronyms.............................................................................................................A-1

A-2. Terms and Definitions .................................................................................................................A-3

Appendix B.Torque Specifications

B-1. General Information ....................................................................................................................B-1

B-1.1. Torque Tips ........................................................................................................................B-2

B-2. Part Supersedure..........................................................................................................................B-3

B-3. Torque Wrench and Extension Calculations................................................................................B-4

Appendix C.Maintenance Standards

C-1. Handling Parts .............................................................................................................................C-1

C-2. Replacement Parts .......................................................................................................................C-3

C-2.1. Background ........................................................................................................................C-3

C-2.2. Acceptable Replacement Parts...........................................................................................C-3

C-2.2.1. Know Your Supplier ................................................................................................C-3

C-2.3. 100% Parts Replacement Requirements ............................................................................C-4

C-2.4. Mandatory Overhaul Replacement Parts ...........................................................................C-5

C-2.5. Authorized Oversize/Undersize Parts ................................................................................C-8

C-2.6. Special Instructions............................................................................................................C-8

C-2.7. Engine Data Plate Replacement.........................................................................................C-8

C-2.7.1. Removal and Installation of Engine Data Plate........................................................C-8

C-3. Safety Wiring Hardware............................................................................................................C-10

C-4. Tab Washer Installation .............................................................................................................C-12

C-5. Heli-Coil® Insert Replacement.................................................................................................C-13

C-5.1. Heli-Coil Removal ...........................................................................................................C-14

C-5.2. Heli-Coil Insertion ...........................................................................................................C-15

C-6. Stud Replacement......................................................................................................................C-16

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C-6.1. Stud Removal .................................................................................................................. C-16

C-6.1.1. Size-on-Size Rosan® Stud Removal..................................................................... C-16

C-6.1.2. Step-Type Rosan® Stud Removal......................................................................... C-17

C-6.2. Stud Installation .............................................................................................................. C-18

C-6.2.1. Rosan® Stud Installation....................................................................................... C-19

C-7. Cotter Pin Installation ............................................................................................................... C-20

C-8. Fuel System Service ................................................................................................................. C-21

C-8.1. Fuel System Purge........................................................................................................... C-21

C-9. Gasket Maker® Application..................................................................................................... C-22

C-10. Gasket Installation .................................................................................................................. C-23

C-10.1. Crush Washer Installation ............................................................................................. C-23

C-11. Hose and Tubing Installation .................................................................................................. C-24

C-12. Harness Routing...................................................................................................................... C-25

C-13. Plug and Fitting Removal ....................................................................................................... C-25

LIST OF TABLES

Table 1-1. Service Documents Incorporated in Manual .............................................. 1-11

Table 1-2. Related Publications ...................................................................................1-15

Table 2-1. Special Tools List .........................................................................................2-1

Table 2-2. Tools, Accessories, and Supply Vendors ..................................................... 2-7

Table 2-3. Common Tools ...........................................................................................2-24

Table 3-1. Qualified SAE J1899 Ashless Dispersant Engine Oil .................................. 3-2

Table 3-2. Qualified SAE J1966 Non-Dispersant Mineral Oil ......................................3-2

Table 3-3. Break-in Oil ..................................................................................................3-2

Table 3-4. Preservative Oil ............................................................................................3-2

Table 3-5. Sealants .........................................................................................................3-4

Table 3-6. Lubricants .....................................................................................................3-5

Table 3-7. Adhesives .....................................................................................................3-8

Table 3-8. Miscellaneous ...............................................................................................3-9

Table 5-1. Authorized Adjustments and Replacements ................................................5-6

Table 6-1. Engine Time Between Overhaul (TBO) .......................................................6-3

Table 6-2. Engine Inspection and Maintenance Schedule .............................................6-5

Table 6-3. Engine Operation Prerequisites ..................................................................6-14

Table 6-4. Fuel System Adjustment Values ................................................................6-15

Table 6-5. Static Ground Setup Compensation Table ................................................. 6-19

Table 6-6. IO-240-A, B With Standard Fuel Pump .....................................................6-20

Table 6-7. Magneto Timing Specifications - Geared Engines ....................................6-54

Table 6-8. Magneto Timing Specifications - Direct Drive Engines ............................ 6-54

Table 6-9. Spark Plug Application Chart ....................................................................6-63

Table 6-10. Spark Plug Rotation Chart .......................................................................... 6-65

Table 6-11. IO-360-D/DB Engine Altitude Leaning Schedule .....................................6-84

Table 6-12. IO-360-ES Engine Altitude Leaning Schedule ..........................................6-85

Table 6-13. IO-360-ES (Cirrus SR20) Engine Altitude Leaning Schedule ................... 6-86

Table 6-14. IO-550-A Engine Altitude Leaning Schedule ............................................6-87

Table 6-15. IO-550-B Engine Altitude Leaning Schedule ............................................ 6-88

Table 6-16. IO-550-C Engine Altitude Leaning Schedule ............................................ 6-89

Table 6-17. IO-550-D, E, F, & L Engine Altitude Leaning Schedule ...........................6-90

Table 6-18. VAPC Parameters ...................................................................................... 6-95

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Table 6-19. Cylinder Inspection Tasks and References ...............................................6-102

Table 6-20. Additional Cylinder Service Document References .................................6-102

Table 6-21. Differential Pressure Test Results ............................................................6-111

Table 6-22. Borescope Inspection Objectives and Corrective Actions .......................6-114

Table 6-23. Crankcase Casting Numbers .....................................................................6-122

Table 6-24. Exhaust Inspection Criteria ......................................................................6-144

Table 6-25. Overspeed Categories ...............................................................................6-160

Table 6-26. Engine Operational Checklist ...................................................................6-167

Table 6-27. 25-Hour Initial Operation Inspection Checklist .......................................6-169

Table 6-28. 50-Hour Engine Inspection Checklist ......................................................6-171

Table 6-29. 100-Hour Engine Inspection Checklist ....................................................6-173

Table 6-30. 500-Hour Engine Inspection Checklist ....................................................6-175

Table 6-31. Cylinder Inspection Checklist ..................................................................6-177

Table 7-1. Aviation Fuel Specifications ........................................................................7-3

Table 7-2. Authorized Fuels by Engine Model ..............................................................7-3

Table 7-3. IO-360-D/DB Engine Altitude Leaning Schedule .....................................7-11

Table 7-4. IO-360-ES Engine Altitude Leaning Schedule ..........................................7-12

Table 7-5. IO-360-ES (Cirrus SR20) Engine Altitude Leaning Schedule ...................7-13

Table 7-6. IO-550-A Engine Altitude Leaning Schedule ............................................7-14

Table 7-7. IO-550-B Engine Altitude Leaning Schedule ............................................7-15

Table 7-8. IO-550-C Engine Altitude Leaning Schedule ............................................7-16

Table 7-9. IO-550-D, E, F, & L Engine Altitude Leaning Schedule ...........................7-17

Table 9-1. Engine Preservation Checklist ......................................................................9-7

Table 10-1. Non-Overhaul Parts Replacement Reference .............................................10-1

Table 10-2. Parts Repair Reference ...............................................................................10-2

Table 10-3. Parts Handling Guidelines ..........................................................................10-2

Table 10-4. Alternator Drive Coupling Slippage .........................................................10-12

Table 10-5. Alternator Cross Reference ......................................................................10-20

Table 10-6. Cylinder Repair vs. Replacement Guidelines ...........................................10-31

Table 10-7. Cylinder Bore Surface Finish Specifications ...........................................10-41

Table 10-8. 5.250 Inch Cylinder Barrel Dimensions ...................................................10-45

Table 10-9. 5.250 Inch Cylinder Barrel Dimensions ...................................................10-46

Table 10-10. 5.250 Inch Piston to Cylinder Clearance ..................................................10-46

Table 10-11. 5.250 Inch Piston to Cylinder Clearance ..................................................10-46

Table 10-12. 5.250 Inch Piston to Cylinder Clearance ..................................................10-46

Table 10-13. 5.000 Inch Cylinder Barrel Dimensions ...................................................10-47

Table 10-14. 5.000 Inch Piston to Cylinder Clearance ..................................................10-47

Table 10-15. 5.000 Inch Piston to Cylinder Clearance ..................................................10-47

Table 10-16. 4.438 Inch Cylinder Barrel Dimensions ...................................................10-48

Table 10-17. 4.438 Inch Piston to Cylinder Clearance ..................................................10-48

Table 10-18. 4.062 Inch Cylinder Barrel Dimensions ...................................................10-49

Table 10-19. 4.062 Inch Piston to Cylinder Clearance ..................................................10-49

Table 10-20. Ring Gap Specifications ...........................................................................10-50

Table 10-21. Ring Gap Specifications ...........................................................................10-51

Table 10-22. Ring Gap Specifications ...........................................................................10-51

Table 10-23. Ring Gap Specifications ...........................................................................10-51

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Table 10-24. Ring Gap Specifications ...........................................................................10-51

Table 10-25. Engine to Piston Cross Reference ............................................................10-52

Table 10-26. Engines Serial Number Applicability ......................................................10-53

Table 10-27. Replacement Components for Low Compression Ratio Cylinders .........10-54

Table 10-28. Cylinder Part Number Conversion ........................................................... 10-54

Table 10-29. Engine Power Train .................................................................................. 10-58

Table 10-30. Crankshaft Assembly Part Number History .............................................10-65

Table 10-31. Crankshaft Assemblies ............................................................................. 10-70

Table 10-32. Crankshaft Hanger Blade Bushing Sizes .................................................10-73

Table 10-33. Wide Rod Crankshaft ...............................................................................10-74

Table 10-34. Counterweight Supersedure .....................................................................10-76

Table 10-35. Counterweight Bushing Bore Dimensions ............................................... 10-84

Table 10-36. Counterweight Bushing Bore Dimensions ............................................... 10-87

Table 10-37. Counterweight Hanger Blade Bushing Dimensions .................................10-89

Table 10-38. Crankshaft Oil Plug Installation Specifications .......................................10-90

Table 10-39. Connecting Rod Specifications ................................................................10-96

Table 10-40. Exhaust Gaskets, Nuts, and Nut Torque Values .................................... 10-107

Table 11-1. Parts Requiring Fluorescent Penetrant Inspection .....................................11-3

Table 11-2. Magnetic Particle Inspection Reference .....................................................11-5

Table 11-3. Connecting Rod Magnetic Particle Inspection Criteria .............................. 11-6

Table 11-4. Crankshaft Ultrasonic Inspection Pass/Fail Action ....................................11-8

Table 12-1. Aircraft Engine Parts Cleaning Guidelines ................................................ 12-2

Table 12-2. Cleaning Tips ............................................................................................. 12-5

Table 12-3. Painting External Parts .............................................................................12-11

Table B-1. Appendix B, Quick Table Reference .......................................................... B-1

Table B-2. Component Specific Torque Specifications ................................................ B-6

Table B-3. Specific Torque Specifications (Non-Lubricated Hardware) .................... B-13

Table B-4. FADEC Components (Non-Lubricated Hardware) ................................... B-13

Table B-5. General Torque Specifications .................................................................. B-14

Table B-6. Hydraulic Line Torque Specifications ...................................................... B-14

Table B-7. Straight Thread Fitting Torque Specifications .......................................... B-15

Table B-8. Hose Fitting (“B” Nut) Torque Specifications .......................................... B-15

Table C-1. Mandatory Overhaul Replacement Parts ..................................................... C-5

Table C-2. Rosan® Stud Primary & Secondary Bore Specifications ......................... C-17

Table C-3. High Strength Sealant and Adhesive Part Numbers .................................. C-25

LIST OF FIGURES

Figure 1-1. Figure and Index Reference .........................................................................1-5

Figure 1-2. Change Page Identification ..........................................................................1-8

Figure 1-3. List of Effective Pages .................................................................................1-9

Figure 2-1. Model E2M Differential Pressure Tester (built in Master Orifice Tool) .....2-9

Figure 2-2. Borescope (Autoscope®) .............................................................................2-9

Figure 2-3. Pulley Alignment Tool ...............................................................................2-10

Figure 2-4. Porta-Test Model 20 ATM-C .....................................................................2-10

Figure 2-5. Gear Driven Alternator Drive Hub Torque Tool .......................................2-11

Figure 2-6. Alternator Drive Hub Torque Tool ............................................................2-12

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Figure 2-7. Worm Shaft Tool and Starter Adapter Disassembly Tool ..........................2-12

Figure 2-8. Oil Control Plug Installation Tool - 360 Engines .......................................2-13

Figure 2-9. Oil Control Plug Installation Tool - 470 Engines .......................................2-13

Figure 2-10. Oil Control Plug Installation Tool - 520/550 Permold Engines .................2-14

Figure 2-11. Oil Control Plug Installation Tool - 470/520/550 Sandcast Engines .........2-14

Figure 2-12. Oil Control Plug Leak Test Fixture ............................................................2-15

Figure 2-13. Needle Bearing Installation Tool - Part 1 ...................................................2-16

Figure 2-14. Needle Bearing Installation Tool - Part 2 ...................................................2-17

Figure 2-15. Bearing Installation Tool ............................................................................2-18

Figure 2-16. Crankcase Needle Bearing Installation Tool, Permold ..............................2-19

Figure 2-17. Crankcase Needle Bearing Installation Tool, Sandcast ..............................2-19

Figure 2-18. Valve Guide Seal Installation Tool ............................................................2-20

Figure 2-19. O-Ring Installation Tool .............................................................................2-21

Figure 2-20. Oil Seal Tool ...............................................................................................2-21

Figure 2-21. Helical Coil Extraction Tool ......................................................................2-22

Figure 2-22. Helical Coil Insertion Tool .........................................................................2-22

Figure 2-23. Helical Coil Expanding Tool ......................................................................2-23

Figure 2-24. Rosan® Stud Removal Tool .......................................................................2-23

Figure 3-1. Anti-Seize Lubricant Application ...............................................................3-11

Figure 3-2. Fuel Injection Sealant Application .............................................................3-11

Figure 3-3. Crankcase Threading Diagram - C75, C85, C90, O200 .............................3-13

Figure 3-4. Crankcase Threading Diagram - O240, IO240, IOF240 ............................3-13

Figure 3-5. Crankcase Threading Diagram - O300 .......................................................3-15

Figure 3-6. Crankcase Threading Diagram - IO360, L/TSIO360 .................................3-15

Figure 3-7. Crankcase Threading Diagram - 520/550 Permold ....................................3-16

Figure 3-8. Crankcase Threading Diagram - 470/520/550 Sandcast ............................3-16

Figure 3-9. Crankcase Threading Diagram - GTSIO520 ..............................................3-17

Figure 3-10. Scavenge Pump Body Threading Diagram ................................................3-18

Figure 3-11. Oil Pump Assembly Threading Diagram ...................................................3-19

Figure 3-12. Oil Pump Assembly Threading Diagram ...................................................3-20

Figure 3-13. Oil Pump Assembly Threading Diagram ...................................................3-21

Figure 3-14. Oil Pump Assembly Threading Diagram ...................................................3-22

Figure 3-15. Oil Pump Assembly Threading Diagram ...................................................3-22

Figure 3-16. Starter Adapter Assembly Threading Diagram ..........................................3-23

Figure 3-17. Accessory Drive Cover Threading Diagram ..............................................3-24

Figure 6-1. Part No. MS51523-B4 Swivel Tee .............................................................6-25

Figure 6-2. Porta-Test Model 20 ATM-C .....................................................................6-26

Figure 6-3. Typical Naturally Aspirated Fuel System Schematic .................................6-27

Figure 6-4. Typical Naturally Aspirated Fuel System Schematic .................................6-27

Figure 6-5. Typical Turbocharged Fuel System Schematic ..........................................6-28

Figure 6-6. Typical Turbocharged Fuel System Schematic ..........................................6-28

Figure 6-7. C-75, C-85, C-90 & O-200-A Oil Servicing Points, typical ......................6-34

Figure 6-8. O-200-D & X Oil Servicing Points, typical ...............................................6-34

Figure 6-9. IO-240-B Oil Servicing Points, typical ......................................................6-35

Figure 6-10. IO-360 Oil Servicing Points, typical ..........................................................6-36

Figure 6-11. IO-360-AF/ES Oil Servicing Points, typical ..............................................6-37

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Figure 6-12. TSIO-360 Oil Servicing Points, typical .....................................................6-38

Figure 6-13. O-470 Oil Servicing Points, typical ...........................................................6-39

Figure 6-14. IO-470/TSIO-470 Oil Servicing Points, typical ......................................... 6-40

Figure 6-15. GTSIO-520 Oil Servicing Points, typical ..................................................6-41

Figure 6-16. IO-550-A, B & C Oil Servicing Points, typical .........................................6-42

Figure 6-17. IO-550-D, E & F Oil Servicing Points, typical ..........................................6-43

Figure 6-18. IO-550-G & N Oil Servicing Points, typical ..............................................6-44

Figure 6-19. IO-550-L Oil Servicing Points, typical ......................................................6-45

Figure 6-20. IO-550-P Oil Servicing Points, typical ......................................................6-46

Figure 6-21. IO-550-R Oil Servicing Points, typical ......................................................6-47

Figure 6-22. TSIO-550 Oil Servicing Points, typical .....................................................6-48

Figure 6-23. 1000 Micron Stainless Steel Oil Strainer ...................................................6-49

Figure 6-24. Suction Screen Oil Types and Part Numbers .............................................6-50

Figure 6-25. O-200 28° BTC Timing .............................................................................6-56

Figure 6-26. O-200 24° BTC Timing .............................................................................6-56

Figure 6-27. Timing Disk and TDC Locator Installed ....................................................6-57

Figure 6-28. No. 1 Cylinder Positioned at Top of Intake Stroke ....................................6-58

Figure 6-29. Crankshaft Positioned at TDC ....................................................................6-58

Figure 6-30. Cylinder No. 1 Top of Compression Stroke ............................................... 6-59

Figure 6-31. No. 1 Cylinder Full Advance Firing Position ............................................6-60

Figure 6-32. Spark Plug Inspection Criteria ...................................................................6-62

Figure 6-33. Lubricate Ignition Wire with MS-122AD, only where shown ...................6-66

Figure 6-34. Elbow Kit Assembly ..................................................................................6-67

Figure 6-35. Oil Pressure Relief Valve Adjustment Screw Locations ...........................6-69

Figure 6-36. Fuel Pump, Naturally Aspirated Engine without 

Integral Mixture Control ............................................................................6-72

Figure 6-37. Fuel Pump, Naturally Aspirated Engine with Integral Mixture Control ....6-72

Figure 6-38. Throttle and Metering Assembly ................................................................6-73

Figure 6-39. Throttle and Control Assembly, Front View ..............................................6-73

Figure 6-40. Throttle and Control Assembly, Side View ...............................................6-74

Figure 6-41. Altitude Compensating Fuel Pump (Auto-Lean),

Naturally Aspirated Engine (without adjustable orifice) ...........................6-77

Figure 6-42. Altitude Compensating Fuel Pump (Auto-Lean),

Naturally Aspirated Engine (with adjustable orifice) ................................6-77

Figure 6-43. Aneroid Equipped Fuel Pump, Turbocharged Engine ............................... 6-78

Figure 6-44. Aneroid and Mixture Control Equipped Fuel Pump, 

Turbocharged Engine .................................................................................6-78

Figure 6-45. Fuel Pressure Regulator, Turbocharged Engine ......................................... 6-80

Figure 6-46. Altitude Leaning Schedule Adjustment Example ......................................6-82

Figure 6-47. Altitude Leaning after Correction .............................................................. 6-83

Figure 6-48. IO-360-D/DB Altitude Leaning Schedule ..................................................6-84

Figure 6-49. IO-360-ES Altitude Leaning Schedule ......................................................6-85

Figure 6-50. IO-360-ES in Cirrus SR20 Altitude Leaning Schedule .............................6-86

Figure 6-51. IO-550-A Altitude Leaning Schedule ........................................................ 6-87

Figure 6-52. IO-550-B Altitude Leaning Schedule ........................................................6-88

Figure 6-53. IO-550-C Altitude Leaning Schedule ........................................................6-89

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Figure 6-54. IO-55-D, E, F & L Altitude Leaning Schedule ..........................................6-90

Figure 6-55. Fixed Wastegate, typical ............................................................................6-92

Figure 6-56. Fixed Wastegate (TSIO-520-T), typical .....................................................6-93

Figure 6-57. Sloped Controller, typical ...........................................................................6-94

Figure 6-58. Variable Absolute Pressure Controller .......................................................6-95

Figure 6-59. Air Conditioning Compressor Belt Tensioning ..........................................6-96

Figure 6-60. Optional Compressor Belt Tensioning, typical ..........................................6-97

Figure 6-61. Alternator Belt Tensioning .........................................................................6-98

Figure 6-62. 85 Amp Alternator Belt Adjustment ..........................................................6-99

Figure 6-63. Front Mount Belt Driven Alternator .........................................................6-100

Figure 6-64. Aft Mounted Alternator Belt Tension Adjustment ...................................6-101

Figure 6-65. Cylinder Power Stroke Areas ...................................................................6-103

Figure 6-66. Model E2M Differential Pressure Tester .................................................6-107

Figure 6-67. Differential Pressure Test Equipment Usage ............................................6-109

Figure 6-68. Normal Combustion Chamber ..................................................................6-115

Figure 6-69. Burned Exhaust Valve ..............................................................................6-115

Figure 6-70. Phosphate-Coated Cylinder with Revised Hone Pattern ..........................6-115

Figure 6-71. Phosphate-Coated Cylinder with Corrosion .............................................6-115

Figure 6-72. Cylinder Barrel Scoring and Piston Rub ..................................................6-116

Figure 6-73. Typical Wear in Upper Ring Travel .........................................................6-116

Figure 6-74. Typical Cylinder Wear .............................................................................6-116

Figure 6-75. Improperly Positioned Baffle Seals ..........................................................6-118

Figure 6-76. Improperly Positioned Baffle Seals ..........................................................6-119

Figure 6-77. Improperly Positioned Aft and Side Peripheral Baffle Seals ...................6-119

Figure 6-78. Improperly Positioned Aft and Side Peripheral Baffle Seals ...................6-120

Figure 6-79. Aft and Side Baffles with Air Gaps ..........................................................6-120

Figure 6-80. Cooling Loss Due to Gaps in Baffle Seals ...............................................6-121

Figure 6-81. Cooling Loss Due to Gaps in Baffle Seals ...............................................6-121

Figure 6-82. Crack in Non-Critical Area of Crankcase, typical ....................................6-124

Figure 6-83. O-200 Engine Crankcase ..........................................................................6-125

Figure 6-84. IO/IOF-240 Engine Crankcase .................................................................6-126

Figure 6-85. O-300 Engine Crankcase ..........................................................................6-126

Figure 6-86. IO/LTSIO/TSIO-360 Series Engine Crankcase .......................................6-127

Figure 6-87. 520/550 Permold Engine Crankcase ........................................................6-127

Figure 6-88. 470/520/550 Sandcast Engine Crankcase .................................................6-128

Figure 6-89. GTSIO-520 Engine Crankcase .................................................................6-128

Figure 6-90. Induction Tube Bead Location .................................................................6-130

Figure 6-91. Properly Installed Induction Tube, Hose and Clamps ..............................6-130

Figure 6-92. Serviceable Throttle/Mixture Control Lever & Shaft Splines ..................6-137

Figure 6-93. Worn Throttle and Mixture Control Lever & Shaft Splines .....................6-138

Figure 6-94. Throttle and Control Assembly Lubrication Points ..................................6-140

Figure 6-95. Throttle and Metering Assembly Lubrication Points ...............................6-140

Figure 6-96. Induction Port Drain Connectors ..............................................................6-141

Figure 6-97. Exhaust Slip joint Inspection ....................................................................6-145

Figure 6-98. V-band Clamp Inspection .........................................................................6-145

Figure 6-99. Wastegate Lubrication Points, typical ......................................................6-147

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Figure 6-100. Check Valve, Detail .................................................................................6-150

Figure 6-101. Single Turbocharger Lubrication (check valve location), typical ............6-150

Figure 6-102. Dual Turbocharger (check valve location), typical .................................. 6-151

Figure 6-103. Check Valve Functional Check ................................................................6-152

Figure 6-104. Alternator Drive Coupling .......................................................................6-155

Figure 6-105. Alternator and Coupling Assembly ..........................................................6-157

Figure 7-1. IO-360-D/DB Altitude Leaning Schedule ..................................................7-11

Figure 7-2. IO-360-ES Altitude Leaning Schedule ......................................................7-12

Figure 7-3. IO-360-ES in Cirrus SR20 Altitude Leaning Schedule .............................7-13

Figure 7-4. IO-550-A Altitude Leaning Schedule ........................................................ 7-14

Figure 7-5. IO-550-B Altitude Leaning Schedule ........................................................7-15

Figure 7-6. IO-550-C Altitude Leaning Schedule ........................................................7-16

Figure 7-7. IO-55-D, E, F & L Altitude Leaning Schedule ..........................................7-17

Figure 10-1. Fuel Injector Nozzle Identification, typical ................................................10-3

Figure 10-2. Turbo Fuel Injector Nozzle Assembly, typical ..........................................10-5

Figure 10-3. Naturally Aspirated Engine Fuel Injector Nozzles ....................................10-7

Figure 10-4. Alternator and Drive Coupling ................................................................. 10-10

Figure 10-5. Alternator Drive Hub Spanner Wrench .................................................... 10-12

Figure 10-6. Alternator and Drive Hub ......................................................................... 10-15

Figure 10-7. Alternator and Drive Hub ......................................................................... 10-15

Figure 10-8. Multi-Part Alternator Drive Hub ..............................................................10-17

Figure 10-9. One Piece Alternator Drive Hub ..............................................................10-17

Figure 10-10. Continental Ignition System .....................................................................10-23

Figure 10-11. Champion (Slick) Ignition System ........................................................... 10-26

Figure 10-12. Continental Pressurized Magneto Filter, typical ......................................10-28

Figure 10-13. Champion (Slick) Pressurized Magneto Filter, typical ............................10-30

Figure 10-14. Cylinder Base O-Ring supporting Connecting Rods ...............................10-33

Figure 10-15. Cylinder Base (Flange) Fasteners ............................................................10-35

Figure 10-16. Cylinder Torque Sequence .......................................................................10-37

Figure 10-17. Cylinder Position Number Location ........................................................10-38

Figure 10-18. NiC3 Cylinder Bore Cross Hatch .............................................................10-41

Figure 10-19. 5.250 Inch Cylinder Measurement Locations ..........................................10-45

Figure 10-20. 5.000 Inch Cylinder Measurement Locations ..........................................10-47

Figure 10-21. 4.438 Inch Cylinder Measurement Locations ..........................................10-48

Figure 10-22. 4.062 Inch Cylinder Measurement Locations ..........................................10-49

Figure 10-23. Ring Gap Measurement Location ............................................................10-50

Figure 10-24. Intake Valve Angle ...................................................................................10-55

Figure 10-25. Part No. 530864 Counterweight Assembly ..............................................10-77

Figure 10-26. Part No. 531017 Counterweight Assembly ..............................................10-77

Figure 10-27. Part No. 639196 Counterweight Assembly ..............................................10-78

Figure 10-28. Part No. 639197 Counterweight Assembly ..............................................10-78

Figure 10-29. Part No. 639195 Counterweight Assembly ..............................................10-79

Figure 10-30. Part No. 639199 Counterweight Assembly ..............................................10-79

Figure 10-31. Part No. 652833 Counterweight Assembly ..............................................10-80

Figure 10-32. Part No. 627821 Counterweight Assembly ..............................................10-80

Figure 10-33. Part No. 639205 and 639210 Counterweight Assemblies ........................10-81

Figure 10-34. Crankshaft Counterweight Bump Service Inspection ..............................10-82

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Figure 10-35. Counterweight Bushing Bore Inspection ..................................................10-84

Figure 10-36. Counterweight Inspection, Repair and Installation ..................................10-86

Figure 10-37. GTSIO-520 Counterweight Inspection, Repair and Installation ..............10-87

Figure 10-38. Crankshaft Hanger Blade Bushing Replacement .....................................10-89

Figure 10-39. Crankshaft Oil Control Plug Leak Test ....................................................10-91

Figure 10-40. Crankshaft Helix Pattern ..........................................................................10-92

Figure 10-41. Connecting Rod Dimensions ....................................................................10-95

Figure 10-42. Retainer Plate and Screws on Front of Crankcase ..................................10-101

Figure 10-43. Crankshaft Nose Oil Seal Parts ..............................................................10-102

Figure 10-44. Split Nose Oil Seal Parts ........................................................................10-105

Figure 10-45. Plug Part No. 641614 in Early Oil Filter Adapters ................................10-108

Figure 10-46. Modified, Old, and New Oil Filter Adapter Housings ...........................10-109

Figure 10-47. Oil Filter Adapter Studs Incorporating an Incomplete Thread ...............10-110

Figure 10-48. Oil Filter Adapter Stud Extension Height ..............................................10-110

Figure 10-49. Oil Filter Adapter Housing .....................................................................10-111

Figure 11-1. Gear Inspection Criteria .............................................................................11-2

Figure 11-2. Crankshaft Ultrasonic Inspection Method Location ...................................11-8

Figure B-1. Torque Wrench ............................................................................................ B-4

Figure B-2. Drive Extensions ......................................................................................... B-4

Figure B-3. Adjusted Torque Wrench Setting ................................................................ B-4

Figure B-4. Extension, Increases Adjusted Torque Wrench Setting .............................. B-5

Figure B-5. Extension, Decreases Adjusted Torque Wrench Setting ............................. B-5

Figure C-1. Right-Hand Thread Safety Wire Installation ............................................. C-10

Figure C-2. Safety Wire Patterns for Right-Hand Threads ........................................... C-11

Figure C-3. Tab Washer Installation ............................................................................. C-12

Figure C-4. Heli-Coil Extraction Tool .......................................................................... C-14

Figure C-5. Installing a Helical Coil Insert ................................................................... C-15

Figure C-6. Rosan® Stud Removal ..............................................................................C-17

Figure C-7. Stud Sizes .................................................................................................. C-18

Figure C-8. Minimum Material Thickness for Helical Coil insertion .......................... C-18

Figure C-9. Rosan® Stud Installation Dimensions ....................................................... C-19

Figure C-10. Cotter Pin Installation ................................................................................ C-20

Figure C-11. Installing Hoses and Fittings .....................................................................C-24

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xviii Standard Practice Maintenance Manual CHANGE 2 26 Aug 2021

Chapter 1. Introduction

1-1. Scope and Purpose of This Manual

This manual provides maintenance instructions for spark ignition, piston aircraft engines operating on aviation gasoline (AvGas). These Instructions for Continued Airworthiness (ICAs) are supplied to the owner with the engine. Instructions in this manual are standard practices, with differences identified by model, for A-65, A-75, C-75, C-85, C-90, C-125, C145, E-165, E-185, E-225, O-200, O-240, IO-240, IOF-240, GO-300, O-300, IO-346, IO360, LTSIO-360, TSIO-360, O-470, IO-470, TSIO-470, GTSIO-520, IO-520, LTSIO-520, TSIO-520, IO-550, IOF-550, TSIO-550, TSIOF-550, TSIOL-550 and TIARA (6-285 and 6-

320) series aircraft engines. For information specific to the Continental engine series, accessories, or the airplane, refer to the appropriate manual. For the specific instructions regarding the electronic equipment on FADEC engines, or for unlisted engine models, refer to the primary ICA.

A list of tools for all applicable engines is provided in Chapter 2. Consumables items, such as lubricants, sealants, and adhesives are listed in Chapter 3. Airworthiness limitations are in Chapter 4. Chapter 5 contains generic installation instructions applicable to our engines. Chapter 6 provides schedule inspection and service intervals and instructions, as well as unscheduled maintenance instructions. Chapter 7 contains general engine operating instructions, applicable to all models. Chapter 8 contains engine troubleshooting instructions. Engine preservation and storage instructions are in Chapter 9. Non-overhaul engine part replacement instructions are in Chapter 10. Chapter 11 contains NonDestructive Inspection guidelines. Chapter 12 contains part cleaning instructions. Appendix A contains a glossary of common terms and acronyms used throughout the manual; Appendix B provides torque specifications, and Appendix C contains maintenance standards.

Introduction

1-1.1. Instructions for Continued Airworthiness

CAUTION: Instructions in Continental document number



M-0, Standard Practice Maintenance Manual, do not apply and shall not be used to maintain Continental Prime or Titan engine products.

Continental document Part No. M-0, is supplemental, as defined by Title 14 CFR§33.4, to the maintenance and overhaul manuals listed below. Together, this manual and those listed below comprise the instructions for continued airworthiness for applicable engines. This manual, and the overhaul manuals and component service manuals (as applicable to engine specification) listed below are delivered to the customer with the engine. Service documents and Airworthiness Directives may also affect ICAs. Refer to Section 1-2.5 for instructions to check current publication status.

Part No. Title Applicability

M-2 Maintenance and Overhaul Manual O-200-D, X

M-6 Maintenance and Overhaul Manual IO-240

M-7 Maintenance and Overhaul Manual IO-360

M-8 Maintenance and Overhaul Manual L/TSIO-360

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Introduction

M-11 Maintenance Manual IO-520 Permold M-16 Maintenance and Overhaul Manual IO-550 Permold M-18 Maintenance and Overhaul Manual TSIO-550 Permold M-22 Maintenance and Overhaul Manual IOF-240 M-24 Maintenance Manual M-26 Maintenance and Overhaul Manual TSIOF-550 M-34 Maintenance and Overhaul Manual GTSIO-520-S OH-15 Overhaul Manual TSIOL-550-C OH-24 Overhaul Manual IOF-550 OMI-15 Operation, Maintenance and TSIOL-550-C

X30008 Overhaul Manual A-65, A-75 X30010 Overhaul Manual C-75, C,85, C90, O-200-A, B X30013 Overhaul Manual C-125, C-145, O-300 X30016 Overhaul Manual E-165, E-185, E-225 X30019 Overhaul Manual GO-300 X30027 Overhaul Manual IO-346 X30033 Overhaul Manual TSIO-470 X30039 Overhaul Manual IO-520 X30045 Overhaul Manual GTSIO-520-C, D, H, K, L,

X30092 Overhaul Manual O-240 (Rolls-Royce) X30144 Overhaul Manual TIARA 6-285 and 6-320 X30531 Alternator Service Instructions Continental alternators X30574 Overhaul Manual TSIO-520-B, BB, BE, D, DB,

X30575 Overhaul Manual LTSIO-520-AE

X30586 Overhaul Manual O-470-A, B, E, G, J, K, L, M

X30588 Overhaul Manual IO-470-C, D, E, F, G, H, J, K,

X30592 Starter Service Instructions Energizer® starters X30600 Overhaul Manual TSIOL-550-A X30601 Maintenance and Operator’s Manual TSIOL-550-A X30605 Maintenance Manual IO-550-D, E, F & L X30607 Overhaul Manual IO-550-D, E, F & L

IOF-550-A, B, C, G, N, P & R

Installation Manual

M, N 

DB, E, EB, J, JB, K, KB, L,  LB, N, NB, U, UB, VB,  WB Permold series

TSIO-520-C, CE, G, H, M, P, R, T, AE, AF Sandcast series

R, S, U

L, M, N, P, R, S, U, V, VO

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1-1.2. Advisories

FWDFWD

AFTAFT

EZREZR

SKYSKY

This manual utilizes three types of advisories; defined as follows:

A warning emphasizes information which, if disregarded, could result in severe injury to personnel or equipment failure.

CAUTION: Emphasizes certain information or instructions, which if disregarded, may result in damage to the engine or accessories.

NOTE: Provides special interest information, which may facilitate performance of a procedure or operation of equipment.

Warnings and cautions precede the steps to which they apply; notes are placed in the manner which provides the greatest clarity. Warnings, cautions, and notes do not impose undue restrictions. Failure to heed advisories will likely result in the undesirable or unsafe conditions the advisory was intended to prevent. Advisories are inserted to ensure maximum safety, efficiency, and performance. Abuse, misuse, or neglect of equipment can cause eventual engine malfunction or failure.

1-1.3. Effectivity Symbols

Variations in engine configuration may require specific instructions or illustrations. When information pertains to only a subset of the applicable engine models, an effectivity symbol will precede the information. Effectivity symbols found in this publication are:

Introduction

WARNING

Forward Mounted Gear Driven Alternator

Aft Mounted Gear Driven Alternator

Energizer Starter

SkyTec Starter

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Introduction

1-1.4. Using this Manual

This manual, the primary engine ICA listed in Section 1-1.1, applicable FAA ADs and Continental service documents, the accessory manuals listed in Table 1-2, and all changes incorporated in the ICAs as revisions constitute the Instructions for Continued Airworthiness (ICAs) prepared by Continental and accepted by the FAA. We prepared this manual in a user-friendly format suited equally for electronic viewing and print. Illustrations in this manual are for reference only, depicting the most prominent configuration in the engine series. Consult the electronic illustrated parts catalog for engine model-specific illustrated parts breakdowns. The current information available from Continental must be used to perform engine service, repair or overhaul.

Continental provides Instructions for Continued Airworthiness based on the design, testing, and certification of engines and parts for which Continental Motors, Inc. is the holder of the Type Certificate (TC) or Parts Manufacture Approval (PMA) issued by the Federal Aviation Administration (FAA).

Continental ICAs are applicable only to Continental engines conforming to the approved, type certified engine model configuration. Continental ICAs must not be used for aftermarket parts or products modified by Supplemental Type Certificate.

WARNING

Installation of aftermarket parts on a Continental engine constitutes a deviation from typedesign criteria. Continental has not participated in design, test, or certification of any aftermarket parts. Continental does not provide product manufacturing specifications to aftermarket parts manufacturers and accepts no liability for the suitability, durability, longevity, or safety of such parts installed on Continental engines. Installation of aftermarket parts on a Continental engine must be performed using Instructions for Continued Airworthiness prepared by the manufacturer and approved by the FAA for the subject installation. For work with the engine installed in the aircraft, the aircraft maintenance manual may also be required to gain access to, perform maintenance, or install some items. Use only the current information from the aircraft manufacturer.

Exploded assembly illustrations accompany instructions throughout the manual. Parts in illustrations (Figure 1-1) are identified with either alpha or numerical callouts (indexes). Corresponding parts listings follow the illustrations for reference. The first time instructions refer to an illustration, the figure number is identified in parentheses, followed by the callout. In subsequent parts references, only the callout will be specified unless the referenced illustration changes.

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Introduction

Figure 1-1. Figure and Index Reference

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Introduction

1-1.5. Compliance

The owner/operator is responsible for ensuring the engine is maintained in an airworthy condition, including compliance with FAA Airworthiness Directives. Engine service life is calculated based on compliance with the aircraft and engine manufacturer’s required instructions, inspections, and maintenance schedule. Failure to comply may void the engine warranty.

Prior to authorizing engine maintenance, the owner must ensure the facility or mechanic meets the Federal Aviation Administration (or equivalent authority) regulatory requirements. The engine owner must verify the repair facility or mechanic uses the most current revision, including change pages of the applicable ICA. Use of Instructions for Continued Airworthiness which have been designated as obsolete, superseded, or inactive is prohibited.

Continental ICAs are written for use by maintenance personnel who possess and apply the knowledge, training, and experience commensurate with persons holding a valid license or certification granted by the governing airworthiness authority to return the engine to an airworthy condition. No other use is authorized.

WARNING

Failure to comply with ICAs may result in personal injury, death and subsequent engine failure. Each person performing maintenance, alteration or preventive maintenance on an engine or accessory must use methods, techniques and practices set forth in the Instructions for Continued Airworthiness or other methods, techniques, and practices found acceptable to the Administrator.

This manual shall be used in conjunction with the latest revision of FAA Advisory Circular 43.13-1, “Acceptable Methods, Techniques, and Practices” as well as related publications and accessory manufacturer’s instructions. Pursuant to Title 14 CFR Part 43,

§43.13(a), each person performing maintenance, alteration, or preventive maintenance on the engine or accessories must use methods, techniques, and practices prescribed in the ICAs or other methods, techniques, and practices found acceptable by the Administrator.

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1-1.6. Order of Precedence

Continental engine operating instructions are generated prior to and independently of the aircraft operating instructions. Continental operating instructions are developed using factory controlled parameters that are not necessarily the same as those specifications required to satisfy a specific aircraft/engine installation.

The aircraft operator must use the aircraft manufacturer’s operating instructions found in the Airplane Flight Manual/ Pilot’s Operating Handbook (AFM/POH) and applicable Airplane Flight Manual Supplements (AFMS) while operating the engine in the aircraft unless the AFM/POH directs otherwise.

Refer to the AFM/POH published by the aircraft manufacturer for operating instructions and specifications relative to your aircraft.

Prior to commencing engine maintenance, consult the Continental web site (www.continental.aero) to verify the current status of the ICAs relating to the intended procedure.

Introduction

WARNING

1-2. Publications

This most current approved version of this manual is delivered to the customer at time of purchase. This manual and all subsequent revisions or changes are published in Adobe portable document format (PDF) and available to view or download from Aircraft Technical Publishers (ATP) web site (www.atp.com).

1-2.1. Publication Access

Printed technical publications may be ordered through Continental technical publications distributor, Aircraft Technical Publishers (ATP). Contact an ATP customer service representative to discuss service subscription options and pricing or visit their web site (www.atp.com).

1-2.2. Publication Changes

Use only the latest revision of all publications. Using superseded information may jeopardize engine airworthiness. Service documents, published by the manufacturer, or Airworthiness Directives, published by the FAA, may alter or provide supplemental information to the Maintenance and Overhaul Manual. Verify and use only the current versions of all instructions.

WARNING

The instructions in this manual represent the best and most complete information available at the time of publication. Product or process improvements may trigger changes to existing product design specifications or procedures contained in publications. As new technical information becomes available, Continental will make the information available to the customer.

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Introduction

Continental releases publication changes in the form of either change pages or complete publication revisions, depending upon the extent of change.

Continental issues service documents in the form of Service Bulletins on a wide variety of topics. Some service documents may affect or supplement information in this manual and should be reviewed prior to performing maintenance. All active service documents applicable to standard maintenance practices have been incorporated in these instructions as of the date of publication.

1-2.3. Update/Change Distribution

Document updates are available on our web site upon notification of FAA document acceptance/approval. Printed publication subscribers receive printed changes and revisions as they are released.

Figure 1-2. Change Page Identification

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