Continental SPARK IGNITED ENGINES MAINTENANCE MANUAL

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Page 1

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

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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 Instructions contained in the Service Documents listed in Section 1-2.4 are superseded by instructions in this manual upon release, except for those Mandatory Service Bulletins (MSBs) and Critical Service Bulletins (CSBs) linked to Airworthiness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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Table of Contents

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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Intentionally Left Blank

xviii Standard Practice Maintenance Manual CHANGE 2 26 Aug 2021

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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

1-2 CHANGE 3

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Page 25

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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Introduction

Document revisions are released if the update changes more than 50% of the contents of a publication. Revisions replace the previous version of a publication from cover to cover. Minor corrections are released as change pages to the original publication, identified with a change number and effective change date in the page footer. Information on the page that changed from the previous edition is identified by a vertical, six-point black line (Figure 1-2), referred to as a “change bar” in the outside margin of the page.

A change page replaces only the previous edition of the affected page. In the event a change page forces repagination, a new page will be inserted with a decimal extension added to the page number. For example, if additional pages are required between pages 16 and 1-7, the inserted page numbers will be 1-6.1, 1-6.2, and so on until sufficient pages are added to incorporate the new material.

Page A of the manual contains the original publication date and an itemized list of changes issued for the technical manual (Figure 1-3). If change pages are issued for the manual, the change will be identified, with an effective date under the heading “Effective Changes for This Manual” on Page A. The list of effective pages, itemizes the pages in each section, by change number. Original pages are designated by a 0 in the List of Effective Pages “Change” column.

Figure 1-3. List of Effective Pages

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Introduction

1-2.4. Service Documents

Continental may issue Service Documents in one of six categories ranging from mandatory (Category 1) to informational (Category 6). Definitions of the categories are listed below:

NOTE: Upon FAA approval, Continental publishes service documents for immediate availability on our web site. The service document cover page indicates the engine models affected by the service document. Service documents may alter or replace the manufacturer’s Instructions for Continued Airworthiness. Insert a copy of applicable Service Documents in affected manuals until the service document instructions are incorporated in the manual, or the service document is canceled or superseded.

1Procedure

Category 1: Mandatory Service Bulletin (MSB)

Used to identify and correct a known or suspected safety hazard which has been incorporated in whole or in part into an Airworthiness Directive (AD) issued by the FAA or have been issued at the direction of the FAA by the manufacturer requiring compliance with an already-issued AD (or an equivalent issued by another country’s airworthiness authority). May contain updates to Instructions for Continued Airworthiness to address a safety issue.

Category 2: Critical Service Bulletin (CSB)

This category identifies a condition that threatens continued safe operation of an aircraft, persons or property on the ground unless some specific action (inspection, repair, replacement, etc.) is taken by the owner or operator. Documents in this category are candidates for incorporation into an FAA Airworthiness Directive. May contain updates to Instructions for Continued Airworthiness to address a safety issue.

Category 3: Service Bulletin (SB)

Information which the product manufacturer believes may improve the inherent safety of an aircraft or aircraft component; this category includes the most recent updates to Instructions for Continued Airworthiness.

Category 4: Service Information Directive (SID)

The manufacturer directs the owner/operator/mechanic in the use of a product to enhance safety, maintenance or economy. May contain updates to Instructions for Continued Airworthiness in the form of maintenance procedures or specifications.

Category 5: Service Information Letter (SIL)

This category includes all information (not included in categories 1 through 4) that may be useful to the owner/operator/technician. May contain updates to Instructions for Continued Airworthiness for optional component installations, which are not covered in the Applicable Operator, Maintenance, or Overhaul Manuals.

Category 6: Special Service Instruction (SSI)

This category is used to address an issue limited to specific model and/or serial number engines. We will distribute SSI notification directly to the affected engine’s owners. service document set but will be made available through our Customer Service Department to owners of the

affected engines only. An SSI may update the applicable engine’s Instructions for Continued Airworthiness.

SSIs will not be included in the general

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Introduction

1-2.4.1. Service Documents Incorporated in this Manual

Applicable technical maintenance and service information contained in the Service Documents listed below, relevant to the engine models covered by this engine manual, have been incorporated in this M-0, Standard Practice Maintenance Manual. This manual supersedes and retires these Service Documents (and all revisions, where applicable) excluding Mandatory Service Bulletins (MSBs) and Critical Service Bulletins (CSBs) identified with an asterisk (*) in Table 1-1 below.

The full content of active Continental Service Documents is available at www.continental.aero. Refer to Section 1-3, “Contact Information” for Continental web site details.

Table 1-1. Service Documents Incorporated in Manual

Affected

Service Document Subject

M67-12, Overboost of Turbocharged Engines Unscheduled Maintenance 6

M71-21, Procedure for Freeing Turbocharger Turbine Shafts which are Dragging or Frozen by Rust Deposits

Troubleshooting 8

Chapter

M72-17R1, Maximum Weight Difference Between Connecting Rods and Pistons in the Same Engine

M75-7R1, Oil Filter Change Scheduled Maintenance 6

M76-4, Propeller Shaft or Crankshaft Oil Seal Replacement Unscheduled Maintenance 10

M76-8, Intake Valve Change Unscheduled Maintenance 10

M76-20, Oil Filters Scheduled Maintenance 6

M77-3, Use of Alternate Fuels in Engines Originally Certified for 80/ 87, 91/96 and 100/130 Grade Fuels

M81-28R1, Oil Filters Scheduled Maintenance 6

M84-5, Gear Driven Alternator Inspection Procedure Alternator Replacement 10

M85-10, Cylinder Hold Down Nuts Cylinder Replacement 10

M87-15, Alternator Ground Strap Alternator Replacement 10

* M88-4, Pro-Tech Oil FIlter Scheduled Maintenance 6

M88-9, Lightning Strikes Unscheduled Maintenance 6

M88-10, Contaminated Fuels Unscheduled Maintenance 6

M89-7R1, Engine Operation after Cylinder Replacement and/or Major Overhaul

M89-9, Excessive Crankcase Pressure Unscheduled Maintenance 8

M90-17, Crankcase Inspection Criteria Scheduled Maintenance 6

SIL93-11B, Service Document Format Service Documents 1

Parts Replacement 10

Engine Operation 7

Unscheduled Maintenance 7

SIL93-15, General Practices for Installation of Lock Wire, Tab Washers, and Cotter Pins

SB94-2, Oil Filter Adapter Mounting Stud Scheduled Maintenance 6

SIL94-5, Mobil AV1 Oil Engine Oil Specifications 3

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Introduction

Table 1-1. Service Documents Incorporated in Manual

Affected

Service Document Subject

SIL94-5, Mobil AV1 Oil Engine Oil Specifications 3

* MSB94-8D, Magneto to Engine Timing Scheduled Maintenance 6

SB95-2, Inspection and Maintenance of Engine Control Cables and Linkage

SB95-3B, Alternator/Generator Drive Coupling Alternator Maintenance 6, 10

SIL95-5, Hose and Tubing Installation Hose and Tubing Installation Appendix C

SB96-7D, Torque Limits Fastener Torque Appendix B

* MSB96

SB96-11B, Propeller Strikes and Hydraulic Lock Unscheduled Inspection 6

SB96-12, Cylinder Continued Airworthiness Scheduled Inspection 6 & 10

SID97-2B, Design, Operation Maintenance and Warranty of Cylinders

-10B, Crankshaft Ultrasonic Inspection Engine Overhaul or

Inspection 6

Crankshaft Repair

Engine Maintenance 6

Chapter

SID97-3G, Continuous Flow Fuel Injection Systems Adjustment Specifications and Instructions

SID97-4F, Cylinder Bore and Piston Fit Specifications Overhaul & Service Limits 10

SB97-6B, Mandatory Replacement Parts Engine Inspection & Assembly Appendix C

SB97-11, Installation of Single Piece Rocker Assembly Bushings Part Numbers 652129 and 652963

SIL98-9E, Time Between Overhaul Periods Scheduled Maintenance 6

SIL99-1, Engine Preservation for Active and Stored Aircraft Engine Preservation and

SIL99-2C, Sealants, Lubricants and Adhesives Authorized by CMI Materials 3

SB00-3A, Crankshaft, Counterweight and Connecting Rod Repair Information

SIL00-9A, Engine Data Plates Data Plate Replacement Appendix C

SIL00-11B, Release of new Cylinder Induction Port Drain Connector Cylinder Assembly 10

SIL03-1, Cold Weather Operation - Engine Preheating Engine Operation 7

SIL03-2C, Currently Active Approved Spark Plug Application Spark Plugs 6

SB03-3, Differential Pressure Test and Borescope Inspection Inspection Criteria 6

SIL04-12A, Authorized Engine Adjustments, Component Replacement and Repositioning

Operational Checks and Adjustments

Cylinder Repairs 10

Recovery

Repair Specifications 10

Engine Specification 5

SID05-1B, Inspection Guidelines for Camshafts and Hydraulic Lifters Unscheduled Maintenance 6

SB05-2, Overspeed Limitations Unscheduled Maintenance 6

*CSB08-3C, Throttle & Mixture Control Levers Fuel Injection System

Assembly

SB08-13, Induction System Hose and Clamp Installation Induction System Inspection &

Assembly

1-12 CHANGE 3

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Introduction

Table 1-1. Service Documents Incorporated in Manual

Affected

Service Document Subject

SB11-3, Alternator and Drive Coupling Installation Alternator Replacement 6, 10

SIL13-2A, Alternator Instructions for Continued Airworthiness Alternator Replacement 6, 10

SB14-8, Exhaust Flange to Cylinder Installation Exhaust System Installation 10

SB16-3, Turbocharger Check Valve Inspection and Cleaning Exhaust System Inspection 6

SB17-01A, Flanged Nut Inspection and Corrosion Prevention Cylinder Inspection 6

SIL17-02, Turbocharger Check Valve Filter Installation, Inspection, and Cleaning

SIL17-03, Oil Filter Anti-stick Gasket Oil and Filter Change 6

SIL18-01, Rocker Assembly Valve, Exhaust (P/N 658745) Rocker Arm Identification 10

SIL19-04, Oil Brand Selection Oil Servicing 6

SB19-05, Valve Guide Application, Installation, and Reaming Procedures

SIL19-10, Disposable Oil Filter Removal Oil and Filter Change 6

SIL21-04A, Improved Rocker Cover Gasket, Part No. 668893 Cylinder Maintenance 10,

* Documents remain active in the service bulletin set.

Maintenance Criteria 6, 8,

Cylinder Maintenance 10

Chapter

Appendix C

Appendix B

1-2.4.2. Service Documents Released After Publication

Continental strives to provide clear, concise, and accurate information and instructions based on best known engineering data at the time of publication. Ongoing process improvements may change a specification or procedure after a manual is released. Service documents, defined in Section 1-2.4, expedite customer notification until the new information is incorporated in the manual text. As service documents are received, note the service document number, release date, title, and applicable section affected by the service document in the blank cells below and insert a copy of the service document behind the last page of this section. Make pen & ink corrections, where appropriate, to the original text in the manual with a citation to the service document; i.e. see SB9X-1. For paragraphs or entire sections, draw an “X” through the affected information in the manual and reference the service document containing the correction

Service Documents Release After This Manual

Document Number: Release Date:

Title:

Document Number: Release Date:

Title:

Document Number: Release Date:

Title:

Document Number: Release Date:

/ /

Affected Sections:

6 January 2023

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Introduction

Service Documents Release After This Manual

Document Number: Release Date:

Title:

Document Number: Release Date:

Title:

Document Number: Release Date:

Title:

Document Number: Release Date:

Title:

Document Number: Release Date:

Title:

Document Number: Release Date:

Title:

Document Number: Release Date:

Title:

Document Number: Release Date:

/ /

Affected Sections:

Title:

Document Number: Release Date:

Title:

Document Number: Release Date:

Title:

Document Number: Release Date:

Title:

Document Number: Release Date:

Title:

Document Number: Release Date:

Title:

Document Number: Release Date:

Title:

Document Number: Release Date:

Title:

/ /

Affected Sections:

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1-2.5. Related Publications

The table below lists the publications, source, and accessibility relevant to Standard Practice installation, maintenance, and overhaul.

Use only the latest revision of all publications. Using superseded information can jeopardize engine airworthiness.

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

Introduction

WARNING

Supplied

With Engine

Electronic Download

Available

Printed Manual

Available

Document Part

Number (P/N)

Table 1-2. Related Publications

Publication Title

Instructions for Continued Airworthiness

M-0 

s manual)

(thi

Standard Practice Maintenance Manual

Yes Yes Yes

X30531 Alternator Service Support Manual Yes Yes Yes X42001 Magneto Service Support Manual (S-1200 Series) Yes Yes Yes X42002 Magneto Service Support Manual (S-20/200 Series) Yes Yes Yes

Illustrated Parts Catalogs

by Engine Model/

Electronic Engine Product Catalog No Yes (view only) No

Specification

1. Our web site (www.continental.aero) provides daily 24-hour access to current service documents and the technical publications Index. Continental is partnered with Aircraft Technical Publishers (ATP, (www.atp.com) to distribute our technical publications on their subscription web site. If you have not subscribed to ATP and are using printed manuals, verify & confirm you have the latest applicable revision with either a service representative (using the “Contact Information” in Section 1-3) or the Service Document Index.

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

1-2.5.1. Suggestions and Corrections

Continental solicits and encourages user comments regarding suggested changes to this manual. Direct recommended changes or questions to the attention of “Publications” at the address listed in Section 1-3, “Contact Information” or send comments via e-mail to cm.techpubs@continental.aero.

Notify our Customer Service Department immediately if you discover incorrect information which adversely affects safety.

Standard Practice Maintenance Manual 1-15 15 Sep 2019

Page 38

Introduction

1-3. Contact Information

Continental factory representatives are available to answer technical questions and encourages suggestions regarding products, parts, or service. If customers have an inquiry or require technical assistance, they should contact their local Continental distributor or field representative. To contact a factory representative, refer to the contact information below:

Continental Aerospace Technologies P. O. Box 90 Mobile, AL 36601

Customer Service Department: Toll free within the continental United States: 1-888-826-5465 International: 1-251-438-8299

Internet: www.continental.aero

1-4. Service Parts

Continental engineering staff develops a complete bill of materials for every engine model specification manufactured. Due to our diverse customer base of aircraft OEM and STC application builders, engine model specifications are developed to accommodate the aircraft manufacturer’s specifications. While many parts fit multiple engine model specifications, interchangeability of parts from one engine model, or model specification, to another is not guaranteed.

1-4.1. Service Part Applicability and Availability

Major engine assemblies and components are permanently identified (steel stamped, engraved, laser etched, or ink-stamped) with a unique part number during the manufacturing process. The latest revision of the Illustrated Parts Catalogs is available on our web site to locate Continental parts for current production engine model specifications and heritage products (no longer in production).

Some parts of assemblies are not available for aftermarket sale for various reasons. Some assemblies are not intended to be disassembled, such as cylinder heads and barrels. For this reason, only the next higher assembly (NHA) is available for aftermarket sales.

1-4.2. Part Supersedure

Innovation and continuous improvements are core values at Continental. The original part numbers used to manufacture your aircraft engine may or may not be available when replacement parts are needed to restore the engine to an airworthy condition. Due to design improvements to the form, fit, or function of the engine part or assembly, it may be necessary to supersede the older part number (used to build the original engine model specifications) and provide a new replacement part or assembly number.

The simplest way to determine the correct part number can be found by comparing the markings on the existing part(s) to part numbers in the Illustrated Parts Catalog (IPC).

To determine if a part number used to assemble your engine has been superseded, consult the Parts Supersedure History page on our web site.

1-16 Standard Practice Maintenance Manual

15 Sep 2019

Page 39

2-1. Special Tools

NOTE: Special tools listed in Table 2-1 are for reference only, not for the purpose of promoting or requiring the customer to purchase from a particular provider. The providers listed are potential sources for the items based on information available at the time of printing. Customers are free to obtain equivalent items from alternate sources which meet or exceed specifications of the listed tools. For FADEC special tools, reference the primary ICA.



Special tool vendor contact information is listed in Table 2-2.

Tools

Chapter 2. Tools

Table 2-1. Special Tools List

Special Tool Use or Reference Suggested Providers Part Number

Maintenance

0-60 psi Pressure Gauge (graduated in 1-

Engine Operational Check Davis Instruments Various

psi increments) 0-30 psi Pressure

Gauge (graduated in

0.2-psi increments)

Engine Operational Check (normally aspirated engines only)

Davis Instruments Various

0-30 psid Differential Pressure Gauge (graduated in 0.2 psi

Engine Operational Check (turbocharged engines only)

Davis Instruments Various

increments) Alternator Drive Hub

Spanner Wrench Alternator Drive Hub

Torque Tool Alternator Drive Hub

Torque Tool Bearing Installation Tool

(Worm Gear Roller Bearing)

Forward Mounted Alternator Drive Hub Assembly Inspection

Forward Mounted Alternator Drive Hub Slippage Inspection

Aft Mounted Alternator Drive Hub Slippage Inspection

90° offset Starter Adapter Assembly

Ideal Aviation 9001-IA

Fabricate according to Figure 2-5

Fabricate according to Figure 2-6

Fabricate according to Figure 2-15

---

Belt Tension Gage Drive Belt Tension Adjustment Ideal Aviation BT-33-73FIA

AUTOSCOPE

Borescope Cylinder Borescope Inspection Q.A. Technologies

Lenox Instrument Company

Differential Pressure Tester

Cylinder Differential Pressure Test

Digital Multimeter Troubleshooting

High Tension Lead Test Kit

Ignition Harness Troubleshooting

Eastern Technology Corporation

Commercial, off the shelf

Eastern Technology Corporation

Model E2M

---

7/16” Injector Nozzle Removal/Installation

Fuel Injector Removal And Installation Ideal Aviation 8167-IA

Tool

Standard Practice Maintenance Manual 2-1 1 Feb 2021 CHANGE 1

Page 40

Tools

Table 2-1. Special Tools List

Special Tool Use or Reference Suggested Providers Part Number

1/2” Injector Nozzle Removal/Installation

Fuel Injector Removal And Installation Ideal Aviation 8168-IA

Tool

Aircraft Tool Supply AA470

Oil Filter Can Cutter Cut Oil Filter Can

Aircraft Tool Supply FC-2000 Champion Aerospace CT-923

Oil Filter Torque Wrench Oil Filter Installation

Oil Strainer, 1000 Micron

Oil Change Arbor Fabrication 2000

Porta-Test Unit Engine Operational Check

Portable Digital EGT/ CHT Tester

Verify EGT/CHT/TIT Accuracy Alcor, Inc. ALCAL 2000

Protractor/Timing Indicator Disc and

Engine Timing

TDC Locator

Aircraft Tool Supply AA472 Champion Aerospace CT-921

Approved Aircraft Accessories (Aero Test)

Eastern Technology Corporation

Model 20 ATM-C

E25

Pulley Alignment Tool Belt Drive Pulley Alignment Ideal Aviation 8082-IA Pulley Puller Remove Generator/Alternator Sheave Ideal Aviation 61-5IA

Timing Light Magneto to Engine Timing

Worm Shaft Tool & Starter Adapter

Starter & Starter Adapter Disassembly

Disassembly Tool

Eastern Technology Corporation

Fabricate according to Figure 2-7

E50

---

Overhaul

Bearing Puller Component Maintenance Borroughs*** 8093C

Boring Bars Cylinder Repair Borroughs***

Carbide Tipped Reamer Valve Guide Reaming Kent-Moore***

8116-1B through 15B

2847-2CP

2847-1CP Common Drive Handle Cylinder Repair Borroughs*** 8122A Common Parts Kit Valve Seat Replacement Borroughs*** 8116 Connecting Rod Boring

& Alignment Fixture Connecting Rod

Bushing Removal/ Installation Set

Connecting Rod Piston Bushing Replacement

Borroughs*** 8111A

Borroughs*** 8098

Connecting Rod Bushing Installation and Removal Tool Adapter

Connecting Rod Piston Pin Bushing Replacement

Borroughs*** 8042C

Kit Connecting Rod

Bushing Reamer

Connecting Rod Bushing Bore Honing

Contact Profilometer Cylinder Bore Honing

Kent-Moore*** 5008 Borroughs*** 8071 Commercial, off the

shelf

N/A

2-2 Standard Practice Maintenance Manual CHANGE 1 1 Feb 2021

Page 41

Table 2-1. Special Tools List

Tools

Special Tool Use or Reference Suggested Providers Part Number

Counterweight Bushing Remover/Replacer Tool

Crankcase Needle Bearing Installer Tool

Counterweight Hanger Blade Bushing Replacement And Counterweight Bushing Replacement

Crankcase Assembly

Borroughs*** 4965A

Fabricate according to Figure 2-16 (Permold)

---

Figure 2-17 (Sandcast) Crankcase Splitter Separate The Crankcase Kent-Moore*** L423 Crankcase Through

Bolt Remover

Crankcase Disassembly Borroughs*** 8114-8

Crankshaft Counterweight Bushing Removal/Installation

Crankshaft Overhaul Borroughs*** 8077C

Fixture Crankshaft Hanger

Blade Bushing Removal/Installation

Crankshaft Overhaul Borroughs*** 8077A

Tool Crankshaft Nose Oil

Seal Installer Tool

Crankshaft Nose Oil Seal Installation

Not require for split type nose oil seals

Kent-Moore*** 5209

5203, 5204, & Cylinder Base Nut Wrenches

Cylinder Maintenance

Kent-Moore***

8158A, 3882, &

3882-2

Borroughs*** 8079

Cylinder Heating Stand Cylinder Maintenance Borroughs*** 8156

Valve Seat Replacement

Cylinder Holding Fixture

Valve Guide Replacement

Borroughs*** 5221B

Valve Seat Machining

Cylinder Holding Fixture Adapters

Valve Seat Replacement Valve Guide Replacement Valve Seat Machining

Borroughs***

5221-13A

5221-15A

5221-16A Cylinder Hone Engine Cylinder Bore Honing Snap On Tools CFL10

Dial Indicator Gear Backlash Measurement

Commercial, off the shelf

---

Exhaust Valve Seat Grinding Stone

Valve Seat Machining Aircraft Tool Supply K95

(Roughening 45) Exhaust Valve Seat

Grinding Stone

Intake Or Exhaust Valve Seat Machining Aircraft Tool Supply K25

(Finishing 45) Expanding Guide

Bodies

Valve Guide Replacement Borroughs***

8116-1 through -

16 Generator Drive Holder Secure The Generator Drive Borroughs*** 4973

Heli-Coil Extracting Tool Helical Coil Insert Replacement

Heli-Coil Installation Tool

Heli-Coil Expanding Tool No. 520-2

Helical Coil Insert Replacement

Stanley Engineered Fastening

---

520-2

Standard Practice Maintenance Manual 2-3 1 Feb 2021 CHANGE 1

Page 42

Tools

Table 2-1. Special Tools List

Special Tool Use or Reference Suggested Providers Part Number

High Speed Steel Reamer

Reaming Valve Guides Kent-Moore***

2847-1HP 2847-2HP

Intake Valve Seat Grinding Stone

Valve Seat Machining Aircraft Tool Supply K106

(Roughening 30) Intake Valve Seat

Grinding Stone

Valve Seat Machining Aircraft Tool Supply K46

(Finishing 30) Needle Bearing Installer

Tool

O-ring Installation Tool Crankcase Hardware Installation

Oil Control Plug Installation Tool

Oil Control Plug Leak Test Fixture

Oil Pressure Relief Spot Facer

Oil Seal Tool

Piston Ring Compressor

Starter Adapter Housing Worm Shaft Needle Bearing Replacement

Borroughs*** 23-1

Fabricate according to Figure 2-19

---

Fabricate according to

Oil Control Plug Replacement

Figure 2-10 through

---

Figure 2-11

Oil Control Plug Replacement

Fabricate according to Figure 2-12

---

Oil Pressure Relief Valve Seat Refacing Kent-Moore*** 8048

Crankcase And Accessory Drive Adapter Oil Seal Installation

Fabricate according to Figure 2-20

---

Engine Cylinder Installation Kent-Moore*** 3601

Piston Ring Removers Piston Ring Removal Kent-Moore*** 8121 Polishing Tool Engine Drive Train Inspection Burroughs*** 8087B Pushrod Spring

Compressor Tool

Reamers Valve Guide Reaming Borroughs***

Reamer, Adjustable Blade

Rocker Arm Bushing Remover/Installer

Rocker Arm Bushing Reamer



Rosan

Stud Remover



Lock Ring

Installer Spark Plug Insert

Remover Spark Plug Insert

Replacer Spark Plug Tap 

(18 mm)

Pushrod Installation Kent-Moore 68-3

8116-1R through 15R

Magneto Drive Adapters Bushing And Oil Seal Installation

Rocker Arm Bushings (Single-Bushing Type) Replacement

Borroughs***

Kent-Moore*** 8118

Size range 2513227132

Ream Rocker Arm Bushing Kent-Moore*** 7232

Remove Rosan Studs

McMaster-Carr Supply Company

2769A13

Rosan Studs Installation Kent-Moore*** 8074

Spark Plug Heli-coil Insert Removal Borroughs*** 4919

Spark Plug Heli-coil Insert Installation Borroughs*** 4918

Repair Damaged Spark Plug Threads/Boss Borroughs*** 445

Test Club Post-Overhaul Testing Hartzell Propeller, Inc.

2-4 Standard Practice Maintenance Manual CHANGE 1 1 Feb 2021

Page 43

Table 2-1. Special Tools List

Tools

Special Tool Use or Reference Suggested Providers Part Number

Valve Guide Boss Reamers

Valve Guide Floating Holder

Valve Guide Reaming Kent-Moore***

Valve Guide Replacement Borroughs*** 3170

4943-1 HS

through -5HS

Valve Guide Remover Valve Guide Replacement Kent-Moore*** 4981 Valve Guide Seal

Installation Tool Valve Seat Grinder Set

“Sioux Brand” Valve Seat Grinder Pilot

0.437 diameter Valve Seat (Straight

Side) Insert Cutters Valve Seat (Step Side)

Insert Cutters Valve Seat Insert

Remover & Replacer Valve Spring

Compressor Tool

Valve Guide Seal Installation

Machining Intake Or Exhaust Valve Seat Aircraft Tool Supply 1675

Machining Intake Or Exhaust Valve Seat Aircraft Tool Supply AEX 437

Valve Seat Repair Kent-Moore*** 5224 & 5225

Valve Seat Repair Kent-Moore***

Valve Seat Replacement Borroughs*** 8086

Engine Cylinder Assembly Kent-Moore*** 3602

Fabricate according to Figure 2-18

---

8135, 8136, &

8138

Overhaul Inspection

Contour Probe Magnetic Particle Inspection

Parker Research Corporation

DA-200

Federal Dimension Air Gage (with setting ring and air plug) or equivalent with

1.1268 Setting Ring

Counterweight Hanger Blade Bushing Replacement Counterweight Bushings Replacement

MAHR Federal D-4000

1.1268 Air Plug

Dial Bore Gauges

Cylinder Bore Inner Diameter Dimensional Inspection

MAHR Federal 545-116

Plug Gauge Cylinder Intake Valve Guide Inspection Kent-Moore*** 2848-1

Krautkramer-

Branson P/N:

Ultrasonic Test Instrument, Portable

Crankshaft Ultrasonic Inspection Krautkramer-Branson

USK 7D OR7S

USL 42

USL 48

USN 50

USN 52 Ultrasonic Test

Instrument Calibration Block

Coaxial Cable - Grade 74 RG174/U 50 ohm Microdot to BNC (6’)

Coaxial Cable MMD to BNC (6’)

Crankshaft Ultrasonic Inspection (Equipment Calibration)

Krautkramer-Branson

Crankshaft Ultrasonic Inspection (For Connecting The Transducer To The

Krautkramer-Branson

Ultrasonic Equipment)

Cylinder Barrel Ultrasonic Inspection Krautkramer-Branson

DSC Block or

Rompas Block

(steel)

Krautkramer-

Branson P/N

118140012

Krautkramer-

Branson P/N

C-047

Standard Practice Maintenance Manual 2-5 1 Feb 2021 CHANGE 1

Page 44

Tools

Table 2-1. Special Tools List

Special Tool Use or Reference Suggested Providers Part Number

Filter (microhenry BNC to BNC)

Cylinder Barrel Ultrasonic Inspection Krautkramer-Branson

KrautkramerBranson P/N 281678-200

Krautkramer-

Fixture 60 Axial Cylinder Barrel Ultrasonic Inspection Krautkramer-Branson

Branson P/N 291-678-000

Krautkramer-

Flaw Detector Cylinder Barrel Ultrasonic Inspection Krautkramer-Branson

Branson P/N USL42 or equivalent

Krautkramer-

Transducer 5.0 MHz,

0.125 diameter

Cylinder Barrel Ultrasonic Inspection Krautkramer-Branson

Branson P/N SMSWS 113-214585

Transducer, Miniature (Gamma Series 5 MHz)

Crankshaft Ultrasonic Inspection (Provide Piezoelectric Effect)

Krautkramer-Branson

KrautkramerBranson P/N MSWS 224-580

Crankshaft Main Bearing 2.2375 –

2.2485 inches (5.6833 –

Crankshaft Ultrasonic Inspection Continental 654478-1

5.7112 cm) and Miniature Wedge 

(45 shear wave)

Crankshaft Ultrasonic Inspection Continental 654484

Crankshaft Main Bearing 2.3630 –

2.3750 inches (6.0020 –

Crankshaft Ultrasonic Inspection Continental 654483-1

6.0325 cm) and Miniature Wedge 

(45 shear wave)

Crankshaft Ultrasonic Inspection Continental 654578

Crankshaft Main Bearing 2.6140 –

2.6250 inches 

Crankshaft Ultrasonic Inspection Continental 654485-1 (6.6396 – 6.6675 cm) and

Miniature Wedge  (45 shear wave)

Micrometers (series 3 point contact inside micrometers)

Crankshaft Ultrasonic Inspection Continental 654484

Counterweight Hanger Blade Bushing

Replacement

Starrett No. 78

Runout Block Set Drive Train Dimensional Inspection Borroughs*** 8117a *or equivalent

**Providers can be subject to change or discontinue manufacturing tools *** The rights to manufacture Borroughs and Kent-Moore tools has been acquired by Kell-Strom Tool Company.

1. Items with Continental part numbers may be purchased directly from Continental.

2-6 Standard Practice Maintenance Manual CHANGE 1 1 Feb 2021

Page 45

2-1.1. Vendor Contact Information

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

Tools

Supplier Address Phone FAX Web Address

American Lubricants / Moly Motor Oil

Aircraft Tool Supply

Alcor

Arbor Fabricating

A. W. Chesterton Company

ASTM

1227 Deeds Dayton, OH 45401

P.O. Box 370 1000 Old U.S. 23 Oscoda, MI 48750

300 Breesport San Antonio, TX 78216

14030 Tuttle Hill Milan, MI 48160

500 Unicorn Park Drive Woburn, MA 01801-3345

100 Barr Harbor Drive West Conshohocken, PA 19428

937-222-2851 618-534-5231 molymotoroil.com

800-248-0638 517-739-1447

800-343-7233 210-349-6491

517-739-1448 aircraft-tool.com

210-308-8536 alcorinc.com

734-626-5864 N/A arborfab.com

800-835-4135 781-438-7000

877-909-2786 610-832-9585

781-438-8971 chesterton.com

N/A astm.org

Borroughs See Kell-Strom Tools Champion Aerospace,

Inc. CRC Industries/Chemical

Products

Crown Equipment Corp.

Davis Instruments

Daubert Chemical

Dow Corning Corporation

1230 Old Norris Road Liberty, SC 29657

885 Louis Drive Warminister, PA 18974

44 S. Washington Street New Bremen, OH 45869

625 E. Bunker Ct. Vernon Hills, IL 60061

4700 South Central Ave Chicago, IL 60638

P.O. Box 997 South Saginaw Road Midand, MI 48686

864-843-1162 864-843-5402

800-272-4620 800-556-5074

800-272-4560 215-674-2196

championaerospace.co m

crcindustries.com

419-629-2311 N/A crown.com

800-358-5525

inotek.com davis.com

708-563-8325 78-496-7367 daubertchemical.com

989-496-4400 800-662-0661

dowcorning.com

Eastern Electronics See Eastern Technology Corporation Eastern Technology

Corporation

42 Nelson St. East Hartford CT 06108

860-528-9821 860-289-7639 easterntech.com

Federal Mogul Southfield, MI 248-354-7700 federal-mogul.com Graham Aircraft Engines

(Motorstor) Hartzell Engine

Technologies (formerly Kelly Aerospace)

Hartzell Propeller Inc.

Henkel Aerospace

Ideal Aviation

PO Box 3214 Peachtree City, GA 30269

Plane Power 2900 Selma Hwy Montgomery, AL 36108

One Propeller Place Piqua, OH 45356

32100 Stephenson Hwy Madison Heights, MI 48071

564 Juanita Avenue Mesa, AZ 85204

770-252-4995 770-252-5270 www.highaero.com

877-359-5355 334-386-5410 hartzellenginetech.com

937-778-4200 937-778-4271 hartzellprop.com

248-583-9300 248-583-2976 henkel.com

480-963-8890 480-963-8887 idealaviation.com

Standard Practice Maintenance Manual 2-7 1 Feb 2021 CHANGE 1

Page 46

Tools

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

Supplier Address Phone FAX Web Address

Kent-Moore See Kell-Strom Tool Company

metrologyworld.com/ storefronts/ krautkramer.html

Krautkramer-Branson

Loctite

LPS Laboratories

Lubriplate

MAHR Federal

McMaster-Carr Supply Company

Merit Abrasives

Miller-Stephenson Chemical Company

Q.A. Technologies

Plane Power®, see Hartzell Engine Technologies

Parker Research Corporation

Shell Oil Company

50 Industrial Park Road Lewistown, PA 17044

1001 Trout Brook Crossing Rocky Hill, CT 06067-3910

4647 Hugh Howell Road Tucker, GA 30084

129 Lockwood St. Newark, NJ 07105

1144 Eddy Street Providence, RI 02905

P.O. Box 4355 Chicago, IL 60680-4355

201 W. Mansville Dr. Compton, CA 90224

6348 Oakton St. Morton Grove, IL 60053

P.O. Box 61085 Savannah, GA 31420

Plane Power 2900 Selma Hwy Montgomery, AL 36108

P.O. Box 1406 Dunedin, FL 34697

P.O. Box 2463 Houston, TX 77252

717-242-0327 334-438-3411

860-571-5100 800-243-4874

800-241-9334 770-243-8800

973-589-9150 800-733-4755

401-784-3271 800-343-2050

860-571-5465 loctite.com

770-243-8899 lpslabs.com

973-589-4432 lubriplate.com

401-784-3246 mahr.com

630-833-0300 630-834-9427 mcmaster.com

800-421-1936 310-639-4242

847-966-2022 800-992-2424

800-472-3094 meritabr.com

847-966-8468 miller-stephenson.com

912-330-0500 912-330-0104 qatek.com

877-359-5355 334-386-5410 hartzellenginetech.com

800-525-3935 727-796-4066

713-241-4819 800-332-6457

727-797-3941 parkreascorp.com

713-241-6511 shell-lubricants.com

Snap On (Tools) 877-740-1900 877-740-1880 snapon.com Stanley Engineered

Fastening

L.S. Starrett Company

Tanair (Tanis Aircraft Services)

U.S. Industrial Tool & Supply

Worldwide Filter (Mouse Milk)

4 Shelter Rock Lane Danbury, CT 06810

121 Crescent Street Athol, MA 01331

P14871 Pioneer Trail Suite. 200 Eden Prairie, MN 55347

14083 South Normandie Ave. Gardena, CA 90249

1689 Abram Court San Leandro, CA 94577

877-364-2781 800-225-5614

800-541-8887 978-249-3551

978-249-8495 starrett.com

stanleyengineeredfaste ning.com

800-443-2136 In Minnesota:

952-224-4426 tanisaircraft.com

952-224-4425 310-464-8400

800-464-8400

310-464-8880 ustool.com

510-483-5122 734-455-3256 mousemilk.com

1. Unless otherwise indicated, type http://www. followed by the Web Address shown in tis column.

2-8 Standard Practice Maintenance Manual

15 Sep 2019

Page 47

Tools

Pressure Regulator

Regulator Pressure Gauge

Cylinder Pressure Gauge

Master Orifice Valve

Slow Fill Valve

Cylinder Adapter

AIR

Pressure Regulator

Regulator Pressure Gauge

Cylinder Pressure Gauge

Master Orifice Valve

Slow Fill Valve

Cylinder Adapter

AIR

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

Figure 2-2. Borescope (Autoscope®)

NOTE: Borescopes are available from multiple manufacturers, with varying levels of features and resolution. The Autoscope® is only one of the available products.

Standard Practice Maintenance Manual 2-9 15 Sep 2019

Page 48

Tools

Figure 2-3. Pulley Alignment Tool

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

2-10 Standard Practice Maintenance Manual

15 Sep 2019

Page 49

Tools

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

Used on Permold 520/550 Permold Series Engines

Standard Practice Maintenance Manual 2-11 15 Sep 2019

Page 50

Tools

Figure 2-6. Alternator Drive Hub Torque Tool

Used on 200/300/240/360 Series Engines

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

2-12 Standard Practice Maintenance Manual

15 Sep 2019

Page 51

NOTE: The Driver for the Oil Control Plug Installation Tool (Figure 2-8 through Figure 2-11) is the same for all installation tools/engine models.

Tools

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

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

Standard Practice Maintenance Manual 2-13 15 Sep 2019

Page 52

Tools

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

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

2-14 Standard Practice Maintenance Manual

15 Sep 2019

Page 53

Tools

Figure 2-12. Oil Control Plug Leak Test Fixture

Standard Practice Maintenance Manual 2-15 15 Sep 2019

Page 54

Tools

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

2-16 Standard Practice Maintenance Manual

15 Sep 2019

Page 55

Tools

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

Standard Practice Maintenance Manual 2-17 15 Sep 2019

Page 56

Tools

Figure 2-15. Bearing Installation Tool

2-18 Standard Practice Maintenance Manual

15 Sep 2019

Page 57

Tools

Crankcase needle bearing installation tools vary by the depth the needle bearing is installed. The needle bearing installed depth for:

• Permold crankcases is 9/16” (see Figure 2-16, 0.625”)

• Sandcast crankcases is 1/2” (see Figure 2-17, 0.50”).

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

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

Standard Practice Maintenance Manual 2-19 15 Sep 2019

Page 58

Tools

Figure 2-18. Valve Guide Seal Installation Tool

2-20 Standard Practice Maintenance Manual

15 Sep 2019

Page 59

Figure 2-19. O-Ring Installation Tool

Medium Knurl

Mill Flat

Stamp P/N On Flat

1/16 Radius

0.783 Dia.

1.200 Dia.

1.00

0.68

5/16

1-1/4 Dia. Before Knurl

1/8x45°

1.00

2.00

3.00

Material 1020 Case Harden

Tools

Figure 2-20. Oil Seal Tool

Standard Practice Maintenance Manual 2-21 15 Sep 2019

Page 60

Tools

Figure 2-21. Helical Coil Extraction Tool

Figure 2-22. Helical Coil Insertion Tool

2-22 Standard Practice Maintenance Manual

15 Sep 2019

Page 61

Tools

Figure 2-23. Helical Coil Expanding Tool

Figure 2-24. Rosan® Stud Removal Tool

Standard Practice Maintenance Manual 2-23 15 Sep 2019

Page 62

Tools

2-2. Mechanic’s Tools

The tools listed below are required to perform overhaul procedures on the engines.

Table 2-3. Common Tools

Open-End Wrenches – 1/4-inch through 1-Inch 1/4-inch Slide hammer Socket Wrenches:

1/4-inch drive

Socket Sizes: 5/32-inch through 1/2-inch

3/8-inch or 1/2-inch drive

Socket Sizes: 7/16-inch through 1-1/2-inch Deep Well Sockets:

1/2-inch drive

Socket Sizes: 7/16-inch drive through 1-inch Calibrated Torque Wrenches:

• 0 to 1000 in-lbs

• 0 to 500 in-lbs

• 0 to 100 ft-lbs Micrometers Ball Peen Hammer Allen Wrenches - assortment Pullers Slotted Screwdrivers – assortment Blind Bearing Remover Phillips Screwdrivers – Nos. 1 and 2 Vernier Calipers Safety Wire Pliers Leather or soft plastic Mallet Common Pliers Small hole gauges, thickness gauges Diagonal Cutter Pliers Feeler Gauges (leaf-type) Needle-Nose Pliers C-Clamps Duck Bill Pliers Brass Wire Brush Snap Ring Pliers (with 90-degree bend) Stiff-bristled, Non-wire Scrub Brush Inspection light/flashlight Dry Blaster Cleaning Tool Two-inch (2”) Merrit Wheel (flap wheel) Air Impact Tool T-handle Drive Toolmaker’s Square Magnifying Glass (10X power) Profilometer Mirror Chamfer Tool Utility Knife Morse Adapter Scissors Heavy Duty Drill Press Crimp Tool Arbor Press (and 8-inch arbors) Wire Ties Vertical Mill Ring Expander Engine Hoist Bench Vise with Shielded Jaws Engine Stand Fiber Drift, Brass Drift, Pin or Punch Transport dolly Magnet Aircraft Tie-downs and Stop-blocks Stud Extractor Tool V-blocks Ezy Out Catch Basins (Fuel and Oil) Wood or Plastic Spatula Permanent Marker Tank Sprayer Strap Wrench

Ratchets:

• 1/4-inch drive

• 3/8-inch drive

• 1/2-inch drive

Heat Gun (variable intensity/ equipped with a small tip)

• Drill, 0.266 (H) Pneumatic drill

• 00.339 Drill High speed borer

• Drill Index

2-24 Standard Practice Maintenance Manual

15 Sep 2019

Page 63

Chapter 3 . Lubricants, Sealants, and Adhesives

3-1. Engine Oil Specifications

WARNING

While it is unlikely any Mobil AV1 brand oil remains available, in use, or in inventory, use of Mobil AV1 is prohibited from use in Continental aircraft engines.

Lubricating oils qualified for use in Continental aviation gasoline (AvGas) engines are required to meet Society of Automotive Engineers (SAE) specifications. SAE J1899 is the specification for aircraft piston engine ashless-dispersant oil. SAE J1966 is the specification for aircraft piston engine non-dispersant mineral oil.

Lubricating oil meeting these specifications is acceptable; proof of conformity is the responsibility of the lubricant manufacturer.

Lubricating oil classified by North Atlantic Treaty Organization (NATO) or Standardization Agreement (STANAG) as interchangeable with oils qualified under SAE J1899 or SAE J1966 and assigned NATO codes O-123 or O-128 shall be considered qualified.

The marketers listed in Table 3-1 have supplied data to Continental indicating the products conform to one or more of the requirements above.

Lubricants, Sealants, and Adhesives

Continental recommended oil grades:

• Above 40°F ambient air, sea level SAE 50 or multi-viscosity

• Below 40°F ambient air, sea level SAE 30 or multi-viscosity

3-1.1. Oil Brand Selection

Reference: SIL19-04

CAUTION: Use the appropriate oil grade applicable to their specific engine or product line and maintain a consistent oil brand to sustain standard engine operations until after overhaul. Use only oil specification approved by the engine Type Certificate Data Sheet.

Lubricant manufacturers produce multiple oil products which comply with specification MHS-24; each containing proprietary formulations for straight weight and multiviscosity oil grades. Operators choose the appropriate oil to service their engine based on Instructions for Continued Airworthiness (ICAs), operating environment, viscosity, brand, and personal preference. Switching oil brands before engine overhaul may result in higher wear rates for lifters and cylinder components, even under normal operating conditions.

Analysis indicates consistent servicing with one brand of oil will result in fewer maintenance events and more consistent oil analysis results. Continue using the same oil brand throughout the service life of the engine. Do not change from an established “oil type” (mineral oil, semi-synthetic oil), even within the selected brand, before engine overhaul.

Standard Practice Maintenance Manual 3-1 1 Feb 2021 CHANGE 1

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Lubricants, Sealants, and Adhesives

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

Supplier Brand

Air BP Lubricants

ExxonMobil Aviation Exxon Elite NYCO S.A. Turbonycoil 3570

Pennzoil Company

Phillips 66 Aviation ConocoPhillips

Shell Aviation

Total Lubricants

Castrol Aviator AD Oil Castrol Aviator A Oil

Pennzoil Phillips 66 Type A 100 AD, 120 AD Phillips 66 Victory Aviation Oil 100AW Phillips 66 X/C Aviation Oil SAE 20W-50, SAE 25W-60 Aeroshell Oil, (Mineral) 65, 80, 100, 2F Anti-Corrosion Formula Aeroshell Multi-grade Oil AD, 15W - 50 Aeroshell Oil W65, W80, W100 Aeroshell Oil W80 Plus, W100 Plus Anti Corrosion Formula Total Aero DM 15W - 50 Total Aero XPD 80 (SAE 40), XPD 100 (SAE 50), XPD 120 (SAE 60)

Aircraft Engine Oil

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

Supplier

Phillips 66 Aviation ConocoPhillips

Shell Aviation

Total Lubricants

Brand

Phillips 66 Type M Aviation Oil 20W-50 (Multi-viscosity) Phillips 66 Type M Aviation Oil 100W (Grade 50) Aeroshell Oil 65 (Grade 30) Aeroshell Oil 80 (Grade 40) Aeroshell Oil 100 (Grade 50) Aeroshell Oil 120 (Grade 60) Total Aero DM 15W - 50 Total Aero 80 (SAE 40) Total Aero 100 (SAE 50)

Table 3-3. Break-in Oil

Type Equivalent Application

SAE J1966 Aviation

MIL-C-6529 Type II Corrosion preventive mineral oil

Non-dispersant mineral oil for piston aircraft engines

Fly-away oil

First 25 hours of engine operation or until oil consumption stabilizes

NOTE: Mineral oil conforming to MIL-C-6529 Type II contains a corrosion preventive additive and must not be used for more than 25 hours or six months, whichever occurs first. If oil consumption has not stabilized in this time, drain the mineral oil, replace the oil filter and replace the discarded mineral oil with SAE J1966 aviation oil.

Table 3-4. Preservative Oil

Type Equivalent Application

MIL-PRF-46002

Grade 1 Oil, Non-Rust VCI-105 Motorstor Engine Protectant

Temporary or Indefinite Storage. Sprayed in cylinders (Section 9)

3-2 Standard Practice Maintenance Manual

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Page 65

3-2. Oil Change Intervals

Refer to the engine maintenance manual and/or the aircraft manufacturer’s or Supplemental Type Certificate (STC) holder’s AFM/POH for oil specifications, specified oil change intervals and inspection procedures.

Oil change intervals published in this manual are minimum requirements. Continental believes more frequent oil and filter changes enhance engine service life. Drain and replenish engine oil every 25 hours of operation or 4 months for engines that incorporate a reusable oil screen. On engines with the full flow oil filters, large or small replaceable oil filter cartridge, change the oil and filter every 50 hours and/or 4 months. Inspect oil screens and oil filter elements for contaminates at each oil change. Oil analysis may be used in addition to the oil screen or filter element inspection, but not as a replacement for it.

3-3. Additives

We often receive inquiries regarding the potential use of alternative fuel and oil additives and/or concentrates (formulated primarily for automotive and industrial engine applications) for use in our aircraft engines. Most of these additives and concentrates are not compatible with air-cooled, light aircraft engines in their operating environments. With the exception of the use of isopropyl alcohol or diethylene glycol monomethyl ether (DiEGME) compound (described in the following paragraph), we do not recommend the use of additives or concentrates in any of our aircraft engines. The use of unapproved additives may void the engine warranty. Use only recommended fuels and lubricants.

Lubricants, Sealants, and Adhesives

WARNING

Mixing of the DiEGME compound with fuel concentration in excess of the recommended (0.15 percent volume maximum) could have a harmful effect on engine components. Use only the manufacturer’s recommended blending equipment and procedures to achieve proper proportioning.

Under certain ambient conditions of temperature and humidity, sufficient quantities of water may exist in the fuel to create restrictive ice formation in the fuel supply. To alleviate this occurrence, it is permitted to add no more than three percent Isopropyl Alcohol to the fuel supply. Also, DiEGME conforming to military specification MILDTL-85470B, if approved by the aircraft manufacturer, may be added for this purpose. DiEGME compound must be carefully mixed with the fuel in concentrations not to exceed

0.15% (by volume).

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Lubricants, Sealants, and Adhesives

3-4. Sealant, Lubricant, and Adhesive Applications

Table 3-5. Sealants

Continental

Part

Number

642188

646940

CRC Copper Coat 401504 Gasket Sealant

F/I Sealant Loctite 569 Hydraulic Sealant

Gasket Maker

646942

Loctite 515 Flange Sealant

649246 Loctite 290 Sealant

Type Application Remarks

Non-beaded gaskets; Apply both sides of starter gasket, oil cooler adapter gasket, vacuum pump adapter gasket, and fuel pump pad cover gasket. Beaded gasket; Apply to non-beaded

0200D, X

side of starter gasket, oil cooler adapter gasket, vacuum pump adapter gasket, and fuel pump pad cover gasket.

All press type plugs (Hubbard etc.) Intake manifold gasket ACC case to crankcase

(crankcase side only)

All models

C-90, O200, IO240, O300,

IO360, LTSIO360, TSIO360 Oil drain back tubes C-90, O200, O300 Oil cooler (both sides) IO360, LTSIO360, TSIO360 Oil seal accessory drive (O.D. only) IO360, LTSIO360, TSIO360 2 bolt suction tube gasket 

(both sides)

Gasket and oil filler neck holes

Cam bore cover gasket  (except beaded gasket)

470, 520 and 550 (where

applicable)

470, 520, 550 (Sandcast), and

GTSIO520

470, 520, 550, GTSIO520,

IO240 Idler pin gasket 470, 520, 550, GTSIO520

In parting line area of 3-way joints

Sump to crankcase or sump to

crankcase to accessory case All gaskets (both sides) except magneto

gasket and gaskets between intake manifold and cylinder head.

TIARA 6-285, 6-230 Oil seal at alternator drive 

(O.D. only) All pipe thread fittings in fuel injection

system (except pipe plug threads in

See Figure 3-2 throttle body units)

Gasket Eliminator

Crankcase parting face, between crkc and sump gasket

Engine nose seal, scavenge oil pump covers, between crankcase and sump gasket, oil pump covers

Between oil sump and sump gasket

642910 oil seal, O.D. of all uncoated oil seals, except fuel pump adapter seal

Between starter adapter gasket & crankcase

Data plate screw installation on throttle bodies

All SI

gaskets only)

All SI

gaskets only)

All SI

applicable

All Permold crankcase models

All models, where applicable

models

models (non-beaded

models, where

3-4 CHANGE 3

Standard Practice Maintenance Manual

6 January 2023

Page 67

Lubricants, Sealants, and Adhesives

Table 3-5. Sealants

Continental

Part

Number

Type Application Remarks

653692 Loctite LocQuic Primer 7649 Crankshaft nose oil seal area All models, where applicable

Crankcase parting face

Apply according to assembly instructions. Reference Figures 3-3 to 3-17.

654663

Loctite 30516 Gasket Sealant (with P/N 641543 Silk Thread)

Accessory drive adapter Pressure oil pump covers

Pressure scavenge pump covers Starter adapter to accessory case Reference Figure 3-16 Use on all pipe threads except as noted

Loctite 567 Teflon PS/T Pipe Sealant. Option - Loctite Pipe Sealant With Teflon (PS/T) 592.

658769

Age Control Per MHS-223, Affix Expiration Date On Each Tube.

Option - P/N 657042, Loctite 565 Adhesive Sealant

N/A Miller-Stephenson MS-122AD

elsewhere All pressure relief valve housing threads Permold 2 studs engine mount 1-3-5 side bottom

All threaded fasteners installed in a stud hole through to an oil source

Use on all pipe threads to oil coolers and other oil sources

Ignition harness terminals at magneto block end & spark plug / ECU terminals

models, where

All SI applicable

Apply before installing threaded fastener

All models (use sparingly on male threads only)

All models, where applicable

1. Spark-Ignited

Continental

Part

Number

646943

646943-1

Loctite 76732 (646943) Loctite 1999141 (646943-1) Anti-Seize Lubricant

Type Application Remarks

654468 Shell #5 MIL-G-3545-C Grease

654514

CRC 336 Rust Preventative Compound

654561 Shell Gadus S2 V220 2

Table 3-6. Lubricants

Fuel injector nozzles  (at cylinder head)

See Figure 3-1

Mechanical tachometer drive housing threads not connected through to an oil

At engine assembly

source. Exhaust studs (applied to nut end

before torque), exhaust slip joints

All except TSIOL550

Vernatherm plug All 0.3125 and larger studs unless

At engine assembly

otherwise noted Throttle body air reference fittings Where applicable

Oil sump return fitting

IO360ES3B, 14B; IO360HB9B

Fuel injection linkages At engine assembly

Apply at pivot points during

Throttle & mixture control linkages

assembly and periodic maintenance

Spray exhaust end of turbocharger After engine test

LTSIO360E, EB, RB;

Apply to oil seal lip only (alternator seal)

TSIO360E, EB, F, FB, GB, KB, LB

Apply to crankshaft nose oil seal lip All models, where applicable

6 January 2023

3-5Standard Practice Maintenance Manual

CHANGE 3

Page 68

Lubricants, Sealants, and Adhesives

Table 3-6. Lubricants

Continental

Part

Number

Type Application Remarks

Starter worm gear & bevel gear teeth Needle bearings and ball bearings Valve stems

All models during engine

assembly

Accessory drive splines and couplings Where applicable Idler gear and pin 470, 520, 550

656817 Super Molyshield Grease

Magneto rubber drive bushings Oil seal lips only

Fuel injection controls, o-rings, springs, shafts, and bushings

Oil pumps (pressure & scavenge)

All models

Except 360, TSIO520D, 

GTSIO520K, which use 50W

motor oil

Coat gear cavity during pump

assembly Adapter (tach reduction) TSIO & LTSIO360

Use only manufacturer’s

N/A

recommended spark plug

Spark plugs All models

thread lubricant

N/A

Chesterton #995 Release Agent or WD-40

Intake Manifold Hoses and Flex Ducts Fuel Pump Aneroid Seal, Turbine shafts

All models

Penetrating lubricant to free

N/A Crown Penetrating Oil Turbine shafts

sticking turbine shafts and

displace moisture Rubber oil seal of spin-on oil filters. Do

not apply to oil filter P/N 658753,

N/A Dow Corning No. 4

658754, or 658755 filters with anti-stick coating on seal.

All models where applicable

Governor pad gaskets (both sides) Starter adapter cover o-rings

N/A Dow Corning G-N Paste Camshaft lobes and tappet faces During engine assembly

Penetrating lubricant to free

N/A Kano Aerokroil Turbine shafts

sticking turbine shafts and

displace moisture

N/A LPS 2

N/A LPS Procyon or LPS 3

N/A Lubriplate 630 AA (optional)

Throttle and Mixture Control Valves Linkages

Flanged Nut (P/N 652541) at Cylinder Base

Throttle and Mixture Control Valves Linkages

N/A Lubriplate 930 AA O.D. of valve guides

Apply at pivot points during

maintenance

Apply after inspection

Apply at pivot points during

assembly

All models during valve guide

installation

Carbon solvent used on Wastegate butterfly and linkage

N/A Mouse Milk

Turbine shafts

turbocharged engines during

preventive maintenance

Penetrating lubricant to free

sticking turbine shafts and

displace moisture

3-6 Standard Practice Maintenance Manual CHANGE 1 1 Feb 2021

Page 69

Continental

Part

Number

N/A

Type Application Remarks

SAE J1966 Grade 50  Aviation Oil

Lubricants, Sealants, and Adhesives

Table 3-6. Lubricants

Quill shaft springs GTSIO520 Crankshaft bearings

Connecting rod bearings Prop driver, driven gears & bearings Camshaft bearings Tachometer gears & adapters

During engine assembly

Accessory spur gear teeth Prop governor transfer collar & sleeve Starter cone, bushing & nut Starter clutch spring (ID & OD) Pistons, piston pins, & piston rings Thrust washers Oil filter adapter seals

During engine assembly

O-rings (unless otherwise specified) Carburetor fuel connections Carburetor-equipped models Valve guide seals Apply to sealing surface V.T.C. unit pistons & centrifugal valves,

rocker arms, valves and tappets

TIARA 6-285, 6-230

Cylinder studs, through bolts, crankcase studs, connecting rod bolts and nuts; and engine accessory studs unless installed in blind or stud holes

Lubricate bolt thread and nut

seat before tightening nuts not through to an oil supply or otherwise specified

Cylinder exhaust port flange studs TSIOL550 ONLY

Standard Practice Maintenance Manual 3-7 15 Sep 2019

Page 70

Lubricants, Sealants, and Adhesives

Continental

Part

Number

Type Application Remarks

Loctite 271 High Strength

646941

Adhesive Sealant (used with P/N 653693 Loctite 7471 Primer)

649306

(optional

646940)

658517

(optional

649366)

Loctite 222 Sealant (or optional Loctite Hydraulic Sealant 569)

Loctite 243 (optional Loctite 242)

Table 3-7. Adhesives

Cylinder deck studs

Crankcase breather tubes

Breakaway torque minimum 100 in-lbs. after two hours

470 & 520 (Sandcast) &

GTSIO520 Crankcase nose seal retainer bolts All models Intake manifold mount studs C-75, C-85, C-90 & O-200 Mechanical tachometer drive studs

trough to an oil source

Where applicable

IO360, LTSIO360, TSIO360,

O470, IO470, TSIO470, Oil gauge rod housing to crankcase

IO520A, B, E, G, J, K, L,

IO550D, E, F, TSIO520A, AE,

AF, C, CE, G, H, M, P, R, T Oil pump gear mounting pin in

accessory cover

Press fit breather and oil fill necks

Rocker cover studs, rocker arm pivot studs, pushrod retainer stud

IO360, LTSIO360, TSIO360

IO240, IO360, LTSIO360,

TSIO360

TIARA 6-285, 6-230

Timing indicator pin GTSIO-520 Top accessory drive gear (breather

slinger) bolts V.T.C. unit bushing retainer screws

TIARA 6-285, 6-230

V.T.C. unit housing to crankshaft Solenoid Valve assembly (bracket to

valve)

Engines with priming system

solenoid valves, as applicable Manifold valve to bracket screws All models Coolant pump impeller ring screws All liquid cooled models Studs 0.25 diameter and smaller

(do not use on cylinder exhaust port

All models

flange)

Mag stud holes and stud holes through an oil source on accessory end of crankcase

0200, IO240, 0300, IO360,

LTSIO360, TSIO360, 470, 520,

550 (apply when installing

studs) All pipe thread fittings in fuel injection

system except pipe plug threads in

All models throttle body unit

Magneto housing pressurization fitting Bolts for nose seal retainer to crankcase Starter adapter - all stud locations

All models, where applicable

Rocker Cover screws on GT style heads

3-8 Standard Practice Maintenance Manual CHANGE 2 26 Aug 2021

Page 71

Table 3-7. Adhesives

Continental

Part

Number

Type Application Remarks

Coolant pump mechanical seal,

652983 Loctite 620 Adhesive Sealant

standard repair on starter adapter bearing bore

654495 Loctite 8531 Adhesive Sealant Starter clutch assembly bearing

654562 Loctite 609 Adhesive / Sealant

Bearing OD installed on starter clutch assembly

655515 Adhesive Sealant (RTV) Alternator assembly

Induction Manifold (Felt to Manifold)

655700 PBC30 Adhesive

Cylinder Baffle (Grommet to Baffle

658503)

Baffle Assembly-Oil Cooler (Seal to Baffle

658064) Bracket-Injection Lines (Bumper To

658493

3M Scotch-Weld 1300 Adhesive

Bracket 658514) Diverter Valve Bracket (Bumper To

Bracket 656225)

EMI Gasket

800126 3M Super 77 Adhesive

Cylinder Baffle (Rubber Isolator To Cylinder Baffle 657488)

Lubricants, Sealants, and Adhesives

All liquid cooled models

O200, O300, IO240, 0470, IO470, IO520, L/TSIO520, IO550, TSIOL550

O200A, B, IO240A, B, O300A

GIO550, GTSIO520, IO520, IO550, IOF550, TSIOL550, TSIOF550

I0360AF, ES; TSI0360MB,RB,SB; LTSI0360RB; I0550G,N,P,R; I0F550; TSI0520BE; TSI0550; TSI0F550D,J,K,P;

IO550G,N,P,R; IOF550N, P, R; TSI0520BE; TSI0550; TSI0F550;

TSI0550K,N

I0550R

I0F550B,C,D,E,F,L

All FADEC (apply to gasket before installing on ECU)

0200D

Table 3-8. Miscellaneous

P/N Type Application Remarks

535011

800154

626531-1

626531-3 Enamel - Gold (1 gal)

626531-6 Enamel - Platinum

626531-7 Enamel - Black

626531-9

Safety wire -.032 in dia. Steel Corrosion Resistant

Safety wire -.020 in dia. Steel Corrosion Resistant

Enamel - Gold (1 qt)

Enamel - Black Gloss  w/catalyst (1 gal)

Where safety wire is required N/A

Where safety wire is required FADEC electronic control units

High temperature paint for cosmetic and corrosion protection

Platinum models only

N/A

Cylinder barrels

1 gallon enamel and 1/2 gallon catalyst Rocker covers, as required

Standard Practice Maintenance Manual 3-9 26 Aug 2021 CHANGE 2

Page 72

Lubricants, Sealants, and Adhesives

Table 3-8. Miscellaneous

P/N Type Application Remarks

N/A

658555-1

--- Permatex 8003B Prussian Blue

“ACCELAGOLD” Turco Products

Primer, Zinc Phosphate (Armor Tech Epoxy Ester Primer)

Corrosion protection interior and exterior aluminum parts

Cylinders (through hardened cylinder barrel touch-up only)

Valve Face to Valve Seat inspection (during valve lapping)

All Models (w/through hardened

cylinder barrels)

N/A

3-10 Standard Practice Maintenance Manual CHANGE 2 26 Aug 2021

Page 73

3-4.1. General Sealant Application Instructions

CAUTION: Never apply anti-seize lubricant to the first two threads to prevent contaminating fuel supply. Only apply to fitting tapered ends up to the first two threads.

CAUTION: Never use Teflon® tape on fluid fittings or fuel injector nozzles. Reference Table 3-5, “Sealants”.

Lubricants, Sealants, and Adhesives

Figure 3-1. Anti-Seize Lubricant Application

CAUTION: Apply P/N 646940, (Loctite 569) fuel injection (F/I) sealant to the tapered threads of the fitting only (ref. Table 3-5). Never use Teflon tape on fluid fittings or fuel injector nozzles.

Figure 3-2. Fuel Injection Sealant Application

Standard Practice Maintenance Manual 3-11 26 Aug 2021 CHANGE 2

Page 74

Lubricants, Sealants, and Adhesives

3-4.1.1. Four Cylinder Engine Crankcase Threading

WARNING

Do not apply any form of sealant to the crankcase cylinder deck, chamfer, cylinder mounting flange, cylinder base O-ring, or cylinder fastener threads. The use of RTV, silicone, Gasket Maker or any other sealant on the areas listed above during engine assembly will cause a loss of cylinder deck stud or through-bolt torque. Subsequent loss of cylinder attachment load, loss of main bearing crush and/or fretting of the crankcase parting surfaces will occur. The result will be cylinder separation, main bearing movement, oil starvation and catastrophic engine failure. USE ONLY CLEAN 50 WEIGHT AVIATION ENGINE OIL ON SURFACES LISTED.

1. Use full strength, non-thinned P/N 654663 (gasket sealant). Shake or mix well before using.

CAUTION: Apply gasket sealant and threading (a continuous, single piece) only as illustrated. Do not apply gasket sealant to crankshaft nose seal area.

2. Apply P/N 654663 (gasket sealant) to 2-4 case half according to the manufacturer’s instructions only in areas where threading is indicated. When applying, use short light brush strokes until an even thin coat is obtained. The gasket sealant should be viscous enough that most of the brush marks disappear; if not, discard the old gasket sealant and reapply with new gasket sealant.

NOTE: Allow the gasket sealant to air dry to a tacky condition before applying silk threading.

3. Apply a thin translucent coat of P/N 646942 (gasket maker), not to exceed 0.010 inch thick, to the 1-3 case half. Apply gasket maker in all areas that will mate against areas where gasket sealant was applied on the matching 2-4 case half (except the through bolt bosses).

4. Apply and position P/N 641543 (a continuous, single piece of grade “D” silk thread) on the 2-4 case half as specified (see Figure 3-3 or Figure 3-4). Ensure the free ends of the thread will be covered by gasket material (except at the nose oil seal).

5. Assemble crankcase halves; install and torque all crankcase hardware in proper sequence in accordance with the applicable overhaul manual as soon as possible.

NOTE: Take care to prevent displacement or damage to the crankshaft oil seal and silk thread. Ensure thrust washer halves and bearing halves remain in place.

6. After crankcase torque, follow the instructions in Section 10-10 to install the nose oil seal.

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Lubricants, Sealants, and Adhesives

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

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

Standard Practice Maintenance Manual 3-13 15 Sep 2019

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Lubricants, Sealants, and Adhesives

3-4.1.2. Six Cylinder Engine Crankcase Threading

WARNING

1. Use full strength, non-thinned P/N 654663 (gasket sealant). Shake or mix well before using.

CAUTION: Apply gasket sealant and threading (a continuous, single piece) only as illustrated.

2. Apply P/N 654663 (gasket sealant) to 2-4-6 case half according to the manufacturer’s instructions only in areas where threading is indicated. When applying, use short light brush strokes until an even thin coat is obtained. The gasket sealant should be viscous enough that most of the brush marks disappear; if not, discard the old gasket sealant and reapply with new gasket sealant.

NOTE: Allow the gasket sealant to air dry to a tacky condition before applying silk threading.

3. Apply a thin translucent coat of P/N 646942 (gasket maker), not to exceed 0.010 inch thick, to the 1-3-5 case half. Apply gasket maker in all areas that will mate against areas where gasket sealant was applied on the matching 2-4-6 case half (except the through bolt bosses).

4. Apply and position P/N 641543 (a continuous, single piece of grade “D” silk thread) on the 2-4-6 case half as specified (see Figure 3-6 through Figure 3-9). Ensure the free ends of the thread will be covered by gasket material (except at the nose oil seal).

5. Assemble crankcase halves; install and torque all crankcase hardware in proper sequence in accordance with the applicable overhaul manual as soon as possible.

NOTE: Take care to prevent displacement or damage to the crankshaft oil seal and silk thread. Ensure thrust washer halves and bearing halves remain in place.

6. After crankcase torque, follow the instructions in Section 10-10 to install the nose oil seal.

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Lubricants, Sealants, and Adhesives

Figure 3-5. Crankcase Threading Diagram - O300

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

Standard Practice Maintenance Manual 3-15 15 Sep 2019

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Lubricants, Sealants, and Adhesives

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

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

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15 Sep 2019

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Lubricants, Sealants, and Adhesives

Figure 3-9. Crankcase Threading Diagram - GTSIO520

Standard Practice Maintenance Manual 3-17 15 Sep 2019

Page 80

Lubricants, Sealants, and Adhesives

3-4.2. Scavenge Pump Body Sealant and Threading

1. Use full strength, non-thinned P/N 654663 (gasket sealant). Shake or mix well before using.

NOTE: Apply gasket sealant and threading (a continuous, single piece) only as illustrated.

2. Apply P/N 654663 (gasket sealant) to scavenge pump body according to the manufacturer’s instructions only in areas where threading is indicated. When applying, use short light brush strokes until an even thin coat is obtained. The gasket sealant should be viscous enough that most of the brush marks disappear; if not, discard the old gasket sealant and reapply with new gasket sealant.

NOTE: Allow the gasket sealant to air dry to a tacky condition before applying silk threading.

3. Apply a thin translucent coat of P/N 646942 (gasket maker), not to exceed 0.010 inch thick, to areas of the starter adapter cover where gasket sealant was applied on the mating surfaces.

4. Apply and position P/N 641543 (a continuous, single piece of grade “D” silk thread) as shown by the dashed lines in Figure 3-10.

5. Assemble and torque as soon as possible in accordance with the applicable overhaul manual.

Figure 3-10. Scavenge Pump Body Threading Diagram

Applicable to scavenge pump bodies, Part Nos. 640741, 652019, 655713,

used on starter adapters 642087 & corresponding 0.015 oversize adapters

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3-4.3. Oil Pump Assembly Sealant and Threading

1. Use full strength, non-thinned P/N 654663 (gasket sealant). Shake or mix well before using.

NOTE: Apply gasket sealant and threading (a continuous, single piece) only as illustrated.

2. Apply P/N 654663 (gasket sealant) to the oil pump housing according to the manufacturer’s instructions only in areas where threading is indicated. When applying, use short light brush strokes until an even thin coat is obtained. The gasket sealant should be viscous enough that most of the brush marks disappear; if not, discard the old gasket sealant and reapply with new gasket sealant.

NOTE: Allow gasket sealant to air dry to a tacky condition before applying silk threading.

3. Apply a thin translucent coat of P/N 646942 (gasket maker), not to exceed 0.010 inch thick, to areas of the oil pump cover where gasket sealant was applied on the mating surfaces.

4. Apply and position P/N 641543 (a continuous, single piece of grade “D” silk thread) as shown by the dashed lines in Figure 3-11 through Figure 3-15.

Lubricants, Sealants, and Adhesives

5. Assemble and torque as soon as possible according to the overhaul manual instructions.

Figure 3-11. Oil Pump Assembly Threading Diagram

Applicable to oil pump assembly, Part Nos. 631713, 632481, 632563, & 641993

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Lubricants, Sealants, and Adhesives

Figure 3-12. Oil Pump Assembly Threading Diagram

Applicable to oil pump assembly, Part No. 632623

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Lubricants, Sealants, and Adhesives

Figure 3-13. Oil Pump Assembly Threading Diagram

Applicable to oil pump assembly,

Part Nos. 646194, 653536, 655121, & 643527

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Lubricants, Sealants, and Adhesives

Figure 3-14. Oil Pump Assembly Threading Diagram

Applicable to oil pump assembly, Part Nos. 643716, 643717, 643743, 643778, 643779, 653494,

653538, 653542, 653542, 653553, 655117, 655119, 655123, 655124, & 655127

Figure 3-15. Oil Pump Assembly Threading Diagram

Applicable to oil pump assembly,

Part Nos. 631149, 632970, 632977, 654437, 655349, & 655680

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Lubricants, Sealants, and Adhesives

3-4.4. Starter Adapter Assembly Sealant and Threading

1. Use full strength, non-thinned P/N 654663 (gasket sealant). Shake or mix well before using.

NOTE: Apply gasket sealant and threading (a continuous, single piece) only as illustrated.

2. Apply P/N 654663 (gasket sealant) to the starter adapter housing according to the manufacturer’s instructions only in areas where threading is indicated. When applying, use short light brush strokes until an thin, even coat is obtained. The gasket sealant should be viscous enough that most of the brush marks disappear; if not, discard the old gasket sealant and reapply with new gasket sealant.

NOTE: Allow gasket sealant to air dry to a tacky condition before applying silk threading.

3. Apply and position P/N 641543 (a continuous, single piece of grade “D” silk thread) as shown by the dashed lines in Figure 3-16.

4. Temporarily install the starter adapter to make an impression of the silk thread on the accessory case.

5. Carefully remove the starter adapter so that the shaft gear does not pull out.

Figure 3-16. Starter Adapter Assembly Threading Diagram

Applicable to starter adapter assembly,

Part Nos. 641348, 646220, & 653074

6. Inspect the thread impression for 100% contact between the starter adapter housing and accessory case.

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Lubricants, Sealants, and Adhesives

7. Apply a thin translucent coat of P/N 646942 (gasket maker), not to exceed 0.010 inch thick, to areas of the accessory case that mate with the gasket sealant on the starter adapter housing.

8. Install and torque the starter adapter according to the instructions in the applicable overhaul manual as soon as possible.

9. Wipe excess sealant from the accessory case and starter adapter.

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

1. Use full strength, non-thinned P/N 654663 (gasket sealant). Shake or mix well before using.

NOTE: Apply gasket sealant and threading (a continuous, single piece) only as illustrated.

2. Apply P/N 654663 (gasket sealant) to 2-4-6 case half. Apply gasket sealant per the manufacturer’s instructions only in areas where threading is indicated. When applying, use short light brush strokes until an even thin coat is obtained. The gasket sealant should be viscous enough that most of the brush marks disappear; if not, remove old gasket sealant and reapply with new gasket sealant.

NOTE: Allow gasket sealant to air dry to a tacky condition before applying silk threading.

3. Apply a thin translucent coat of P/N 646942 (gasket maker), not to exceed 0.010 inch thick, to the mating area of the accessory drive cover.

4. Apply and position P/N 641543 (a continuous, single piece of grade “D” silk thread) as shown by the dashed lines in Figure 3-17.

5. Assemble and torque as soon as possible according to the overhaul manual instructions.

Figure 3-17. Accessory Drive Cover Threading Diagram

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Airworthiness Limitation Section

Chapter 4. Airworthiness Limitation Section

Each aircraft engine certified under Title 14 Code of Federal Regulations (CFR), § 33 Amendment 9 or later requires an Airworthiness Limitation Section in the principal (primary) Instructions for Continued Airworthiness that is segregated and clearly distinguishable from the rest of the manual. Consult Section 1-1.1 of this manual to determine the part number of the primary ICA for your engine.

Continental engine Instructions for Continued Airworthiness with an initial publication date later than 1984 contain an Airworthiness Limitation Section.

Continental piston aircraft engines certified under CAR 13 or prior to 14CFR § 33 Amendment 9 predate the Airworthiness Limitation Section requirement; consult the latest revision of Continental SIL97-1 for information regarding engine Instructions for Continued Airworthiness that do not contain an Airworthiness Limitation Section.

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Airworthiness Limitation Section

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Chapter 5 .Engine Removal & Installation

5-1. Engine Removal

5-1.1. Tools and Consumable Supplies

WARNING

Ensure engine hoist and slings are designed to support the weight of the total engine weight, including accessories.



Use of engine lifting eyes to lift the aircraft is strictly prohibited.

CAUTION: Keep crankshaft axis horizontal during handling operations.

1. Engine Hoist (rated for 800 lbs. minimum)

2. Two (2) engine slings (rated for 800 lbs. minimum)

3. Engine Transport Stand

4. Catch Basins (oil and fuel)

Engine Removal & Installation

5. Tank Sprayer with Stoddard Solvent (exterior engine cleaning)

5-1.2. Engine Removal Procedure

Reference the principal ICA (Section 1-1.1) for the engine being installed for removal procedures.

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Engine Removal & Installation

5-2. Engine Installation

5-2.1. Common Tools and Consumable Supplies

WARNING

Ensure engine hoist and slings are designed to support the weight of the total engine weight, including accessories.



Keep crankshaft axis horizontal during handling operations.

1. Engine Hoist (rated for 800 lbs. minimum)

2. Two (2) engine slings (rated for 800 lbs. minimum)

3. Oil conforming to SAE J1966 (break-in oil, non-dispersant mineral oil) MIL-C6529 Type II (Fly-away oil)

4. Ashless dispersant oil conforming to SAE J1899

5. MIL-PRF-46002, Grade 1 oil

6. Approved fuel for the engine model (see Section 7-2.2) or Type Certificate Data Sheet (TCDS)

7. Spark plugs and copper gaskets

8. MS20995 Type A Safety Wire (0.020” and 0.032”)

9. Cable ties or nylon lacing cord

10. Bladder-type pressure pot (at least 1 gallon capacity)

11. Type 1 flammable fuel container (at least one gallon capacity)

12. Clean fuel hoses (fuel system setup)

13. AN union fittings (fuel system setup)

14. Rubber grommets (bulkhead and baffle pass-through)

15. MS-122AD Spray (procured from Miller-Stephenson)

16. Spark Plug Manufacturer’s recommended spark plug thread lubricant

17. Continental P/N 646940, Hydraulic Sealant

18. Continental P/N 646943, Anti-seize Lubricant

19. Continental P/N 658769, PS/T Pipe Sealant

20. Other supplies required by the aircraft manufacturer’s instructions.

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5-2.2. Engine Receipt and Handling

When the engine arrives, inspect the crating for damage. If the engine crating appears damaged, notify the freight shipping company for resolution. If the crating appears intact, proceed to Section 5-2.3.

5-2.3. Uncrating the Engine

1. Remove the lag screws attaching the wooden cover to the base.

2. Lift the wooden cover and remove it.

3. Open the plastic bag wrapped around the engine.

4. Inspect the engine according to the “Acceptance Inspection” criteria in Section 5-

2.5.

NOTE: The engine is preserved for long term storage at the factory; if it is not immediately installed after acceptance, refer to the “Engine Preservation and Storage” instructions in Chapter 9 for ongoing corrosion protection instructions. Environmental conditions (humidity), seasonal changes, and engine usage influence susceptibility to corrosion. In areas of high humidity, corrosion can occur within two days of uncrating the engine. The owner/operator is responsible for recognizing the risk of corrosion and taking the appropriate precautions.

Engine Removal & Installation

5. If the engine will be stored for any length of time, refer to the “Engine Preservation and Storage” instructions in Section 9.

5-2.4. Crating an Engine for Shipping

1. Lower the engine onto the container base.

2. Attach the engine using shock mounts and bolts.

3. Cover the engine with a plastic bag.

4. Install and attach the container cover to the base.

5-2.5. Acceptance Inspection

CAUTION: If hidden engine damage or corrosion is discovered, contact Continental (see “Contact Information” in Section 1-3). Do not install or place a damaged/corroded engine in storage.

1. Verify the engine serial number and model number on the engine nameplate are the same as specified in the engine logbook and the packing slip.

2. Inspect the engine for signs of damage or corrosion.

a. If the engine exhibits no sign of damage or corrosion, proceed with installation.

b. If damage or corrosion is discovered, contact the supplier of the engine for

disposition.

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Engine Removal & Installation

5-2.6. Engine Transport

Refer to the “Engine Installation Drawings” in the primary ICA (Section 1-1.1) for lifting eye locations.

CAUTION: Do not allow chains to become entangled on the engine or its hardware. Ensure the area is clear when lifting the engine. Do not allow the front, rear, sides or bottom of the engine to strike any obstructions as the extreme weight may damage the engine or its components.

1. Attach a hoist to the engine lifting eyes located at the top of the crankcase backbone.

2. Take up slack on the hoist prior to loosening the engine mount bolts; remove the bolts from the shipping shock mounts.

3. Lift the engine and install it on a transportation stand or dolly.

5-2.7. Engine Installation Procedures

Refer to the engine installation instructions in the primary ICA for the engine being installed when installing a like engine as a replacement. For engines being installed for the first time in a new aircraft, refer to the engine installation manual.

NOTE: The installer is authorized to reposition engine component fittings, if necessary, to mate with the aircraft interfaces, See Section 5-2.8.

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Engine Removal & Installation

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

Converters

Continental supplies engines to aircraft Original Equipment Manufacturer’s (OEM) and STC Converters. These engines have been assembled, tested and inspected in accordance with Continental FAA approved quality system standards and FAA issued Production Certificate.

NOTE: Fitting orientation is determined at the time engine model specification is designated for the aircraft application. If fitting orientation adjustment is required for every engine installation, a model specification change request may be more appropriate than repeated repositioning of fittings.

Normally, only minor adjustments to the engine fuel system will be necessary at engine installation (Reference Section 6-4.7, “Engine Operational Check”). Occasionally, minor adjustment may be necessary to other engine systems, components, or to position fittings for best routing and fit.

Continental hereby authorizes the specified adjustment and component replacements listed in Table 5-1 to OEM and STC Converters who are approved by the FAA as an aircraft production facility or FAA Approved modification facility.

Personnel performing the specified adjustment and component replacements must be a licensed Airframe and Power Plant mechanic or be approved by the OEM or STC Converter facilities quality assurance to be capable of performing the specific task. Work shall be performed in accordance with applicable continued airworthiness instructions including but not limited to the engine Installation Manual, Maintenance and Overhaul (or Overhaul) Manual, Service Documents.

All work performed in accordance with these instructions must be documented by the individual performing the task on the OEM or STC Converters FAA approved Quality Inspection Document and traceable by engine and/or aircraft serial numbers.

Adjustments and/or replacements accomplished in accordance with these instructions must be documented by the OEM on the aircraft production paper work. Additionally, the OEM must provide Continental notification of adjustments and replacements accomplished in accordance with these instructions. If a component part is replaced, the OEM must provide the part number and serial number of the component removed and the part number and serial number of the component installed. Return of any removed component is to be coordinated with Continental via the OEM/Converter Customer Portal.

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Engine Removal & Installation

Table 5-1. Authorized Adjustments and Replacements

Authorized Adjustments Authorized Replacements

Accessory Drive Belts Alternator

Baffles and Baffle Seals Baffles

Engine Control Cable Support Brackets and Attachment Points

Fluid Lines and Hoses, Attachment and Support Engine Mount Legs

Fuel Pump, Throttle & Fuel Control Unit Fittings Exhaust System Components

• Fuel Drain Fitting(s) Fuel Injector Nozzles

• Fuel Inlet Fitting Fuel Injection Lines and Hoses

• Fuel Return Fittings Ignition Harness

• Fuel Vapor Return Fittings Manifold Valve

Fuel System Adjustment Magnetos

Induction System Hose Clamps Magneto Sensor(s)

Magneto Orientation (positioning) Oil Coolers and adapter plates

Magneto Timing to Engine Oil Filters

Oil Supply and Return Fittings Oil Screens

Reference Air Fittings Oil Pump

Worm Screw Clamps Oil Sump and Gasket

Carburetor and/or Carburetor Airbox

Crankshaft/Propeller Shaft Nose Oil Seal

Spark Plugs

Starter Adapter Assembly

Starter Motor

Turbocharger and Turbocharger System Components

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5-2.9. Engine Pre-oiling

See also “Lubrication System Priming” in Section 10-12.3.

Do not exceed the starter duty cycle to rotate the engine during engine pre-oiling. Persistent engagement of the starter to rotate the crankshaft will exceed the starter duty cycle and may result in premature starter failure.

1. Install and torque the spark plugs and ignition lead wires according to the “Ignition System Maintenance” instructions in Section 6-4.9.

2. Verify lubrication lines, fittings, hoses, screens, and filters are in place prior to preoiling.

3. Obtain a 1-gallon capacity bladder-type pressure pot with an output pressure of 50 psi (not to exceed 60 psi).

4. Connect the pre-oiler supply hose to the engine oil pressure output (fitting). It may be necessary to disconnect the aircraft oil pressure sensor fitting according to the aircraft manufacturer's instructions.

5. Remove the rocker covers.

Engine Removal & Installation

WARNING

6. Open the pre-oiler valve and monitor the rocker arms for oil flow. Depending upon oil temperature, it may take several minutes to see an indication of oil flow.

7. Close the pre-oiler valve upon verification of oil flow at the rocker arms.

8. Install the rocker covers with new gaskets according to the “Cylinder Installation” instructions in the primary ICA (Section 1-1.1). Torque the rocker cover fasteners to Appendix B specifications.

9. Disconnect the pre-oiler supply hose and cap; connect the aircraft oil pressure sensor to the engine oil pressure output according to the aircraft manufacturer's instructions.

WARNING

Do not operate the engine unless the oil is properly serviced.

10. Check the oil level in the sump using the oil gauge rod (dip stick). Verify the engine oil is at the proper level according to instructions in the primary ICA (Section 1-1.1) for the engine model.

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Engine Removal & Installation

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Chapter 6. Engine Inspection and Service

6-1. Engine Inspection Introduction

Inspections described in this chapter apply only to the Continental engines covered by this manual. Perform the engine inspections according to the instructions provided. Perform aircraft inspections according to the aircraft manufacturer's instructions. Refer to the following sections:

• Section 6-2, “Inspection and Maintenance Schedule”

• Section 6-3, “Time Between Overhaul”

• Section 6-4, “Scheduled Inspections”

• Section 6-5, “Unscheduled Maintenance”

• Section 6-6, “Inspection Checklists”

Some inspections are at predetermined intervals (scheduled) while others are based on circumstance (unscheduled). Engine servicing is performed at scheduled intervals but may also be performed “on condition.” The first part of this chapter is devoted to scheduled maintenance intervals and associated procedures; unscheduled maintenance instructions follow the scheduled maintenance instructions.

NOTE: Discrepancies discovered by the person conducting the scheduled or unscheduled inspections, even if the discrepancy is not an itemized inspection item, should be corrected upon discovery. Fuel and oil system contamination affects engine performance and service life. If oil or fuel system contamination is discovered, do not limit the correction to the symptom; isolate and correct the source of the contamination, including any residual material left in the engine by the source of the contamination.

Engine Inspection and Service

6-2. Inspection and Maintenance Schedule

Unless another FAA-approved Inspection Program is established, the Engine Inspection and Maintenance Schedule shows the inspections for the subject engines covered by this manual in their original type design. The inspections described in this chapter apply to the engine and not to the aircraft. Refer to the Aircraft Manufacturer’s manual for airframe inspection requirements.

The inspections are progressive; commencing from the date the engine is placed in service. The inspection intervals are tracked by Engine Log entries and designated by hours of operation or calendar time, whichever occurs first. Inspection techniques must be executed consistently for reliability.

6-3. Time Between Overhaul

Continental provides operational limitations and instructions for your engine along with the requirements for continued airworthiness as specified in the engine Operator Manuals, Maintenance Manuals, Overhaul Manuals, and Service Documents. The Time Between Engine Overhaul provided in this document applies only to engines that have been operated and maintained in accordance with these instructions. Engine mounted components and accessories require overhaul at the same hourly and calendar intervals as the engine, unless otherwise specified by the component or accessory manufacturer.

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Engine Inspection and Service

An engine’s published TBO DOES NOT mean that every engine will operate the number of hours or years listed without requiring component replacements and/or unscheduled maintenance events. Noncompliance with Continental instructions for continued airworthiness, operational and/or environmental factors may necessitate repair or replacement of the engine, engine components and accessories earlier than the published TBO.

TBO periods were established on most Continental engines beginning in the 1960s. Since that time, Continental has made significant engineering improvements to virtually all major engine components. Continental has refined manufacturing processes and implemented computer numerical controlled (CNC) machining tools enabling Continental factory engines to meet higher standards than possible when the engines were originally granted FAA Type Certificates. These improvements have enabled Continental to increase TBO limits for many of our new and rebuilt engines.

Continental recommends the following factors be used, along with the engine’s published TBO, to determine the engine’s continued airworthiness:

1. Environmental corrosion occurs internally and externally on an engine. This naturally occurring process can affect continued airworthiness of the engine and engine mounted components or accessories. Regardless if the engine has been operated regularly or has been in storage; gaskets, seals, and synthetic and natural rubber goods deteriorate over time. Replace or overhaul the engine upon accumulating the operating hours specified in Table 6-1, or twelve (12) years after being placed in service, whichever occurs first.

2. For engines used in aerial spraying, TBO is 1200 hours or twelve (12) years whichever occurs first.

3. Engines used in parachute jumping, glider towing, banner towing, blimp propulsion, or other unusually stressful applications may require more frequent overhauls than listed.

4. The quality of parts, accessories and workmanship utilized during routine maintenance, engine top overhaul and major overhaul has a direct effect on the service life of the engine. Also, the maintenance and condition of engine-related components - including, but not limited to, propeller, propeller governor, vacuum pump, gear driven alternator, mount, baffles, instrumentation, and controls has a direct effect on engine durability. The TBO periods listed are predicated on the engine having been maintained according to the Instructions for Continued Airworthiness, (ICA) accepted by the FAA, specified in the engine Maintenance Manual, Overhaul Manual, and Service Documents, and operated within the limitations published in the engine operating instructions or the aircraft manufacturer’s Aircraft Flight Manual / Pilot’s Operating Handbook (AFM / POH).

5. Continental does not provide a TBO for engines that have been:

• Assembled with parts not supplied by Continental

• Assembled with parts that do not conform to the original FAA approved type

design for the engine

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Engine Inspection and Service

• Modified from the original type certificate configuration

• Overhauled or repaired in a manner that is inconsistent with the specifications,

limits, and instructions provided in the Continental Instructions for Continued Airworthiness and FAA Airworthiness Directives

6. The “Hobbs Meter” is commonly used by the aviation industry as an acceptable device to record time elapsed while electrical power is applied to the device. The conditions under which the Hobbs Meter records operation vary widely within the aviation industry. Continental does not specify a method to record engine operating hours, rather, Continental defers to the end application installer.

NOTE: TBO periods specified in this document are only estimates and do not reflect warranty periods. For engine warranty coverage, refer to the original Aircraft Engine Warranty received with the engine.

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

HOURS/YEARS

ENGINE MODEL SEE NOTE

A65, A75 and C75, C85, C90 Series

O-200-A, B

O-200-D

IO-240-A, B

IOF-240-B

IO-346-A

C125, C145 Series and O-300-A, B, C, D

GO-300-A, C, D, E

IO-360-A, AB, B, C, D, G, H, J, K

IO-360-CB, DB, GB, HB, JB

IO-360-AF, ES, KB

TSIO-360-A, AB, B, C, D, E, F, H

LTSIO-360-E

TSIO-360-CB, DB, HB, JB

L/TSIO-360-EB, FB, GB, KB, LB, MB, RB, SB

E165, E185, E225 Series

O-470-A, B, E, G, N, P

O-470-J, K, L, M, R, S

O-470-U

IO-470-C, D, E, F, G, H, J, K, L, M, N, P, R, S, U, V, VO

TSIO-470-B, C, D

IO-520-B, BA, C, M

IO-520-A, BB, CB, D, E, F, J, K, L, MB

L/IO-520-P

1, 2

1, 2, 3

1, 2

ENGINE

S/N BEFORE

1006000

ENGINE

S/N 1006000

AND LATER

1800/12

1800/12 2000/12

2000/12 2200/12

1500/12

1800/12

1200/12

1500/12

1500/12 1700/12

2000/12 2200/12

1400/12

1400/12 1600/12

1800/12 2000/12

1500/12

1500/12 1700/12

2000/12 2200/12

1500/12 1700/12

1400/12

1700/12

1700/12 1900/12

2000/12 2200/12

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Engine Inspection and Service

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

HOURS/YEARS

ENGINE MODEL SEE NOTE

GTSIO-520-F, K

GTSIO-520-C, D, H

GTSIO-520-L, M, N

GTSIO-520-S

TSIO-520-B, D, E, J, K, L, N

TSIO-520-BB, C, DB, EB, G, H, JB, KB, LB, M, P, R, T

TSIO-520-NB

TSIO-520-M, P, R

TSIO-520-AF, CE, UB, VB, WB

L/TSIO-520-AE

TSIO-520-BE

IO-550-A, B, C, D, E, F, L

IO-550-G, N, P, R

IOF-550-N

TSIO-550-B, E

TSIO-550-C, G, J, K, N

TSIOF-550-D, J, K, P

TSIOL-550-A, B, C

1, 4

1, 2

1, 2, 5

1, 2

ENGINE

S/N BEFORE

1006000

ENGINE

S/N 1006000

AND LATER

1200/12

1600/12

N/A 1800/12

1400/12

1400/12 1600/12

1600/12 1800/12

2000/12 2200/12

1700/12 1900/12

2000/12 2200/12

1600/12 1800/12

2000/12 2200/12

2000/12

1. If an engine consistently accumulates 40 or more hours per month since being placed in service, add 200 hours to recommended TBO.

2. Engines with Serial Number 1006000 or higher include an additional 200 hours to TBO (as noted in Table 6-1, column 3).

3. Applies to: new and rebuilt O-470U Model Specifications 11, 12, 13, 14, 17, 18, and subsequent numbers manufactured, new or rebuilt, or overhauled (2002 or later).

4. Applies to GTSIO-520-C, D, H engine models listed utilizing cylinder part number 653453, or superseding (cylinder production released APRIL 1993-verify part number on cylinder flange). Also, all parts must be replaced as directed by the applicable current service bulletins, illustrated parts catalogs, and overhaul manuals. A log book entry is required.

5. Applies to new and rebuilt TSIO-520-M Spec. 6, 7, and 8; TSIO-520-P Spec. 5 and 6; TSIO-520-R Spec. 7, 9, 10, and 11, or new and rebuilt TSIO-520-M, P, and R model engines with subsequent specification numbers.

6-4 CHANGE 3

Standard Practice Maintenance Manual

6 January 2023

Continental SPARK IGNITED ENGINES MAINTENANCE MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual

Chapter 1. Introduction

1-1. Scope and Purpose of This Manual

1-1.1. Instructions for Continued Airworthiness

1-1.2. Advisories

1-1.3. Effectivity Symbols

1-1.4. Using this Manual

1-1.5. Compliance

1-1.6. Order of Precedence

1-2. Publications

1-2.1. Publication Access

1-2.2. Publication Changes

1-2.3. Update/Change Distribution

1-2.4. Service Documents

1-2.4.1. Service Documents Incorporated in this Manual

1-2.4.2. Service Documents Released After Publication

1-2.5. Related Publications

1-2.5.1. Suggestions and Corrections

1-3. Contact Information

1-4. Service Parts

1-4.1. Service Part Applicability and Availability

1-4.2. Part Supersedure

2-1. Special Tools

Chapter 2. Tools

2-1.1. Vendor Contact Information

2-2. Mechanic’s Tools

Chapter 3 . Lubricants, Sealants, and Adhesives

3-1. Engine Oil Specifications

3-2. Oil Change Intervals

3-3. Additives

3-4.1. General Sealant Application Instructions

3-4.1.1. Four Cylinder Engine Crankcase Threading

3-4.1.2. Six Cylinder Engine Crankcase Threading

3-4.2. Scavenge Pump Body Sealant and Threading

3-4.3. Oil Pump Assembly Sealant and Threading

3-4.4. Starter Adapter Assembly Sealant and Threading

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

Chapter 4. Airworthiness Limitation Section

Chapter 5 .Engine Removal & Installation

5-1. Engine Removal

5-1.1. Tools and Consumable Supplies

5-1.2. Engine Removal Procedure

5-2. Engine Installation

5-2.1. Common Tools and Consumable Supplies

5-2.2. Engine Receipt and Handling

5-2.3. Uncrating the Engine

5-2.4. Crating an Engine for Shipping

5-2.5. Acceptance Inspection

5-2.6. Engine Transport

5-2.7. Engine Installation Procedures

5-2.9. Engine Pre-oiling

Chapter 6. Engine Inspection and Service

6-1. Engine Inspection Introduction

6-2. Inspection and Maintenance Schedule

6-3. Time Between Overhaul