Continental Refrigerator IO-240-A, IO-240-B Installation And Operation Manual

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IO-240-A

CONTINENTAL® AIRCRAFT ENGINE

INSTALLATION

AND

OPERATION

MANUAL

FAA APPROVED

Publication OI-6

2011 CONTINENTAL MOTORS, INC. OCT 2011

Supersedure Notice

This manual is a revision of the Continental Motors IO-240 Operation and Installation Manual, Part No. X30620, released on January 1996. Upon FAA Approval, this manual supersedes X30620 in its entirety.

Effective Changes for this Manual

0..........31 October 2011

List of Effective Pages

Document Title: IO-240 Series Engine Installation & Operation Manual Publication Number: OI-6 Initial Publication Date: 31 October 2011

Page Change Page Change Page Change Page Change

Cover............................0

A...................................0

i-xii................................0

1-1 thru 1-10.................0

2-1 thru 2-32.................0

3-1 thru 3-30.................0

4-1 thru 4-28.................0

A-1 thru A-4..................0

B-1 thru B-10................0

C-1 thru C-20 ...............0

Published and printed in the U.S.A. by Continental Motors, Inc. Available exclusively from the publisher: P.O. Box 90, Mobile, AL 36601 Copyright © 2011 Continental Motors, Inc. All rights reserved. This material may not be reprinte d, republished, broadcast, or o therwise

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.

A IO-240 Series Engine Installation & Operation Manual

31 October 2011

Service Document and Technical References

Technical information in the service documents listed below relevant to the engine models covered by this engine manual have been incorporated in the manual. The full content of active Continental Motors engine service documents is available http://continentalmotors.aero. Refer to Section 1-3, “Contact Information” for Continental Motors web site details.

Service Document Subject Affected Chapter

M64-18, Turbocharger Field Conversion Engine Modification N/A M72-17R1, Maximum Weight Difference Allowance Between

Connecting Rods and Pistons in the Same Engi ne M73-13, Reaming and Bushing Rocker Shaft Bosses M75-6R1, Conversion of Engines From One Model to Another Engine Configuration N/A

M76-4, Installation Of Propeller Shaft Or Nose Oil Seals Oil Seal Replacement N/A M76-5R1, Remote Mounted Oil Coolers

M76-8, Intake Valve Change M76-15, Fuel Pumps

M77-19, Intake and Exhaust Rocker Arm Identification and Application

M81-8R1, Fuel Pump Screen Restriction M81-25, Exhaust Flange to Cylinder Installation Procedures Engine Installation N/A

M86-9, Crankcase Modification Engine Overhaul N/A M87-15, Alternator Ground Strap Alternator Replacement N/A M88-9, Lightning Strikes Unscheduled Maintenance 4 M88-10, Contaminated Fuels Unscheduled Maintenance 3 & 4 M89-7R1, Engine Operation after Cylinder Replacement and/or

Major Overhaul M89-9, Excessive Crankcase Pressure Unscheduled Maintenance 4 M89-18, EGT Recommendations EGT Leaning 4

M90-9, New TCM Magneto and Harness Applications M90-13, Exhaust Valve Stem Corrosion/Erosion Inspection & Overhaul N/A

M90-17, Crankcase Inspection Criteria Inspection N/A M91-4, Piston Identification and Piston Ring Application Bulletin Piston Replacement N/A M91-9, Cam and Lifter Lubrication during Rebuild Overhaul N/A M93-8, Rocker Arm to Rotocoil Clearance Rocker Arm Clearance N/A M93-10, TCM Ignition Systems Service Bulletin 639 Inspection N/A SIL93-11A, New Service Document Format Service Documents 1 MSB93-12, Valve Retainer Key Installation Inspection Inspection N/A SIL93-14, CFC Compliance N/A N/A

Engine Assembly and Overhaul

Cylinder Repair and Overhaul

Engine Installation and Oil Servicing

Engine Maintenance and Overhaul

Fuel Pump and Camshaft Replacement

Engine Assembly N/A Fuel Pump Inspection and

Parts Replacement

Engine Operation-break-in 4

Magneto and Ignition Harness Replacement

N/A N/A

N/A N/A N/A

N/A

IO-240 Series Engine Installation & Operation Manual i 31 October 2011

Service Document Subject Affected Chapter

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

CSB94-1, TCM Ignition CSB641 Magneto Coil N/A SIL94-5, Mobil AV-1 Oil Authorized Lubricants N/A MSB94-8D, Magneto to Engine Timing Service N/A SB95-2, Inspection and Maintenance of Engine Control Cables

and Linkage SB95-3B, Alternator/Generator Drive Couplings Inspection N/A CSB95-4, Intake Valve Guide Seal Inspection N/A N/A SIL95-5, Hose and Tubing Installation Hose and tubing installation Appendix C CSB96-1, Starter Gear and Clutch Assembly, P/N 653575 Starter Replacement N/A

SID96-6, TCM Ignition SB653 SB96-7C, Torque Limits fastener torque Appendix B MSB96-10, Requirements for Ultrasonic Inspection SB96-11B, Propeller Strikes and Hydraulic Lock Scheduled Inspection 4

SB96-12, Continued Airworthiness for TCM Cylinders Scheduled Inspection N/A SIL97-1, Airworthiness Limitations Airworthiness Limitations N/A SID97-2B, TCM Cylinder Warranties N/A N/A SID97-3E,Procedures and Specifications for Adjustment of TCM

Continuous Flow Fuel Injection Systems SID97-4C, Cylinder Bore and Piston Fit Specifications Overhaul & Service Limits N/A

SB97-6B, Mandatory Replacement Parts CSB97-10A, Piston Pin Plug Wear Service Limits N/A

SIL97-14, Replacement Cylinder Assembly Cylinder Replacement N/A SB97-15, TCM Ignition Service Bulletin SB660 N/A N/A CSB98-1B, Intake and Exhaust Valve Inspection Service Limits N/A

SIL98-9A, Time Between Overhaul Periods

SIL99-1, Engine Preservation for Active and Stored Aircraft SIL99-2C, Current Listing of Sealants, Lubricants and Adhesives

Authorized by TCM SB99-8, Engine Fuel Injection System Preservation SB00-3A, Crankshaft, Counterweight and Connecting Rod

Repair Information SB00-4A, Australian AVGAS Contamination Inspection and Operation N/A SIL00-7A, Oil Gauge Rod Application Oil Servicing N/A SIL00-9A, Engine Data Plates N/A N/A SB00-10, Fuel Pump Seal Fuel Pump Installation N/A

Standard Practices Appendix C

Inspection N/A

Engine Operation-Hot magneto Test

Crankshaft Removal & Replacement

Engine Operational Check and Engine Specifications

Engine Inspection & Assembly

Engine Specifications, Scheduled Maintenance

Engine preservation and returning an engine to service after storage

Materials Throughout Fuel Injection system

storage Repair Specifications N/A

N/A

3, 4

Appendix C

ii IO-240 Series Engine Installation & Operation Manual 31 October 2011

Service Document Subject Affected Chapter

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

CSB02-8, TCM Ignition Systems CSB664 N/A N/A SIL03-1, Cold Weather Operation – Engine Preheating Preheating procedures 4 SIL03-2B, Currently Active Approved Spark Plug Application Spark plugs 2 & 3 SIL03-3, Differential Pressure Test and Borescope Inspection Inspection Criteria N/A SIL03-7, IO-240 Series Magneto Drive Gear Inspection Criteria N/A SIL04-2, Cylinder Barrel Ultrasonic Inspection N/A N/A SB04-4, Manifold Valve Spring Replacement Overhaul Repairs N/A CSB04-5A, TCM Ignition Systems CSB665A Magneto Service N/A SB04-10, Piston Pin Marking Overhaul Repairs N/A SB04-11, Valve Guide Application, Installation and Reaming Valve Guide Repairs N/A

SIL04-1A, Installation of Optional Altitude Compensating Fuel Pump on IO-240-B Series Engines

SIL04-8 Optional Replacement Starter fo IO-240 Series Engines SIL04-9, IO240B13B Manifold Valve Replacement, Heat Isolation

Modifications, and Throttle Body Modifications SIL04-12A, TCM Authorized Engine Adjustments, Component

Replacement and Repositioning SID05-1, Design, Operation and Maintenance of TCM Camshafts

and Hydraulic Lifters SB05-2, Overspeed Limitations Unscheduled Maintenance 4 SIL05-3, Engine Specification Numbers Engine Specification 2

SIL05-4A, IO-240 Series PN 656850 Inline Fuel Filter Installation and Inspection Procedures

SIL05-5A, IO-240-B Series Manifold Valve Fuel Scavenge System Installation

SIL05-6A, IO-240-B Series Product Upgrades SB07-1, Connecting Rod Piston Pin Bushing Inspection Inspection N/A

SB07-3, Procedures and Specifications for adjustment of TCM IO-240-B17B Fuel Injection System installed on Diamond DA20C1 Aircraft

SB07-8, Recommended Minimum RPM & Manifold Pressure Cruise Operations Limits

SB08-3A, Throttle & Mixture Control Arms N/A 4 SB08-4, Fuel Injection System Contamination SB08-8, Slick Service Bulletin SB2-08 Magneto Inspection N/A

SB08-9A, Slick Service Bulletin SB3-08A Magneto Inspection N/A

Cylinder Assembly N/A

Fuel System Specification and Engine Operational Check

Engine Specification and Parts Replacement

Engine Specification 3, 4 Engine Specification N/A Inspection Criteria N/A

Engine Specification, Inspection, Component Replacement

Engine Operation 4

Engine Specification, Inspection, Replacement

3, 4

3 & 4

IO-240 Series Engine Installation & Operation Manual iii 31 October 2011

Service Document Subject Affected Chapter

SB08-13, Induction System Hose and Clamp Installation SB09-14, Camshaft Corrosion Treatmen Engine Inspection N/A

SIL640, Service Document Format Service Documents Preface & 1 SB643B, Maintenance Intervals for TCM Bendix Magnetos Inspection & Operation N/A SB653, Hot Magneto Test Inspection & Operation 3 & 4

Induction System Inspection & Assembly

Appendix C

Service Documents Released After Publication

Continental Motors 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 Chapter 1, expedite customer notification and serve as the prevailing instruction over conflicting information until the new information is incorporated in the manual text. As service documents are received, note the service document number , releas e date, title, a nd applicable sec tion af f ected 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 Bulletins Release After This Manual

Bulletin Number: Release Date: Title: Bulletin Number: Release Date: Title: Bulletin Number: Release Date: Title: Bulletin Number: Release Date: Title: Bulletin Number: Release Date: Title: Bulletin Number: Release Date: Title: Bulletin Number: Release Date: Title: Bulletin Number: Release Date:

/ /

Affected Sections:

Title:

iv IO-240 Series Engine Installation & Operation Manual 31 October 2011

Service Bulletins Release After This Manual

/ /

Affected Sections:

Affected Sections: Title: Bulletin Number: Release Date: Title: Bulletin Number: Release Date: Title: Bulletin Number: Release Date: Title: Bulletin Number: Release Date: Title: Bulletin Number: Release Date: Title: Bulletin Number: Release Date: Title: Bulletin Number: Release Date: Title:

/ /

Affected Sections:

Bulletin Number: Release Date:

IO-240 Series Engine Installation & Operation Manual v 31 October 2011

/ /

Affected Sections:

PREFACE

Continental Motors provides Instructions for Continued Airworthiness based on the design, testing, and certification of engines and parts for which Continental Motors is the holder of the Type Certificate (TC) or Parts Manufacture Approval (PMA) issued by the Federal Aviation Administration (FAA). Instructions in Continental Motors engine manuals, which include maintenance, repair limits, overhaul, and installation, are applicable only to engines and parts supplied by Continental Motors.

Except for F AR part 43.3 authorized owner preventive maintenance, Continental Motors ICAs are written for exclusive use by FAA (or equivalent authority) licensed mechanics or FAA (or equivalent authority) certified repair station employees working under the supervision of an FAA licensed mechanic. 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 certification requirements. No other use is authorized.

Installation of aftermarket parts on a Continental Motors engine constitutes a deviation from FAA approved type-design criteria. Continental Motors has not participated in design, test, or certification of any aftermarket parts. Continental Motors 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 Motors engines. Installation of aftermarket parts on a Continental Motors engine must be performed using Instructions for Continued Airworthiness prepared by the manufacturer and accepted by the FAA for the subject installation. Continental Motors ICAs must not be used for such parts.

Service documents may contain general information or information specific to a group of engines or be in effect for a limited time frame. Service Documents may also contain advance changes to the ICAs. It is the responsibility of the organization/person maintaining or operating the engine to verify that current and complete information, including Service Documents, FAA Airworthiness Directives (ADs), and publications are used.

To facilitate the use of current data, Continental Motors provides information on the Continental Motors web site. The information available includes a listing of the latest manual versions, service documents, FAA ADs, and other information applicable to the ICAs.

Manuals published since 2003 are available on the Continental Motors web site to Fixed Base Operators (FBOs) who subscribe to Continental Motors Internet Services. Information available to Continental Motors engine owners is also available to FBOs. Printed manuals and service subscriptions are also available. Refer to “Publication Access” in Section 1-2.3.

vi IO-240 Series Engine Installation & Operation Manual 31 October 2011

TAB LE OF CON TE NT S

Chapter 1. Introduction

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

1-1.1. Effectivity Symbols...................................................................................................... 1-1

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

1-1.3. Using this Manual...................... ......................................................................... ......... 1-1

1-2. Publications...................................................................................................... 1-3

1-2.1. Service Documents ...................................................................................................... 1-3

1-2.2. Related Publications.................................................. ..................................... .............. 1-4

1-2.3. Publication Access....................................................................................................... 1-5

1-2.4. Publication Changes..................................................................................................... 1-5

1-2.4.1. Update/Change Distribution..............................................................................1-5

1-2.4.2. Suggestions and Corrections .............................................................................1-7

1-3. Contact Information......................................................................................... 1-8

Chapter 2. Engine Description

2-1. General Engine Description............................................................................. 2-1

2-1.1. Engine Model Number Definition ............................................................................... 2-2

2-1.2. Cylinder Number Designations.................................................................................... 2-2

2-2. Detailed Engine Description............................................................................ 2-3

2-2.1. Crankcase..................................................................................................................... 2-3

2-2.2. Engine Drive Train...................................................................................................... 2-4

2-2.2.1. Crankshaft..........................................................................................................2-4

2-2.2.2. Connecting Rods................................................................................................2-5

2-2.2.3. Camshaft...........................................................................................................2-6

2-2.3. Accessory Case........................................................................................................... 2-6

2-2.4. Cylinders...................................................................................................................... 2-7

2-2.4.1. Pistons................................................................................................................2-9

2-2.4.2. Hydraulic Valve Tappets...................................................................................2-9

2-2.5. Lubrication System.................................................................................................... 2-10

2-2.5.1. Oil Pump................................................................... ..................................... ..2-11

2-2.5.2. Oil Sump................................................................... ..................................... ..2-12

2-2.5.3. Oil Pressure Relief Valve ................................. .................................... ... ........2-12

2-2.5.4. Oil Cooler Adapter ................................................... ..................................... ..2-12

2-2.6. Ignition System .......................................................................................................... 2-14

2-2.7. Fuel System................................................................................................................ 2-16

2-2.7.1. Fuel Pump........................................................................................................2-16

2-2.7.2. Fuel Injectors...................................................................................................2-18

2-2.8. Starter Assembly........................................................................................................ 2-18

2-2.9. Alternator ................................................................................................................... 2-18

2-2.10. Engine Cooling ............ ......................................................................... ..................... 2-19

2-2.11. Induction System........................................................................................................ 2-20

2-3. Engine Specifications and Operating Limits ................................................. 2-21

2-3.1. Accessory Drive Ratios........................................................ ...................................... 2-25

2-3.2. Performance Data....................................................................................................... 2-25

IO-240 Series Engine Installation & Operation Manual vii 31 October 2011

2-3.2.1. IO-240-A Performance Charts ........................................................................2-26

2-3.2.2. IO-240-B Performance Charts.........................................................................2-28

Chapter 3.Engine Installation

3-1. Engine Installation........................................................................................... 3-1

3-1.1. Common Tools and Consumable Supplies Required .................................................. 3-1

3-1.2. Engine Receipt and Handling...................................................................................... 3-1

3-1.2.1. Uncrating the Engine.........................................................................................3-2

3-1.2.2. Crating an Engine for Shipping.........................................................................3-2

3-1.2.3. Acceptance Inspection....................................................................................... 3-2

3-1.3. Engine Transport.......................................................................................................... 3-2

3-2. Installation Procedures..................................................................................... 3-4

3-2.1. Prepare the Airframe for Engine Installation............................................................... 3-4

3-2.2. Prepare the Engine for Installation .............................................................................. 3-4

3-2.3. Installation Sequence................................................................................................... 3-5

3-2.3.1. Engine Pre-oiling............................................................................................... 3-7

3-2.3.2. Fuel Purge and Leak Check............................................................................... 3-8

3-2.4. Installation Inspection.................................................................................................. 3-9

3-2.5. Preflight and Run-up.................................................................................................... 3-9

3-3. Engine Installation Drawings ......................................................................... 3-11

3-3.1. IO-240-A Installation Drawings ................................................................................ 3-11

3-3.2. IO-240-B Installation Drawings ................................................................................ 3-15

3-3.3. IO-240 Common Installation Drawings .................................................................... 3-22

Chapter 4. Engine Operation

4-1. Introduction...................................................................................................... 4-1

4-2. Flight Prerequisites .......................................................................................... 4-1

4-2.1. Oil Change Interval........................................................................................... ........... 4-2

4-2.2. Engine Fuel Requirements........................................................................................... 4-2

4-2.3. Flight Check and Break-In........................................................................................... 4-2

4-2.3.1. Engine Break-In ................................................................................................4-3

4-2.3.2. Flight Check ......................................................................................................4-5

4-3. Normal Operation ............................................................................................ 4-7

4-3.1. Pre-operational Requirements...................................................................................... 4-7

4-3.2. Engine Start..................................................................... ..................................... ........ 4-8

4-3.2.1. Cold Start...........................................................................................................4-9

4-3.2.2. Flooded Engine................................................................................................4-10

4-3.2.3. Hot Start ............................................................................................. ............. 4-10

4-3.3. Ground Run-up .......................................................................................................... 4-10

4-3.4. Taxi Preparation.................................................................................. ....................... 4-12

4-3.5. Power Control............................................................................................................ 4-12

4-3.6. Take-Off..................................................................................................................... 4-13

4-3.7. Climb ......................................................................................................................... 4-14

4-3.8. Cruise......................................................................................................................... 4-15

4-3.9. Descent....................................................................................................................... 4-16

4-3.10. Landing ...................................................................................................................... 4-16

viii IO-240 Series Engine Installation & Operation Manual

31 October 2011

4-3.11. Engine Shutdown .................................. ..................................................................... 4-17

4-4. Emergency Operation .................................................................................... 4-18

4-4.1. Engine Fire During Start............................................................... ............................. 4-18

4-4.2. Engine Fire During Flight............................................................. ............................. 4-18

4-4.3. In-Flight Restart......................................................................................................... 4-19

4-4.4. Engine Roughness...................................................................................................... 4-19

4-4.5. High Cylinder Head Temperature..................................... ......................................... 4-19

4-4.6. High Oil Temperature ................................................................................................ 4-20

4-4.7. Low Oil Pressure........................................................................................................ 4-20

4-5. Engine Operation in Abnormal Environments .............................................. 4-21

4-5.1. Engine Operation in Extreme Cold................................................. ........................... 4-21

4-5.1.1. Engine Preheating................................. ..................................... ... ...................4-22

4-5.2. Engine Operation in Hot Weather............................................................ .................. 4-26

4-5.2.1. Cooling an Engine in Hot Weather..................................................................4-26

4-5.2.2. Engine Restart in Hot Weather........................................................................4-27

4-5.2.3. Ground Operation in Hot Weather ..................................................................4-27

4-5.2.4. Take-off and Initial Climb Out in Hot Weather ..............................................4-27

4-5.3. Ground Operation at High Density Altitude.............................................................. 4-28

4-6. Troubleshooting ............................................................................................. 4-28

Appendix A. Glossary

A-1. Acronyms........................................................................................................ A-1

A-2. Glossary.......................................................................................................... A-2

Appendix B.Torque Specifications

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

B-1.1. Torque Tips ................................................................................................................. B-1

B-2. Cylinder Torque Procedure.............................................................................. B-2

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

Appendix C.Standard Practices

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

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

C-2.1. Background................................................................................................................. C-2

C-2.2. Acceptable Replacement Parts.................................................................................... C-2

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

C-2.3. 100% Parts Replacement Requirements..................................................................... C-3

C-2.4. Mandatory Overhaul Replacement Parts .................................................................... C-4

C-2.5. Authorized Oversize/Undersize Parts......................................................................... C-4

C-3. Torque.............................................................................................................. C-4

C-4. Safety Wiring Hardware .................................................................................. C-5

C-5. Tab Washer Installation.................................................................................... C-7

IO-240 Series Engine Installation & Operation Manual ix 31 October 2011

C-6. Helical Coil Insert Replacement...................................................................... C-8

C-6.1. Helical Coil Removal................................................................................................... C-9

C-6.2. Helical Coil Insertion................................................................................................. C-10

C-7. Stud Replacement.......................................................................................... C-11

C-7.1. Stud Removal............................................................................................................. C-11

C-7.1.1. Size-on-Size Rosan® Stud Removal...............................................................C-11

C-7.1.2. Step-Type Rosan® Stud Removal...................................................................C-12

C-7.2. Stud Installation......................................................................................................... C-13

C-7.2.1. Rosan® Stud Installation.................................................................................C-14

C-8. Cotter Pin Installation.................................................................................... C-15

C-9. Fuel System Service ...................................................................................... C-16

C-9.1. Fuel System Purge..................................................................................................... C-16

C-10. Gasket Maker® Application.......................................................................... C-17

C-11. Gasket Installation......................................................................................... C-18

C-12. Hose and Tubing Installation......................................................................... C-19

C-13. Harness Routing............................................................................................. C-20

LIST OF TABLES

Table 1-1. Related Publications .................................................................................... 1-4

Table 2-1. IO-240-A Specifications and Operating Limits .......................................... 2-21

Table 2-2. IO-240-B Specifications and Operating Limits .......................................... 2-23

Table 2-3. Accessory Drive Ratios .............................................................................. 2-25

Table 4-1. IO-240 Operating Limits .............................................................................. 4-4

Table B-1. General Torque Specification .......................................................................B-5

Table B-3. Hose Fitting (“B” Nut) Torque Specification ...............................................B-6

Table B-2. Tube Fitting Torque Specifications ..............................................................B-6

Table B-4. Component Specific Torque Specifications .................................................B-7

Table B-5. Specific Torque for Non-Lubricated Hardware ..........................................B-10

Table C-1. Rosan® Stud Primary & Secondary Bore Specifications ..........................C-12

x IO-240 Series Engine Installation & Operation Manual

31 October 2011

LIST OF ILLUSTRATIONS

Figure 1-1. Figure and Index Reference ................................................................... 1-2

Figure 1-2. Change Page Identification .................................................................... 1-6

Figure 1-3. List of Effective Pages ........................................................................... 1-7

Figure 2-1. Engine Model Definition .......................................................................2-2

Figure 2-2. Cylinder Number Designation ............................................................... 2-2

Figure 2-3. IO-240 Crankcase Features .................................................................... 2-3

Figure 2-4. Engine Drive Train ................................................................................ 2-4

Figure 2-5. Crankshaft .............................................................................................. 2-5

Figure 2-6. Connecting Rod ..................................................................................... 2-5

Figure 2-7. Camshaft ................................................................................................ 2-6

Figure 2-8. Accessory Case Features ....................................................................... 2-7

Figure 2-9. Cylinder Features ................................................................................... 2-8

Figure 2-10. Piston Features ....................................................................................... 2-9

Figure 2-11. IO-240-A Lubrication .........................................................................2-10

Figure 2-12. IO-240-B Lubrication ......................................................................... 2-11

Figure 2-13. Oil Pump ..............................................................................................2-12

Figure 2-14. IO-240-A Oil Cooler Adapter ............................................................. 2-13

Figure 2-15. IO-240-B Oil Cooler Adapter .............................................................2-13

Figure 2-16. IO-240-B Oil Cooler/Filter Adapter ................................................... 2-13

Figure 2-17. Continental Motors Magneto Part Number Structure .......................... 2-14

Figure 2-18. Continental Motors Ignition Distribution ............................................ 2-15

Figure 2-19. Slick Ignition Distribution ................................................................... 2-15

Figure 2-20. IO-240 Standard Fuel Injection System ............................................... 2-16

Figure 2-21. Standard Fuel Pump ............................................................................. 2-17

Figure 2-22. Altitude Compensating Fuel Pump ...................................................... 2-17

Figure 2-23. Fuel Injector ......................................................................................... 2-18

Figure 2-24. Engine Cooling .................................................................................... 2-19

Figure 2-25. IO-240-A Induction System ................................................................. 2-20

Figure 2-26. IO-240-B Crossflow Induction System ............................................... 2-20

Figure 2-27. IO-240-A Fuel Flow vs. Brake Horsepower ........................................ 2-26

Figure 2-28. IO-240-A Sea Level Performance ....................................................... 2-27

Figure 2-29. IO-240-B Fuel Flow vs. Brake Horsepower ........................................ 2-28

Figure 2-30. IO-240-B Sea Level Performance ........................................................ 2-29

Figure 3-1. IO-240-A Top View .............................................................................3-11

Figure 3-2. IO-240-A Left Side View ....................................................................3-12

Figure 3-3. IO-240-A Front View .......................................................................... 3-13

Figure 3-4. IO-240-A Rear View ........................................................................... 3-14

Figure 3-5. IO-240-B Top View ............................................................................. 3-15

Figure 3-6. IO-240-B Left Side View .................................................................... 3-16

Figure 3-7. IO-240-B Front View ...........................................................................3-17

Figure 3-8. IO-240-B Rear View ............................................................................ 3-18

Figure 3-9. IO-240-B w/optional Oil Cooler-Filter Adapter Top View ................. 3-19

Figure 3-10. IO-240-B w/optional Oil Cooler-Filter Adapter Left Side View ........ 3-20

Figure 3-11. IO-240-B w/optional Oil Cooler-Filter Adapter Rear View ................ 3-21

IO-240 Series Engine Installation & Operation Manual xi 31 October 2011

Figure 3-12. Propeller Flange ................................................................................... 3-22

Figure 3-13. Exhaust Flange Dimensions ................................................................ 3-23

Figure 3-14. Standard Fuel Pump Installation .......................................................... 3-23

Figure 3-15. Standard Fuel Pump Adjustments ....................................................... 3-24

Figure 3-16. IO-240-B Altitude Compensating Fuel Pump Adjustments ................ 3-24

Figure 3-17. Throttle Lever Installation ................................................................... 3-25

Figure 3-18. Oil Cooler Adapter Connections ......................................................... 3-25

Figure 3-19. Oil Cooler Adapter Connections ......................................................... 3-26

Figure 3-20. Oil Cooler-Filter Adapter Connections ............................................... 3-26

Figure 3-21. IO-240-A Air Intake Flange ................................................................ 3-27

Figure 3-22. Alternator Connections ........................................................................ 3-27

Figure 3-23. Engine Mounts ..................................................................................... 3-28

Figure 3-24. Continental Motors Magneto Ignition Schematic ............................... 3-29

Figure 3-25. Champion (Slick) Magneto Ignition Schematic .................................. 3-29

Figure 3-26. Airframe Ignition Switch Connections to Magneto ............................. 3-30

Figure B-1. Torque Wrench ......................................................................................B-3

Figure B-2. Drive extensions ....................................................................................B-3

Figure B-3. Extension increases applied torque ........................................................B-4

Figure B-4. Extension decreases applied torque .......................................................B-4

Figure C-1. Right-hand-thread safety wire installation .............................................C-5

Figure C-2. Safety wire Patterns for Right-Hand Threads ........................................C-6

Figure C-3. Tab Washer Installation .........................................................................C-7

Figure C-4. Helical Coil Extraction Tool ..................................................................C-9

Figure C-5. Installing a Helical Coil Insert .............................................................C-10

Figure C-6. Rosan® Stud Removal Tool ................................................................C-12

Figure C-7. Rosan® stud removal tool installed on stud ........................................C-12

Figure C-8. Stud Sizes ............................................................................................C-13

Figure C-9. Minimum Material Thickness for Helical Coil insertion ....................C-14

Figure C-10. Rosan® Stud Installation Dimensions .................................................C-14

Figure C-11. Cotter Pin Installation ..........................................................................C-15

Figure C-12. Installing Hoses and Fittings ...............................................................C-19

xii IO-240 Series Engine Installation & Operation Manual

31 October 2011

Chapter 1 . Introduction

1-1. Scope and Purpose of This Manual

This manual is part of the interface control document for IO-240-A and B engine models. This manual provides airframe interface requirements, installation instructions and engine operating instructions to supplement the Airplane Flight Manual (POH)/Pilot’s Operating Handbook (POH).

Instructions in this manual are specific to the IO-240 Series engines. For information specific to other Continental Motors engine series, accessories, or the airplane, refer to the appropriate manual. Chapters are arranged in sequential order to install, test, and operate the engine.

1-1.1. Effectivity Symbols

Va riations in IO-240 Series engine models require specific instructions or illustrations. If peculiar information pertains to only a specific engine model in the series, an effectivity symbol will accompany the information. Effectivity symbols found in this publication are:

IO-240-A IO-240-B IO-240-B with altitude compensating fuel pump

Introduction

1-1.2. Advisories

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 , ef ficiency, and performance. Abuse, misuse, or neglect of equipment can cause eventual engine malfunction or failure.

1-1.3. Using this Manual

Except for engine installation drawings, illustrations in this manual are for reference only, depicting the most prominent configuration in the engine series. Consult the parts catalogs for engine model-specific illustrated parts breakdowns.

WARNING

This manual and the accessory manuals listed in Table 1-1 and certain service documents, and other related publications constitute the Instructions for Continued Airworthiness

IO-240 Series Engine Installation & Operation Manual 1-1 31 October 2011

Introduction

(ICAs) prepared by Continental Motors and accepted by the Federal Aviation Administration (FAA). This manual is prepared in a user -friendly format suited equally for electronic viewing and print.

Exploded assembly illustrations accompany instructions throughout the manual. Parts in illustrations (Figure 1-1.) are identified with 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.

WARNING

Continental Motors ICAs are applicable only to Continental Motors engines conforming to the approved, type certified engine model configuration. Continental Motors ICAs must not be used for aftermarket parts.

Figure 1-1. Figure and Index Reference

1-2 IO-240 Series Engine Installation & Operation Manual

31 October 2011

1-2. Publications

1-2.1. Service Documents

Continental Motors 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 Motors 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 manufacturer’s ICAs. 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 cancelled or superseded.

1Procedure

Category 1: Mandatory Service Bulletin (MSB)

Used to identify and correct a known or suspected safety hazard which has b een 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 (ICAs) 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 ICAs to address a safety issue.

Introduction

Category 3: Service Bulletin (SB)

Information which the product manufacturer believes may improve the i nherent safety of an aircraft or aircraft component; this category includes the most recent updates to ICAs.

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 ICAs in the form of maintenance procedures or specifications.

Category 5: Service Information Letter (SIL)

This category includes all information (not inclu ded in categories 1 through 4) that may be useful to the owner/operator/technician. May contain updates to ICAs 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

IO-240 Series Engine Installation & Operation Manual 1-3 31 October 2011

Introduction

1-2.2. Related Publications

The table below lists related publications, source, and accessibility relevant to IO-240 Series engine installation and operation.

WARNING

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

Table 1-1. Related Publications

Supplied With

Publication

Engine

Maintenance and Overhaul Manual (M-6) Yes S-20/S-200 Magneto Service Manual (X42002) Yes Yes Yes

Service Documents No Yes Yes Parts Catalog No Yes (view only)No

Available download at

web site

Yes

Printed Manual Available for Purchase

Yes

1. Our web site (http://continentalmotors.aero) provides 24-hour access to engine technical data via the Internet. If you are an internet service subscriber, you can access our web site to confirm and review the latest revision of this manual. If you have not subscribed to internet service and are using printed manuals, contact using the “Contact Information” on page 8. to confirm you have the latest revision of the manual.

1-4 IO-240 Series Engine Installation & Operation Manual

31 October 2011

1-2.3. Publication Access

Contact an authorized Continental Motors distributor to discuss service subscription options and pricing or visit the Continental Motors web site. Printed technical publications may be ordered through authorized Continental Motors distributors or via the Internet at http://continentalmotors.aero.

1-2.4. Publication Changes

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 Motors will make the information available to the customer.

New information may be contained in Continental Motors service documents. Service documents applicable to engines and accessories within the scope of this manual must be complied with as defined in these documents. This manual and other related publications noted herein constitute the ICAs prepared by Continental Motors and accepted by the FAA.

Introduction

WARNING

Continental Motors releases publication changes in the form of either change pages or complete publication revisions, depending upon the extent of change. Service Documents may supplement or replace technical information contained in one publication or an entire series of publications. Such Service Documents represent a change to the published ICA until the individual publications incorporate the latest technical information.

1-2.4.1. Update/Change Distribution

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

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.

IO-240 Series Engine Installation & Operation Manual 1-5 31 October 2011

Introduction

Change Bar

Change Number

Change Date

Change Bar

Change Number

Change Date

Change Bar

Change Number

Change Date

1-6 IO-240 Series Engine Installation & Operation Manual

Figure 1-2. Change Page Identification

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.” 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.

31 October 2011

Introduction

Effective Manual Changes and Change Dates

Itemized List of Effective Pages

Effective Manual Changes and Change Dates

Itemized List of Effective Pages

Figure 1-3. List of Effective Pages

1-2.4.2. Suggestions and Corrections

Continental Motors 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 email to CM.techpubs@continental.aero.

Notify our Customer Service Department immediately, using our toll-free number, if you discover incorrect information which adversely affects safety.

IO-240 Series Engine Installation & Operation Manual 1-7 31 October 2011

Introduction

1-3. Contact Information

Continental Motors is 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 Motors distributor or field representative. To contact a factory representative, refer to the contact information below:

Continental Motors, Inc. P. O. Box 90 Mobile, AL 36601

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

Internet: http://continentalmotors.aero.

1-8 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Chapter 2 . Engine Description

2-1. General Engine Description

IO-240 engines are four-cylinder, four-stroke reciprocating aircraft engines. IO-240-A & B engines are designed for fixed pitch, ground adjustable, or electric constant speed propellers. There is no provision for a hydraulic propeller governor. Cylinder displacement of 240 cubic inches is achieved with a 4.44 inch bore and a 3.88 inch stroke. IO-240 series engines are equipped with continuous flow fuel injection and a either an updraft or a downdraft induction system, depending on the engine model.

IO-240 series engines are designed with a wet sump, positive displacement oil pump installed in the accessory case. When properly maintained, under normal operating conditions, the desired oil pressure is maintained by a pressure relief valve located in the accessory case. Engine cranking is accomplished by a geared starter mounted on the accessory case.

A gear driven alternator is installed on the accessory case. The engine is equipped with two gear-driven magnetos. The downdraft exhaust system is supplied by the airframe manufacturer.

IO-240 series engines have a doweled, six bolt propeller flange.

Engine Description

IO-240 Series Engine Installation & Operation Manual 2-1 31 October 2011

Engine Description

I O-240-B1

Specification Number Model Identifier

Cubic Inch Displacement Horizontally Opposed Cylinders Fuel Injected

Shipping Designation

I O-240-B1

Specification Number Model Identifier

Cubic Inch Displacement Horizontally Opposed Cylinders Fuel Injected

Shipping Designation

2-1.1. Engine Model Number Definition

The description of each alphanumeric character in the engine model number is given below for the example engine model number IO-240-B1B (Figure 2-1).

Figure 2-1. Engine Model Definition

2-1.2. Cylinder Number Designations

Refer to Figure 2-2:

• The front of the engine is the end closest to the propeller and the rear of the engine is

the accessory end.

• V iewed from the rear of the engine, the left-side cylinders are designated by even num-

bers 2-4, with Cylinder 2 being closest to the rear.

• The right side cylinders have odd number sequential designation 1-3, with Cylinder 1

being closest to the rear.

• Firing order of the engine is 1-3-2-4.

Figure 2-2. Cylinder Number Designation

2-2 IO-240 Series Engine Installation & Operation Manual

31 October 2011

2-2. Detailed Engine Description

REAR CRANKSHFT BEARING BORE

Cyl #2 Cyl #4

2-4 OR L/H

CRANKCASE HALF

INTERMEDIATE

CRANKSHAFT BEARING BORE

BACKBONE

CRANKSHAFT NOSE

SEAL LAND

FRONT

CRANKSHAFT

BEARING BORE

CAMSHAFT

BEARING BORE

TAPPET GUIDES

SPINE BELOW

CAMSHAFT

BEARING BORE

OIL SUMP

MOUNT FLANGE

ACCESSORY CASE

MOUNT FLANGE

TAPPET GUIDES

FUEL PUMP MOUNTING PAD

REAR CRANKSHFT BEARING BORE

Cyl #2 Cyl #4

REAR CRANKSHFT BEARING BORE

Cyl #2 Cyl #4

2-4 OR L/H

CRANKCASE HALF

INTERMEDIATE

CRANKSHAFT BEARING BORE

BACKBONE

CRANKSHAFT NOSE

SEAL LAND

FRONT

CRANKSHAFT

BEARING BORE

CAMSHAFT

BEARING BORE

TAPPET GUIDES

SPINE BELOW

CAMSHAFT

BEARING BORE

OIL SUMP

MOUNT FLANGE

ACCESSORY CASE

MOUNT FLANGE

TAPPET GUIDES

FUEL PUMP MOUNTING PAD

2-2.1. Crankcase

Two aluminum alloy castings are joined along the vertical center plane to form the crankcase. The individual castings (with studs and inserts) are referred to as the “left crankcase” and “right crankcase.” The crankcase provides a tight enclosure, sufficiently rigid to support the crankshaft, camshaft and bearings, with oil galleries for lubrication.

Bosses molded in the crankcase castings are line bored in the assembled crankcase halves to form bearings for the camshaft and saddles for precision crankshaft main bearing inserts. Guides are bored through lateral bosses for hydraulic tappets. There are six studs and two through-bolts for attaching cylinder base flanges. The fuel pump mounting pad is located on the left crankcase half, forward of Cylinder 4 (Figure 2-3).

Cylinder mounting pads on the left and right crankcase are offset to permit each crankpin to transmit the rotational force to the piston through the connecting rod. The crankcase interior is vented by a breather assembly comprised of a tube and baffle assembly with a side extension for a hose attachment. The breather assembly is pressed into a boss on the top side of the right crankcase half, forward of Cylinder 3.

Engine Description

Figure 2-3. IO-240 Crankcase Features

IO-240 Series Engine Installation & Operation Manual 2-3 31 October 2011

Engine Description

Starter

Alternator

Crankshaft

Camshaft

Fuel Pump & Vacuum Pump Driv e Shaft

Camshaft GearTachometer

Drive Shaft Oil Pump

Drive Gear

Oil Pump Driven Gear

Starter

Alternator

Crankshaft

Camshaft

Fuel Pump & Vacuum Pump Driv e Shaft

Camshaft GearTachometer

Drive Shaft Oil Pump

Drive Gear

Oil Pump Driven Gear

2-2.2. Engine Drive Train

The engine drive train (Figure 2-4) consists of the crankshaft, camshaft and drive gears. The crankshaft has a propeller flange at one end to attach a propeller for thrust. The starter gear meshes with the outer teeth of the rear crankshaft gear to turn the crankshaft until the fuel mixture in the cylinder is ignited by the spark plugs. A drive gear at the rear end of the crankshaft interfaces with a gear mounted on the rear end of the camshaft to synchronize intake and exhaust valve movement and magneto rotation, as well as supply driving force to the gear driven alternator. The oil pump driven gear, along with the optional tachometer drive are gear driven by the inner row of teeth on the camshaft. The engine driven fuel pump, and the optional vacuum pump drive are driven by a gear on the forward end of the camshaft.

Figure 2-4. Engine Drive Train

2-2.2.1. Crankshaft

The crankshaft (Figure 2-5) is an aircraft quality steel forging with three machined, main journals supported by precision-bearing inserts in each of the three bearing saddles machined in the crankcase. Four machined rod journals provide attachment of the connecting rod assemblies.

The crankshaft gear is indexed on the crankshaft by a dowel and secured by machined bolts. A neoprene oil seal over the crankshaft flange is seated between the crankcase castings in the front shaft exit area, and is sealed to the crankshaft by a helical spring inside the seal's cavity.

2-4 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Description

CRANKSHAFT FLANGE

FRONT MAIN JOURNAL

ROD JOURNAL

ROD JOURNAL ROD JOURNAL

REAR MAIN JOURNAL

MIDDLE MAIN JOURNAL

OIL PASSAGE

CRANKSHAFT FLANGE

FRONT MAIN JOURNAL

ROD JOURNAL

ROD JOURNAL ROD JOURNAL

REAR MAIN JOURNAL

MIDDLE MAIN JOURNAL

OIL PASSAGE

CRANKSHAFT FLANGE

FRONT MAIN JOURNAL

ROD JOURNAL

ROD JOURNAL ROD JOURNAL

REAR MAIN JOURNAL

MIDDLE MAIN JOURNAL

OIL PASSAGE

NOTE: Some older models use castellated nut with cotter pin

SPIRAL LOCK NUT

BRONZE BUSHING

CONNECTING ROD

CONNECTING ROD CAP

ROD BOLT

SHELL BEARING

The flange type crankshaft has a propeller mount flange forged on the front end with six tapped bushings pressed into holes spaced equally around the flange. Six bolts, screwed into the shaft flange bushings, clamp the propeller between a loose front flange and the shaft flange.

Figure 2-5. Crankshaft

2-2.2.2. Connecting Rods

The connecting rods halves (Figure 2-6) are machined from a single forging of aircraft quality steel and cut into two pieces, splitting the center of the larger opening of the connecting rod assembly. The resulting pieces, called the rod and cap are fitted with a two piece bearing and attach to the crankpin or rod journal with special bolts and nuts.

The portion of the rod between the rod and the crankpin and piston pin ends is called the “I” beam. A split steel-backed bronze bushing is pressed into the piston pin end and machined for a precision pin-to-bushing fit.

Figure 2-6. Connecting Rod

IO-240 Series Engine Installation & Operation Manual 2-5 31 October 2011

Engine Description

FRONT REAR

#4 EXH #3 EXH #2 EXH #1 EXH

#3 & 4 INTAKE

#1 & 2 INTAKE

M/J

C/L C/L C/L C/L C/L C/L

M/J M/J

C/L - CAM LOBE

M/J - MAIN JOURNAL

2-2.2.3. Camshaft

The camshaft forging is machined on three main journals, six cam lobes and the gear mount flange at the rear of the camshaft (Figure 2-7). The lobes and journals are ground and hardened. Camshaft main journals are supported in the crankcase by machined bearing saddles. Hydraulic tappets move inward and outward in their bores, following the eccentric shape of the cam lobes. Four unequally spaced bolts secure the gear to the camshaft and ensure proper positioning, locating the gears' timing mark in relation to the cam lobes. The camshaft gear has internal teeth to drive the alternator. A front-mounted bevel gear drives the accessory drive bevel gear and fuel pump through a common shaft.

Figure 2-7. Camshaft

2-2.3. Accessory Case

The accessory case (Figure 2-8) aluminum alloy casting is attached to the rear of the engine crankcase, aligned with crankcase dowels. The accessory case is secured to the crankcase by crankcase studs and various attaching hardware. Accessory mount pads on the rear surface are machined in one plane parallel to the machined parting flange which surrounds the front side of the casting. Mounting pads for the magnetos, alternator cover, starter, tachometer drive, oil filter adapter, oil pressure relief valve and an oil suction screen boss are provided. The accessory case casting has two holes above and three studs to attach the starter. A mounting pad is provided for a permanent oil screen housing. In lieu of the oil screen housing, an oil filter adapter, with a screw-on type oil filter is also available.

The oil pump housing is machined into the internal portion of the accessory case. A machined, threaded boss is located on the lower right side of the accessory case for installation of a non-adjustable oil pressure relief valve. Oil pump gear chambers are machined in the interior of the accessory case. The oil pump drive gear shaft hole is machined in-line with the camshaft and the driven gear shaft hole is directly above it.

A semicircular opening at the accessory case bottom is a machined threaded hole to accommodate installation of the oil suction tube. Passages cast into the accessory case allow oil to flow from the oil suction tube to the oil pump gears, pressure relief valve, and main oil gallery. The tachometer drive shaft is the slotted end of the oil pump driven gear shaft.

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31 October 2011

Engine Description

STARTER MO UNTING PAD

MAGNETO MOUNTIN G PAD

TACH DRIVE MOUNTING PAD

ALTERNATOR MOUNTING PAD

OIL SCREEN HOUSING MOUNTING PAD

OIL PRESSURE HOUSING

MAGNETO MOUNTING PAD

RELIEF VALVE

2-2.4. Cylinders

The IO-240 engine have four, horizontally-opposed, air cooled cylinders, two on the left side and two on the right side of the engine. The cylinders, pistons and valve drive train provide the momentum to sustain crankshaft movement. Aviation fuel and air are drawn into a cylinder during the intake stroke, compressed by the piston during the compression stroke and then ignited by a high intensity spark from each spark plug (two per cylinder). As the mixture is ignited, the expanding gases force the piston to move inward toward the crankshaft during the power stroke.

The head and barrel assembly (Figure 2-9) consists of externally finned aluminum alloy head casting and a steel, nitrided cylinder barrel for wear resistance. Helical coil thread inserts are installed in upper and lower spark plugs holes. A rotocoil assembly retains two concentric springs surrounding the exhaust valve and is locked to the stem by tapered, semi-circular keys which engage grooves around the valve stems. An outer retainer holds two concentric springs which surround the intake valve and is locked to the stem by tapered, semi-circular keys which engage grooves on the stem.

IO-240 Series engines use a cross flow cylinder head design. The intake ports are located on top of the cylinder head while the exhaust ports are located below. There are separate intake and exhaust valve rocker covers made from zinc-plated stamped sheet steel. This cylinder design is used in conjunction with a Balanced Induction System mounted above the engine.

Figure 2-8. Accessory Case Features

IO-240 Series Engine Installation & Operation Manual 2-7 31 October 2011

Engine Description

ROCKER SHAFT

ROCKER ARM

VALVE RETAIN ER

KEYS

ROTOCOIL

EXHAUST

VALVE GUIDE

OUTER SPRING INNER SPRING

SPRING SEAT

INTAKE VALVE GUIDE

INTAKE VALVE SEAT INSERT

INTAKE VALVE

CYLINDER BARREL

EXHAUST

VALVE

COOLING FINS

CYLINDER HEAD

CYLINDER BARREL

COOLING FINS

CYLINDER BASE

FLANGE

CYLINDER SKIRT

ROCKER COVER

RETAINER

EXHAUST VALVE SEAT INSERT

THRUST WASHER

(ONE ON EACH SIDE

OF EACH ROCKER ARM)

Figure 2-9. Cylinder Features

2-8 IO-240 Series Engine Installation & Operation Manual

31 October 2011

2-2.4.1. Pistons

PISTON PIN

MANGANESE PHOSPHATE COATING

GRAPHITE COATED SKIRT

COMPRESSION

RING

COMPRESSION

RING

OIL CONTROL RING

OIL SCRAPER RING

Pistons (Figure 2-10) are aluminum alloy castings with a steel insert cast into the top ring groove. The skirts are solid and have cylindrical relief cuts at the bottom. Pistons have three ring grooves above the piston pin bore and one ring groove below. Compression rings are installed in the top and second grooves. The groove below the piston pin bore contains an oil scraper . A center grooved and slotted oil control ring is installed in the third groove which has six oil drain holes to the interior. Weight differences are limited to ½ ounce between opposing cylinders bays. Piston pins are full floating with permanently pressed-in aluminum end plugs.

Engine Description

2-2.4.2. Hydraulic Valve Tappets

Figure 2-10. Piston Features

The hydraulic valve tappet (lifter) provides an interface between the camshaft lobe and the remaining valve train. Lifters ride on the eccentric cam lobes, opening and closing the intake and exhaust valves mechanically via push rod tubes and rocker arms, converting the cam lobe profile into a linear movement for intake and exhaust valves actuation. The hydraulic mechanism inside the hydraulic mechanism maintains zero clearance between the valve and actuating components.

IO-240 Series Engine Installation & Operation Manual 2-9 31 October 2011

Engine Description

OIL SUCTION TUBE

OIL PRESSURE RELIEF VALVE

CRANKSHAFT BEARINGS

CAMSHAFT BOSS

INTAKE

EXHAUST

PUSHROD HOUSING

PUSHROD

HYDRAULIC LIFTERS

OIL SUMP

OIL PUMP GEARS

OIL FILTER SCREEN

OIL COOLER ADAPTER

OIL SUCTION TUBE

OIL PRESSURE RELIEF VALVE

CRANKSHAFT BEARINGS

CAMSHAFT BOSS

INTAKE

EXHAUST

PUSHROD HOUSING

PUSHROD

HYDRAULIC LIFTERS

OIL SUMP

OIL PUMP GEARS

OIL FILTER SCREEN

OIL COOLER ADAPTER

2-2.5. Lubrication System

The engine lubrication system (Figure 2-11 and Figure 2-12) delivers lubricating oil throughout the engine to various bearings, bushings, and engine components. The wet sump lubrication system consists of an internal engine-driven oil pump, a fixed, nonadjustable pressure relief valve, an oil sump and oil sensing ports. Various optional oil cooler adapters allow connection of an optional remote mounted oil cooler.

2-10 IO-240 Series Engine Installation & Operation Manual

Figure 2-11. IO-240-A Lubrication

31 October 2011

Engine Description

OIL SUCTION TUBE

OIL PRESSURE RELIEF VALVE

CRANKSHAFT BEARINGS

CAMSHAFT BOSS

INTAKE

EXHAUST

PUSHROD HOUSING

PUSHROD

HYDRAULIC LIFTERS

OIL SUMP

OIL PUMP GEARS

OIL FILTER AND BYPASS ASSEMBLY

OIL COOLER ADAPTER

OIL SUCTION TUBE

OIL PRESSURE RELIEF VALVE

CRANKSHAFT BEARINGS

CAMSHAFT BOSS

INTAKE

EXHAUST

PUSHROD HOUSING

PUSHROD

HYDRAULIC LIFTERS

OIL SUMP

OIL PUMP GEARS

OIL FILTER AND BYPASS ASSEMBLY

OIL COOLER ADAPTER

2-2.5.1. Oil Pump

IO-240 Series Engine Installation & Operation Manual 2-11 31 October 2011

Figure 2-12. IO-240-B Lubrication

The engine-driven, gear type oil pump (Figure 2-13) is a positive displacement pump that consists of two meshed steel gears that revolve inside the oil pump cavity machined in the accessory case. The camshaft drives the oil pump drive gear, which drives the oil pump driven gear. The oil pump driven gear is supported by a shaft pressed into the accessory case and the oil pump cover plate. The oil pump drive gear shaft is supported by bushings pressed into the accessory case. The oil pump gear shaft incorporates provisions to drive a mechanical tachometer.

The oil pump housing and oil pump gear chambers are machined in the interior of the accessory case. The oil pump drive gear shaft bore is machined in-line with the camshaft; the driven gear shaft rests in the bore directly above the drive shaft.

Engine Description

Figure 2-13. Oil Pump

2-2.5.2. Oil Sump

The oil sump body is a welded unit composed of front and rear halves of pressed sheet steel. A thick mounting flange ring, an oil filler neck, and drain plug boss are welded to the body to complete the assembly. The oil sump plug boss has provisions for safety wiring the plug. A bracket welded to the neck attaches the oil sump to a stud in the lower crankcase engine mounting arm. At the neck of the oil filler pipe, a locking device retains the dip stick. The dipstick is marked in quarts to the full mark.

2-2.5.3. Oil Pressure Relief Valve

A machined, threaded boss is located on the lower right side of the accessory case for installation of a non-adjustable oil pressure relief valve. Its passages are connected to the oil pump outlet passage. This valve opens when the oil pump pressure exceeds the specified operating limit and directs oil back to the oil sump.

2-2.5.4. Oil Cooler Adapter

The IO-240 engine features an oil cooler adapter (Figure 2-11) or oil cooler/filter adapter, located on the lower 2-4 side crankcase. The IO-240-A (Figure 2-14) and B oil cooler adapters (Figure 2-15 and Figure 2-16) function the same but differ physically. Each incorporates a bypass valve in the event of a clogged oil cooler and have provisions for the attachment of an externally-mounted oil cooler, with bosses for oil temperature and pressure sensors. The oil cooler/filter adapter offers the same functions as the oil cooler adapters with the added feature of a threaded boss for a spin on oil filter.

2-12 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Figure 2-14. IO-240-A Oil Cooler Adapter

OIL BY-PASS FLOW

PLUG

OIL BY-PASS VALVE

PLUG

OIL TEMP.

PORT

OIL FLOW BACK

TO ENGINE

OIL PRESSURE PORT

OIL FLOW OUT TO EXTERNAL

OIL COOLER

OUT

OIL BY-PASS FLOW

PLUG

OIL BY-PASS VALVE

PLUG

OIL TEMP.

PORT

OIL FLOW BACK

TO ENGINE

OIL PRESSURE PORT

OIL FLOW OUT TO EXTERNAL

OIL COOLER

OUT

OUTOUT

ININ

Engine Description

Figure 2-15. IO-240-B Oil Cooler Adapter

IO-240 Series Engine Installation & Operation Manual 2-13 31 October 2011

Figure 2-16. IO-240-B Oil Cooler/Filter Adapter

Engine Description

S 6 R N -1201

Model Number

S-20 Serles

21: Dog-Ear Mount, Impulse Coupled 25: Deep Flange Mount, Impulse Coupled

S-200 Serles

200: Dog Ear Mount, With Retard Breaker 201: Deep Flange Mount, With Retard Breaker 204: Dog Ear Mount 205: Deep Flange Mount

S-1200 Serles

1201: Deep Flange Mount, With Retard Breaker 1205: Deep Flange Mount 1208: Short Flange Mount, With Retard Breaker 1209: Short Flange Mount 1225: Deep Flange Mount, Impulse Coupled 1227: Short Flange Mount, Impulse Coupled 1251: Pressurized Version of 1201 1255: Pressurized Version of 1205 1258: Pressurized Version of 1208 1259: Pressurized Version of 1209

D-3000 Serles

3000: Impulse Coupled 3200: With Retard Breaker

Magneto Configuration

S = Single Type Magneto: one drive, one output distributor D = Dual Type Magneto: one drive, two output distributors

Cylinders Fired

4 = Four Cylinders 6 = Six Cylinders 8 = Eight Cylinders

Rotatlon

(Viewed Looking in to Drive End)

L = Left (counterclockwise)

R = Right (clockwise)

Designator

N = Scintilla Design

SC = Short Cover

Suffix: S-20 and S-200 Series Only

T= Tachometer Breaker Points P= Pressurized

S 6 R N -1201

Model Number

S-20 Serles

21: Dog-Ear Mount, Impulse Coupled 25: Deep Flange Mount, Impulse Coupled

S-200 Serles

200: Dog Ear Mount, With Retard Breaker 201: Deep Flange Mount, With Retard Breaker 204: Dog Ear Mount 205: Deep Flange Mount

S-1200 Serles

D-3000 Serles

3000: Impulse Coupled 3200: With Retard Breaker

Magneto Configuration

S = Single Type Magneto: one drive, one output distributor D = Dual Type Magneto: one drive, two output distributors

Cylinders Fired

4 = Four Cylinders 6 = Six Cylinders 8 = Eight Cylinders

Rotatlon

(Viewed Looking in to Drive End)

L = Left (counterclockwise)

R = Right (clockwise)

Designator

N = Scintilla Design

SC = Short Cover

Suffix: S-20 and S-200 Series Only

T= Tachometer Breaker Points P= Pressurized

2-2.6. Ignition System

Two magnetos, installed on the aft side of the accessory case use magneto drive adapters to interface with the crankshaft gear. IO-240 Series engines are fitted with either Champion (Slick) 4301or Continental Motors S4LSC-21 series magnetos, designed to provide ignition for four cylinder aircraft engines. The Continental Motors magneto model number identifies the key features of each magneto model, as shown in Figure 2-17. The engine firing order (Figure 2-18) is determined by the camshaft lobes; magneto firing order is sequential from the number one position and must be synchronized to the crankshaft.

To obtain the retard spark necessary for starting, the magnetos may be equipped with a starting vibrator for a shower of sparks type ignition or employ impulse couplings within the magneto. Impulse couplings rotate the magneto between impulse trips faster than engine cranking speed, thus generating a better spark for starting the engine and automatically retard the spark during engine cranking. After engine start, impulse couplings function as normal magneto drive couplings.

2-14 IO-240 Series Engine Installation & Operation Manual

Figure 2-17. Continental Motors Magneto Part Number Structure

31 October 2011

Engine Description

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, 1

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Figure 2-18. Continental Motors Ignition Distribution

Figure 2-19. Slick Ignition Distribution

IO-240 Series Engine Installation & Operation Manual 2-15 31 October 2011

Engine Description

2-2.7. Fuel System

The Fuel System (Figure 2-20) is composed of an engine-driven fuel pump, a fuel manifold valve, an induction system throttle body and fuel injector assemblies. The multiport, continuous flow fuel injection system controls fuel flow to match engine requirements. The fuel metering unit/throttle controls the amount of intake air admitted through the intake manifold and meters the proportionate amount of fuel to the fuel manifold valve.

Figure 2-20. IO-240 Standard Fuel Injection System

2-2.7.1. Fuel Pump

An engine-driven, positive displacement fuel pump (Figure 2-21) delivers fuel to the fuel injectors. Fuel enters the fuel pump at the well of the swirl chamber where the fuel is centrifuged and the liquid is separated from fuel vapor. The liquid fuel is directed to the fuel pump blades. The fuel pump blades force the fuel to the fuel pump outlet through various fittings, and fuel lines to the fuel manifold valve.

The fuel pump is directly driven at the same speed as the crankshaft; fuel flow and pressure vary directly with engine speed. An adjustable relief valve maintains pump flow and pressure for the lower engine speeds, while an adjustable orifice controls fuel pump

2-16 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Description

PATH TO RELIEF VALVE

FUEL INLET

STOP PIN

VAPOR RETURN

DRY BAY DRAIN

FUEL SUPPLY TO ENGINE

MIXTURE CONTROL

LOW PRESSURE RELIEF VALVE

ANEROID ADJUSTMENT

PATH TO RELIEF VALVE

FUEL INLET

STOP PIN

VAPOR RETURN

DRY BAY DRAIN

FUEL SUPPLY TO ENGINE

MIXTURE CONTROL

LOW PRESSURE RELIEF VALVE

ANEROID ADJUSTMENT

pressure for the higher engine speeds. This combination of mechanical control circuits ensures proper pump pressure and delivery for all engine operating speeds.

IO-240-B model engines may be equipped with an altitude compensating fuel pump which adjusts fuel pressure to compensate for atmospheric variations (Figure 2-22). The IO-240-B fuel system with altitude compensating fuel pump incorporates a fuel filter between the fuel pump and fuel manifold valve. From the fuel filter, fuel flows to the fuel manifold valve and subsequently to the injector nozzles.

Figure 2-21. Standard Fuel Pump

Figure 2-22. Altitude Compensating Fuel Pump

IO-240 Series Engine Installation & Operation Manual 2-17 31 October 2011

Engine Description

A check valve on the fuel pump permits the use of an auxiliary electric fuel boost pump during engine priming and starting (allows the aircraft boost pump to bypass the engine driven fuel pump) or in the unlikely event of an engine driven fuel pump malfunction.

2-2.7.2. Fuel Injectors

The fuel discharge nozzle is located in the cylinder head. The nozzle outlet is screwed into a tapped fuel nozzle bore in the cylinder head. The nozzle body has a drilled central passage with a counterbore at each end. The lower end is the fuel outlet. The upper bore contains a removable jet for nozzle calibration. Near the top, radial holes connect the upper counterbore with the outside of the nozzle body for air admission. A shroud is mounted on the nozzle body and extends over the nozzle body. The nozzle shroud is sealed to the nozzle body by o-rings. The nozzle shrouds are referenced to upper deck pressure to provide a positive air pressure differential to insure proper fuel atomization at all operating parameters.

Nozzles are calibrated in several ranges and tuned to each cylinder position for optimum balance of engine performance and fuel economy. Each nozzle is identified with the cylinder position number and flow rate engraved on the nozzle body wrench flats.

Figure 2-23. Fuel Injector

2-2.8. Starter Assembly

Several electric starter motors are approved for use on IO-240 engines, all available starter configurations mount on the rear of the accessory case. Starter engagement is controlled by the airframe wiring harness and ignition switch contactor.

2-2.9. Alternator

IO-240 engines incorporate a boss on the rear of the engine accessory case for mounting a direct drive alternator. A 12 volt, 60 amp gear driven alternator is standard equipment for current engines. Optional belt-driven and lightweight alternators are available, with retrofit capabilities to older model specifications.

2-18 IO-240 Series Engine Installation & Operation Manual

31 October 2011

The alternator generates electrical current for recharging aircraft batteries and powering aircraft electrical systems. For a description of the aircraft electrical and charging system, see the applicable Airframe Manufacturer's Instructions. For a detailed description of Continental Motors alternators, refer to the Alternator Service Instructions.

2-2.10. Engine Cooling

The engine cylinders are cooled by transferring heat from the cylinder barrel and cylinder head cooling fins to the surrounding airflow. The airframe engine cowling, baffles, and baffle seals direct cooling air (which is ram air-induced by the aircraft's forward speed) evenly around the cylinders. This airflow is regulated by the size of the cooling air inlets and outlets. Increasing or decreasing outlet size with the use of cowl flaps changes airflow and is used as an aid in controlling engine operating temperatures.

Engine Description

Figure 2-24. Engine Cooling

IO-240 Series Engine Installation & Operation Manual 2-19 31 October 2011

Engine Description

FUEL PUMP

THROTTLE

INDUCTION SYSTEM

FUEL PUMP

THROTTLE

INDUCTION SYSTEM

2-2.11. Induction System

IO-240-A engines feature an updraft induction system. The air throttle is mounted below the engine. Induction tubes deliver air from the throttle body to the intake ports on top of the cylinder.

Figure 2-25. IO-240-A Induction System

The IO-240-B downdraft induction system (Figure 2-26), consists of the air throttle and manifold body mounted on top of the engine. Intake tubes carry induction air from the manifold to the individual cylinder intake ports. Crossflow design cylinders improve airflow efficiency through the cylinder head. Air flows from the aircraft air inlet/alternate air door to the engine cylinders through the Induction System.

Figure 2-26. IO-240-B Crossflow Induction System

2-20 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Description

2-3. Engine Specifications and Operating Limits

Table 2-1. IO-240-A Specifications and Operating Limits

General

Model IO-240-A FAA Type Certificate E7S0 Installation Drawing Number 653200 Compression Ratio 8.5:1 Number of Cylinders 4 Firing Order 1-3-2-4 Time Between Overhaul (TBO) 2000 accumulated hours or 12 years Bore 4.43 in. 112.7 cm Stroke 3.875 in. 98.4 cm Piston Displacement 240 cubic inches L

Crankshaft Speed & Brake Horsepower

Rated Maximum Continuous Operation

Crankshaft Speed (Maximum rated) 2800 rpm Engine Idle Speed, Minimum 675 rpm Rated Manifold Pressure 29.5 in. Hg Full Throttle (Sea Level) Maximum Recommended Cruise 94 bhp @ 2550 rpm

1 Performance is based on sea level, standard da y, zero water vapor pressure conditions at the throttle inlet and exhau st exit with no

engine accessory load. Standard day conditions are 2 9.92 in. Hg a nd 59 °F. Horsepower will vary approximately 1% for each 10°F (5.6° C) change in compressor inlet air temperature. Corre ction must also b e made for the effect of exhaust back pressure and ac cessory drive losses. Contact Continental Motors engineering for correction factors for specific applica tions.

125 BHP -0/+5% @ 2800 RPM

Fuel System Specifications

Fuel Minimum Grade

100 or 100-LL

Fuel System Pressure & Flow Refer to the Fuel System Operational Check in

Section 6-3.7.3 of the Maintenance and Overhaul Manual (M-6)

Boost Fuel Pump Specifications Refer to engine model specification

2 This engine is certified for operation with 100-LL Blue or 100 Green aviation fuel. If the minimum fuel grade is not available, use the next

higher available grade. Never use a lower grade fuel.

Fuel Consumption

Power Level BHP (kW) lbs./hr (max) Rated Power, 100% 125 (93.2) .560 Cruise, 75% 94 (70.0) .404 Cruise, 65% 81 (60.4) .407 Cruise, 55% 69 (51.5) .406

Ignition

Spark Plugs to be used FAA Approved Radio Shielded Ignition Timing 22°± 1° BTC Spark Plug Gap Spark plug manufacturer’s specified gap.

IO-240 Series Engine Installation & Operation Manual 2-21 31 October 2011

Engine Description

Table 2-1. IO-240-A Specifications and Operating Limits

Cylinder Head Temperature

Maximum Cruise Operational Temperature

Maximum Allowable Operational Temperature Minimum Takeoff Temperature

360° to 420°F 182° to 215°C 460°F 238°C 240°F 1 16°C

Exhaust

Exhaust System back pressure, maximum, measured at port, in Hg (kPa) 2.0 (6.75) EGT Thermocouple Probe, minimum distance from port, in. (mm) 2.0/2.50 (50.8/63.5)

Oil

Oil Pressure - Normal Operation @ 75° to 240°F (24° to116°C) 30 to 60 psig

Maximum Allowable Oil Pressure

(cold oil) Minimum Oil Pressure @ Idle (600 RPM) Maximum Allowable Oil Temperature Minimum Take-off Oil Temperature

100 psig 10 psig at or below 200°F 240°F 1 16°C 75°F 24°C

Cruise Flight Oil Temperature 170° to 220° F 77° to 104° C Oil Sump Capacity 6.0 quarts 5.67L Usable Oil - 16° Nose Up 3.0 quarts 2.8L Usable Oil - 10° Nose Down 3.0 quarts 2.8L Oil Grade, Specification SAE J-1899 (normal ops) SAE J-1966 (break-in CAUTION: Oil must be aviation oil conforming to SAE J-1899 or SAE J-1966 specifications

Brake Specific Oil Consumption

Maximum BSOC = 0.006 lb. X (engine rated power) X (% power at which measured/100) X (duration of test in hours) 1 quart = 1.875 pounds

Engine Physical Specifications

Weight, dry (basic engine), lb. (kg) +/- 2.5% Basic engine, minus accessories Detailed weights by Specification Number

246.0 (111.6) Refer to engine model specification

Overall Dimensions, inches (mm) Height Width Length

23.5

31.4

29.8

(596.9) (797.6) (756.9)

Center of Gravity, inches (mm) Forward of rear accessory case Below crankshaft centerline Beside crankshaft centerline toward 1-3 side

Moment of Inertia, standard accessory package Roll Longitudinal Axis, (I Pitch Lateral Axis, (I Yaw Vertical Axis, (I

1. Measured with bayonet thermocouples

) 32.2 371

x-x

) 32.2 371

y-y

) 52.9 609

z-z

14.55

0.96

0.06 in·lb·sec

(mm·kg·sec2)

369.6

24.4

1.5

2-22 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Description

Table 2-2. IO-240-B Specifications and Operating Limits

General

Model IO-240-B FAA Type Certificate E7S0 Installation Drawing Number 653910 IO-240-B1

656846 IO-240-B17 and beyond Compression Ratio 8.5:1 Number of Cylinders 4 Firing Order 1-3-2-4 Time Between Overhaul (TBO) 2000 accumulated hours or 12 years Bore 4.43 in. 112.7 cm Stroke 3.875 in. 98.4 cm Piston Displacement 240 cubic inches L

Crankshaft Speed & Brake Horsepower

Rated Maximum Continuous Operation

125 BHP -0/+5% @ 2800 RPM Crankshaft Speed (Maximum rated) 2800 rpm

Engine Idle Speed, Minimum 675 Rated Manifold Pressure 29.5 in. Hg Full Throttle (Sea Level) Maximum Recommended Cruise 94 bhp @ 2550 rpm

1 Performance is based on sea level, standard da y, zero water vapor pressure conditions at the throttle inlet and exhau st exit with no

Fuel System Specifications

Fuel Control System Fuel Minimum Grade

Multi-port, Continuous Flow

100 or 100-LL Fuel System Pressure & Flow Refer to the Fuel System Operational Check in

Section 6-3.7.3 of the Maintenance and Over-

haul Manual (M-6) Boost Fuel Pump Specifications Refer to engine model specification

2 This engine is certified for operation with 100-LL Blue or 100 Green aviation fuel. If the minimum fuel grade is not available, use the next

higher available grade. Never use a lower grade fuel.

Fuel Consumption

Power Level BHP (kW) lbs./hr (max) Rated Power, 100% 125 (93.2) .560 Cruise, 75% 94 (70) .404 Cruise, 65% 81 (60.4) .407 Cruise, 55% 69 (51.4) .406

Ignition

Spark Plugs to be used FAA Approved Radio Shielded Ignition Timing 26°± 1° BTC Spark Plug Gap Spark plug manufacturer’s specified gap.

IO-240 Series Engine Installation & Operation Manual 2-23 31 October 2011

Engine Description

Table 2-2. IO-240-B Specifications and Operating Limits

Cylinder Head Temperature

Maximum Cruise Operational Temperature

Maximum Allowable Operational Temperature Minimum Takeoff Temperature

360° to 420°F 182°to 215°C 460°F 238°C 240°F 1 16°C

Maximum Allowable Cylinder Base 310°F 154°C

Exhaust

Exhaust System back pressure, maximum, measured at port, in Hg (kPa) 2.0 (6.75) EGT Thermocouple Probe, minimum distance from port, in. (mm) 2.0/2.50 (50.8/63.5)

Oil

Oil Pressure - Normal Operation @ 75° to 240°F (24° to116°C) 30 to 60 psig Maximum Allowable Oil Pressure

(cold oil) Minimum Oil Pressure @ Idle (600 RPM) Maximum Allowable Oil Temperature Minimum Take-off Oil Temperature

100 psig 10 psig at or below 200°F 240°F 1 16°C 75°F 24°C

Cruise Flight Oil Temperature 170° to 220°F 77° to 104°C Oil Sump Capacity 6.0 quarts 5.67L Usable Oil - 16° Nose Up 3.0 quarts 2.8L Usable Oil - 10° Nose Down 3.0 quarts 2.8L Oil Grade, Specification SAE J-1899 (normal ops) SAE J-1966 (break-in CAUTION: Oil must be aviation oil conforming to SAE J-1899 or SAE J-1966 specifications

Brake Specific Oil Consumption

Maximum BSOC = 0.006 lb. X (engine rated power) X (% power at which measured/100) X (duration of test in hours) 1 quart = 1.875 pounds

Engine Physical Specifications

Weight, dry (basic engine), lb. (kg) +/- 2.5% Basic engine, minus accessories Detailed Weights by Specification Number

246.0 (111.6) Refer to engine model specification

Overall Dimensions, inches (mm) Height Width Length

23.5

31.4

29.8

(596.9) (797.6) (756.9)

Center of Gravity, inches (mm) Forward of rear accessory case Below crankshaft centerline Beside crankshaft centerline toward 1-3 side

Moment of Inertia, standard accessory package Roll Longitudinal Axis, (I Pitch Lateral Axis, (I Yaw Vertical Axis, (I

1. Measured with bayonet thermocouples

) 32.2 371

x-x

) 32.2 371

y-y

) 52.9 609

z-z

14.55

0.96

0.06 in·lb·sec

(mm·kg·sec2)

369.6

24.4

1.5

2-24 IO-240 Series Engine Installation & Operation Manual

31 October 2011

2-3.1. Accessory Drive Ratios

Accessory drive ratios are the same for all of the IO-240 series engines, except as noted.

Tab le 2-3 . Acc es sory Drive Ratios

Engine Description

Maximum Torque

Direction of

Accessory

Tachometer Starter Motor CCW 24.727 50 -- -Alternator (gear driven) CCW 2.035:1 60 10 0 100 Alternator (belt driven) CCW 3.333:1 30 100 100 Fuel Pump

Vacuum Pump

1. CW=Clockwise Rotation CCW=Counterclockwise rotation; viewed facing the drive; OPT= Optional

2. Drive is an AND20000 pad modified for speed only

Rotation

CW, OPT 0.500:1 7 50 25

CCW 1:1 40 800 -CW 1:1 25 -- --

Drive Ratio

to Crankcase

(in. lbs.)

Cont. Static

Maximum Overhang Moment, (in lbs.)

2-3.2. Performance Data

Refer to the applicable engine Detailed Model Specification For complete engine technical specifications, installation requirements, certification data, and engine test stand performance.

WARNING

Performance charts included in this manual indicate uninstalled engine performance under controlled conditions and will vary from installed performance. The charts are neither intended nor suitable for installed performance specifications or flight planning. Consult the Airplane Flight Manual or Pilot's Operating Handbook for installed aircraft performance specification.

IO-240 Series Engine Installation & Operation Manual 2-25 31 October 2011

Engine Description

2-3.2.1. IO-240-A Performance Charts

Figure 2-27. IO-240-A Fuel Flow vs. Brake Horsepower

2-26 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Description

Figure 2-28. IO-240-A Sea Level Performance

IO-240 Series Engine Installation & Operation Manual 2-27 31 October 2011

Engine Description

2-3.2.2. IO-240-B Performance Charts

Figure 2-29. IO-240-B Fuel Flow vs. Brake Horsepower

2-28 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Description

Figure 2-30. IO-240-B Sea Level Performance

IO-240 Series Engine Installation & Operation Manual 2-29 31 October 2011

Engine Description

Intentionally Left Blank

2-30 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Chapter 3 .Engine Installation

3-1. Engine Installation

Engine Installation Drawings are provided in Section 3.3.

3-1.1. Common Tools and Consumable Supplies Required

1. Engine Hoist

2. Oil conforming to SAE J-1966 (break-in oil, non-dispersant mineral oil) MIL-C6529 Type II (Fly-away oil)

3. Ashless dispersant oil conforming to SAE J-1899

4. MIL-P-46002, Grade 1 oil

5. 100-LL Blue or 100 Green aviation fuel

6. Spark plugs and copper gaskets

7. Safety Wire (.032”)

8. Cable ties

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

Engine Installation

10. Type 1 flammable fuel container

11. Clean fuel hoses

12. AN union fittings

13. Rubber grommets

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

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

16. Loctite Hydraulic Sealant

17. Anti-seize Lubricant

18. Loctite Pipe Sealant

19. Other supplies and consumables required by the airframe manufacturer

3-1.2. Engine Receipt and Handling

When the engine arrives, inspect the crating for damage. If the engine crating appears damaged, contact our Customer Service Department (refer to “Contact Information” in Section 1-3 and the freight shipping company. If the crating appears intact, proceed to Section 3-1.2.1.

IO-240 Series Engine Installation & Operation Manual 3-1 31 October 2011

Engine Installation

3-1.2.1. 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 3-

1.2.3.

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 of the Maintenance and Overhaul Manual (M-6) 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.

5. If the engine will be stored for any length of time, refer to the “Engine Preservation and Storage” instructions in Chapter 9 of the Maintenance and Overhaul Manual (M-6).

3-1.2.2. 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.

3-1.2.3. Acceptance Inspection

CAUTION: If the hidden engine damage or corrosion is discovered, contact Continental Motors (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. Do not install a damaged or corroded engine or place it in storage.

3-1.3. Engine Transport

Refer to the “Engine Installation Drawings” in Section 3-3 for the engine lifting eye locations.

3-2 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Installation

CAUTION: Do not allow chains to become entangled on the engine or its hardware. Be sure 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.

IO-240 Series Engine Installation & Operation Manual 3-3 31 October 2011

Engine Installation

3-2. Installation Procedures

3-2.1. Prepare the Airframe for Engine Installation

1. Verify the airframe fuel filter and boost pump are installed and operate according to the airframe manufacturer’s instructions.

WARNING

Purge the aircraft fuel tanks and lines to remove all contamination prior to connecting the main fuel supply to the fuel pump inlet. Failure to purge contamination may cause erratic fuel injection system operation.

Fuel injectors are sensitive to dirt and particulate contamination. To avoid contamination, do not disconnect fuel line connections between the fuel pump and the fuel injectors.

CAUTION: Follow the airframe manufacturer’s schedule interval for airframe mounted fuel and oil hoses. Hoses become brittle with age; we recommend hose replacement coincident with engine overhaul to avoid immediate contamination or failure at a later date.

2. Replace all aircraft flexible oil and fuel hoses according to the aircraft manufacturer’s instructions prior to engine installation.

3. Clean the aircraft fuel strainer and allow at least one quart of fuel to flow through the strainer and fuel supply line into a Type 1 fuel container through a paper filter.

4. Inspect the paper filter for contamination; if the fuel supply is free of contamination, proceed with engine installation. If contaminants are found in the fuel supply, isolate and correct the source of contamination prior to connecting the aircraft fuel supply to the engine driven fuel pump.

3-2.2. Prepare the Engine for Installation

Remove packing material, tags, and the preservative fluid from the oil sump of new, rebuilt, overhauled or stored engines prior to installation.

NOTE: If the engine won’t be installed immediately, refer to the “Engine Preservation and Storage” instructions in Chapter 9 of the Maintenance and Overhaul Manual (M-6).

1. Remove the shipping plugs or dehydrator plugs from the spark plug holes.

2. Remove the AN-4060 protectors from the ignition leads.

3. Place a basin under the engine to catch the cylinder preservation oil.

NOTE: NOTE: A small amount of preservative oil remaining in the cylinder bore is acceptable; it will burn off during the first engine start.

4. Turn the crankshaft through at least two complete revolutions to remove the cylinder preservation oil from the cylinders.

5. Catch the cylinder preservation oil draining out of the lower spark plug holes.

3-4 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Installation

NOTE: If corrosion or abnormal conditions are discovered during the borescope inspection, contact the supplier (If the engine was obtained from Continental Motors, refer to

“Contact Information” in Section 1-

3) for disposition instructions.

6. Inspect the cylinder bores with a borescope for rust and contamination according to

the “Cylinder Borescope Inspection” instructions in Section 6-3.9.4 of the Maintenance and Overhaul Manual (M-6).

7. Remove the oil sump drain plug and drain the remaining cylinder preservation oil

from the oil sump. Drain plug locations are depicted in the “Engine Installation Drawings” in Section 3-3.

8. Reinstall the oil sump drain plug with a new crush washer; torque the drain plug to

Appendix B specifications; safety wire the drain plug according to instructions in Appendix C.

9. Place a catch basin underneath the fuel pump. Remove the shipping cap installed on

the fuel pump inlet fitting. Disconnect the fuel pump outlet hose from the outlet fitting. Allow the preservative fluid to drain from the fuel pump and hose; reconnect the fuel hose to the fuel pump outlet fitting and torque the fitting to Appendix B specifications. Re-install the shipping cap.

NOTE: Optional accessories such as hydraulic pumps, vacuum pumps, etc. may be installed in the accessory drive pads located on the upper rear portion of the crankcase. Remove the accessory drive covers and install new gaskets. Install accessories in accordance with the airframe manufacturer’s instructions.

10. Install all airframe manufacturer-required components according to the airframe manufacturer’s instructions, including the following:

a. Cooling baffles b. Hoses and fittings c. Brackets d. Ground straps e. Hydraulic or vacuum pumps f. Exhaust system g. Other airframe manufacturer required item(s)

11. Install the engine in the sequence indicated in Section 3-2.3.

3-2.3. Installation Sequence

1. Install the engine in the airframe mounts according to the airframe manufacturer’s instructions. Refer to the “Engine Installation Drawings” in Section 3-3 for engine dimensions, clearances, and connections.

IO-240 Series Engine Installation & Operation Manual 3-5 31 October 2011

Engine Installation

NOTE: IO-240 engines with a bypass fuel system incorporate two fuel hose connections at the airframe firewall. Ensure both connections are properly connected and torqued during engine installation.

2. Connect the fuel supply, vapor return and fuel pump drain connections to the engine driven fuel pump fittings according to airframe manufacturer’s instructions.

3. Install the exhaust system according to the airframe manufacturer's instructions.

Oil pressure is applied to the face of the accessory drive pads. If gasket or accessory covers are not properly installed and torqued to Appendix B specifications, oil leakage will occur.

4. Connect the remote oil cooler (if equipped) hoses to the engine oil cooler adapter according to the airframe manufacturer's instructions.

5. Service the engine to the specified oil sump capacity according to the “Engine Oil Servicing” instructions in Section 6-3.7 of the Maintenance and Overhaul Manual (M-6).

6. Turn the Ignition Switch to the OFF position.

WARNING

Do not install the ignition harness “B” nuts on the spark plugs until the propeller installation and the ignition system operational checkout is complete. Failure to comply can result in bodily injury when the propeller is rotated during installation.

7. Connect the starter and alternator wiring according to airframe manufacturer’s instructions.

8. Install the propeller according to the airframe and propeller manufacturer's instructions.

9. Connect the airframe ignition switch wiring to the P-leads of each magneto and perform a functional check of the circuit to verify the ignition switch properly disables the magnetos.

10. If the magnetos were loosened or rotated during engine installation, adjust magneto to engine timing according to the “Magneto Timing” instructions in Section 6-3.9.1 of the Maintenance and Overhaul Manual (M-6).

11. Install any remaining aircraft accessories listed below according to the airframe manufacturer's instructions.

a. Pneumatic, freon or vacuum pumps b. Tachometer (mechanical) drive cable or (electrical) sensor connection c. Oil temperature sensor and oil pressure sensor connections d. Fuel pressure sensor and fuel flow sensor connections

3-6 IO-240 Series Engine Installation & Operation Manual

31 October 2011

e. Exhaust Gas Temperature sensor connections f. Manifold pressure gauge line g. Throttle and mixture control cables h. Remaining airframe manufacturer’s supplied accessories and instrument

connections

12. Perform the “Engine Pre-oiling” procedure according to Section 3-2.3.1.

13. Complete a “Fuel Purge and Leak Check” according to instructions in Section 3-

2.3.2

Do not operate the engine until all hardware, spark plugs, gaskets, and seals are in place and torqued and the oil sump is properly filled to the specified capacity with oil.

14. Perform the “Engine Operational Check” according to instructions in Section 6-3.7 of the Maintenance and Overhaul Manual (M-6).

3-2.3.1. Engine Pre-oiling

NOTE: f engine cylinders were installed or the engine is new or has been overhauled, follow the “Engine Preoiling Method 1” instruction in Section 3-2.3.1.1.

Engine Installation

WARNING

Engine pre-oiling must be accomplished prior to engine start-up after engine installation or overhaul/re-assembly. Two methods are provided in Section 3-2.3.1.1 and Section 3-

2.3.1.2; “Engine Preoiling Method 1” is preferred.

3-2.3.1.1. Engine Preoiling Method 1

1. Install and torque the spark plugs and ignition lead wires according to the “Spark Plug Maintenance” instructions in Section 6-3.9.2 and “Ignition Harness Maintenance” instructions in Section 6-3.9.3 of the Maintenance and Overhaul Manual (M-6).

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 50 psi output pressure (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 airframe oil pressure sensor fitting according to the airframe manufacturer's instructions.

5. Remove the rocker covers.

6. Open the pre-oiler valve and monitor the rocker areas for oil flow. Depending upon oil temperature, it may take up to 20 minutes to see an indication of oil flow.

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

IO-240 Series Engine Installation & Operation Manual 3-7 31 October 2011

Engine Installation

8. Install the rocker covers with new gaskets according to the “Rocker Arm Installation” instructions in Section 17-4.3 of the Maintenance and Overhaul Manual (M-2). Torque the rocker cover fasteners to Appendix B specifications.

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

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 “Engine Oil Servicing” instructions in Section 6-3.7.1 of the Maintenance and Overhaul Manual (M-6).

3-2.3.1.2. Engine Preoiling Method 2

1. Service the engine oil level (See “Engine Oil Servicing” instructions in Section 6-

3.7.1 of the Maintenance and Overhaul Manual (M-6)).

CAUTION: If the engine oil cooler adapter is connected to an airframe mounted oil cooler, the oil cooler and hoses will contain trapped air that oil servicing will not evacuate from the engine lubrication system. Failure to purge the air from the oil cooler and hoses prior to engine start will damage the engine.

WARNING

2. Turn the fuel selector valve to the OFF position.

3. Position the mixture control to the IDLE/CUTOFF position and ensure the magneto switch(es) are in the OFF position.

Do not continuously operate the starter for more than 30 seconds.

4. Engage the starter for no longer than 30 seconds or until oil pressure is indicated on the oil pressure gage. After 30 seconds, allow 3 to 5 minutes to allow the starter to cool before engaging the starter again. If no oil pressure is indicated after three 30 second engage/cooling intervals, check connections and gauge operation.

5. Install and torque the spark plugs and ignition lead wires according to the “Spark Plug Maintenance” instructions in Section 6-3.9.2 and “Ignition Harness Maintenance” instructions in Section 6-3.9.3 of the Maintenance and Overhaul Manual (M-6).

3-2.3.2. Fuel Purge and Leak Check

Prior to shipping from the factory , the fuel injection system was pres erved with MIL-PRF6081D Grade 1010. The preservative fluid was drained during completion of Section 3-

2.2. Flushing the system with aircraft fuel will complete the purge and prime the fuel injection system for operation.

WARNING

1. Disconnect the fuel supply at the inlet to the fuel manifold valve.

3-8 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Installation

2. Connect a length of the appropriate size hose to the aircraft fuel supply using an AN

union fitting and secure the end of the hose in a properly grounded Type 1 flammable fluid container.

CAUTION: Ensure the ignition switch is in the OFF position and clear the rotational arc of the propeller before proceeding.

3. Have an assistant turn the aircraft master power switch on.

4. Place the aircraft boost pump in the ON position for approximately one minute

while cycling the throttle and mixture controls through the full range of travel several times.

5. Turn the aircraft boost pump and Master Power switches to the OFF positions.

6. Close the mixture and throttle controls.

7. Inspect the paper filter for contamination; isolate and correct the source of

contamination and continue flushing until no contamination is present in the paper filter.

8. Remove the extra length of hose and union installed in step 2 from the fuel manifold

supply hose.

9. Connect the fuel manifold valve fuel supply hose to the inlet fitting on the manifold

valve and torque the fuel hose “B” nut to Appendix B specifications.

NOTE: Place approved containers at the induction system drain locations to collect fuel as it is drained overboard.

10. Turn the aircraft Master Power Switch to the ON position.

11. With the Mixture control in FULL RICH and the Throttle ¼ OPEN, turn the aircraft boost pump to the ON position.

12. Inspect all fuel lines, hoses and fitting for evidence of fuel leakage.

13. Place the mixture control to IDLE CUT-OFF and CLOSE the THROTTLE.

14. Turn the aircraft fuel boost pump OFF.

15. Turn the aircraft Master Power Switch OFF.

16. Correct any discrepancies noted.

17. Dispose of the fuel/oil mixture according to local hazardous material regulations.

3-2.4. Installation Inspection

Perform a “Visual Inspection” of the engine according to the instructions in Section 6-3.6 of the Maintenance and Overhaul Manual (M-6) prior to engine start.

3-2.5. Preflight and Run-up

Perform an Engine Operational Check after completing the engine installation and before performing the flight check according to the Airplane Flight Manual (AFM) or Pilot Operating Handbook (POH). Perform a flight check before releasing the engine for

IO-240 Series Engine Installation & Operation Manual 3-9 31 October 2011

Engine Installation

normal service to ensure the installed engine meets the manufacturer’s performance and operational specifications.

The fuel system must be adjusted after installation in the airframe according to the “Engine Operational Check” instructions in Section 6-3.7 of the Maintenance and Overhaul Manual (M-6) to ensure proper operation. Correct all discrepancies prior to release for flight.

IO-240 engines are neither designed, nor approved, for continuous negative or zero “G” operation. Engine Mount loads shall not exceed FAR 23 utility category load factors.

CAUTION: Adhere to the “Engine Specifications and Operating Limits” in Section 2-3 during Flight Check.

CAUTION: Check the oil level in the sump and service, if necessary to the capacity specified in Section 2-3, “Engine Specifications and Operating Limits” with oil meeting the SAE specification described in “Engine Oil Specifications” in Section 3-2.1 of the Maintenance and Overhaul Manual (M-6). Pressure check the fuel system for leaks before starting the engine.

WARNING

NOTE: Perform a flight check according to instructions in Section 4-2.3.2 before releasing the engine for normal operations. New and rebuilt engines, and engine with one or more new cylinders or pistons, require a 25-hour break-in. After installation, avoid prolonged ground operation at high power.

1Procedure

1. Perform an “Engine Operational Check” instructions in Section 6-3.7 of the Maintenance and Overhaul Manual (M-2).

2. Perform a “Flight Check” according to instructions in Section 4-2.3.2.

3-10 IO-240 Series Engine Installation & Operation Manual

31 October 2011

3-3. Engine Installation Drawings

10.156

10.50

9.31

LIFTING EYE Ø0.625”

FUEL VENT DRAIN

0.43765-20 UNF-2A

MAGNETO

STARTER TERMINAL

0.56-18 UNC-21

LIFTING EYE Ø0.88”

10.156

10.50

9.31

LIFTING EYE Ø0.625”

FUEL VENT DRAIN

0.43765-20 UNF-2A

MAGNETO

STARTER TERMINAL

0.56-18 UNC-21

LIFTING EYE Ø0.88”

Installation drawings are provided to assist the airframe manufacturer determine appropriate fittings and fasteners for airframe interconnect and determine engine compartment fit and limit requirements. Variations between the IO-240-A and subsequent engine models require separate engine installation drawings. Pay particular attention to the model depicted when referencing drawings for engine installation requirements.

3-3.1. IO-240-A Installation Drawings

Engine Installation

Figure 3-1. IO-240-A Top View

IO-240 Series Engine Installation & Operation Manual 3-11 31 October 2011

Engine Installation

OIL COOLER ADAPTER

CYLINDER HEAD TEMPERATURE (CHT) THERMOCOUPLE

0.375-24 UNF-2A

FUEL INLET

0.56-18 UNF-2A

6.25

23.45

29.82

14.55

7.18

0.96

19.78

EXHAUST PORT 4X 2.47

3.81

6.61

8.25

ALTERNATOR

3.00

OIL COOLER ADAPTER

CYLINDER HEAD TEMPERATURE (CHT) THERMOCOUPLE

0.375-24 UNF-2A

FUEL INLET

0.56-18 UNF-2A

6.25

23.45

29.82

14.55

7.18

0.96

19.78

CLC

EXHAUST PORT 4X 2.47

3.81

6.61

8.25

ALTERNATOR

3.00

Figure 3-2. IO-240-A Left Side View

3-12 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Installation

31.41

16.27

8.25

8.30

12.12

IDLE PRESSURE ADJUSTMENT (CW TO INCREASE)

FUEL PUMP

CYLINDER DRAIN

0.4375-20 UNF-2A (4 Places)

FUEL DRAIN

0.4375-20 UNF-2A

31.41

16.27

8.25

8.30

12.12

IDLE PRESSURE ADJUSTMENT (CW TO INCREASE)

FUEL PUMP

CYLINDER DRAIN

0.4375-20 UNF-2A (4 Places)

FUEL DRAIN

0.4375-20 UNF-2A

Figure 3-3. IO-240-A Front View

IO-240 Series Engine Installation & Operation Manual 3-13 31 October 2011

Engine Installation

31.41

3.50 3.50

5.25

11.56

SPARK PLUG

OIL PRESSURE RELIEF VALVE

OIL SCREEN ASSY

TACHOMETER DRIVE ADAPTER A854 TYPE 1

AIR/OIL SEPARATOR RETURN 0.250-18 NPTF

OIL SUMP

ALTERNATOR

OIL DRAIN PLUG

0.88 HEX, 0.625-18

31.41

3.503.50 3.503.50

5.25

11.56

SPARK PLUG

OIL PRESSURE RELIEF VALVE

OIL SCREEN ASSY

TACHOMETER DRIVE ADAPTER A854 TYPE 1

AIR/OIL SEPARATOR RETURN 0.250-18 NPTF

OIL SUMP

ALTERNATOR

OIL DRAIN PLUG

0.88 HEX, 0.625-18

Figure 3-4. IO-240-A Rear View

3-14 IO-240 Series Engine Installation & Operation Manual

31 October 2011

3-3.2. IO-240-B Installation Drawings

35°

22 2

AND 20000 PAD VAC PUMP DRIVE ROTATION CW DRIVE RATIO 1:1

2X R0.12-0.19

[3.05-4.83]

2.248-2.250 [57.01-57.15]

(F8-2)

(0.50)

0.31 [7.87]

2.10

4.14

[105.161]

[53.34]

(F7-2)

[91.19]

3.59

30°

LCYL.#3

[328.42]

12.93

9.281

[235.74]

CYL.#1

2.968

[75.39]

4.76

[120.90]

1.38

[35.05]

LCYL.#4

[361.95]

14.25

11.406

[289.71]

CYL.#2

5.093

2.25

[57.15]

Optional Altitude

Compensating

Fuel Pump

35°

22 2

AND 20000 PAD VAC PUMP DRIVE ROTATION CW DRIVE RATIO 1:1

2X R0.12-0.19

[3.05-4.83]

2.248-2.250 [57.01-57.15]

(F8-2)

(0.50)

0.31 [7.87]

2.10

4.14

[105.161]

[53.34]

(F7-2)

[91.19]

3.59

30°

LCYL.#3

[328.42]

12.93

9.281

[235.74]

CYL.#1

2.968

[75.39]

4.76

[120.90]

1.38

[35.05]

LCYL.#4

[361.95]

14.25

11.406

[289.71]

CYL.#2

5.093

2.25

[57.15]

Optional Altitude

Compensating

Fuel Pump

Engine Installation

Figure 3-5. IO-240-B Top View

IO-240 Series Engine Installation & Operation Manual 3-15 31 October 2011

Engine Installation

Figure 3-6. IO-240-B Left Side View

3-16 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Installation

Figure 3-7. IO-240-B Front View

IO-240 Series Engine Installation & Operation Manual 3-17 31 October 2011

Engine Installation

Figure 3-8. IO-240-B Rear View

3-18 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Installation

Figure 3-9. IO-240-B w/optional Oil Cooler-Filter Adapter Top View

IO-240 Series Engine Installation & Operation Manual 3-19 31 October 2011

Engine Installation

Figure 3-10. IO-240-B w/optional Oil Cooler-Filter Adapter Left Side View

3-20 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Installation

Figure 3-11. IO-240-B w/optional Oil Cooler-Filter Adapter Rear View

IO-240 Series Engine Installation & Operation Manual 3-21 31 October 2011

Engine Installation

Ø ----------

Ø 0.508-0.521 6 HOLES

Ø4.000

4.880

4.870

ARP 502 MODIFIED

PROP FLANGE

Ø 0.500-0.501 2 HOLES

30°

Ø ----------

Ø 0.508-0.521 6 HOLES

Ø4.000

4.880

4.870

ARP 502 MODIFIED

PROP FLANGE

Ø 0.500-0.501 2 HOLES

30°

3-3.3. IO-240 Common Installation Drawings

Figure 3-12. Propeller Flange

3-22 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Installation

2X R 0.31

Ø2.50 B.C.

15°

0.3125-24 UNF-3A STUD

0.78 EXTENSION HEIGHT

Typical 4 Places

0.06

Ø1.50

R 0.97

EXHAUST MOUNTING FLANGE

2X R 0.31

Ø2.50 B.C.

15°

0.3125-24 UNF-3A STUD

0.78 EXTENSION HEIGHT

Typical 4 Places

0.06

Ø1.50

R 0.97

EXHAUST MOUNTING FLANGE

Figure 3-13. Exhaust Flange Dimensions

Figure 3-14. Standard Fuel Pump Installation

IO-240 Series Engine Installation & Operation Manual 3-23 31 October 2011

Engine Installation

VAPOR RETURN (LOCATED ON OPPOSITE

SIDE ON MOST FUEL PUMPS)

FUEL INLET

IDLE CUTOFF

FULL RICH

LOW PRESSURE RELIEF VALVE CW = INCREASE

METERED POWER

CW = INCREASE

DRAIN

FUEL OUTLET (UNMETERED PRESSURE)

LOW PRESSURE RELIEF VALVE CW = INCREASE

FUEL INLET

VAPOR RETURN

VAPOR RETURN (LOCATED ON OPPOSITE

SIDE ON MOST FUEL PUMPS)

FUEL INLET

IDLE CUTOFF

FULL RICH

LOW PRESSURE RELIEF VALVE CW = INCREASE

METERED POWER

CW = INCREASE

DRAIN

FUEL OUTLET (UNMETERED PRESSURE)

LOW PRESSURE RELIEF VALVE CW = INCREASE

FUEL INLET

VAPOR RETURN

Low Pressure Relief Valve CW= Increase

Mixture Control

Aneroid Adjustment CCW= Increase

Pump Output

Vapor Return

Fuel Inlet

Drain

Low Pressure Relief Valve CW= Increase

Mixture Control

Aneroid Adjustment CCW= Increase

Pump Output

Vapor Return

Fuel Inlet

Drain

Figure 3-15. Standard Fuel Pump Adjustments

3-24 IO-240 Series Engine Installation & Operation Manual

Figure 3-16. IO-240-B Altitude Compensating Fuel Pump Adjustments

31 October 2011

Figure 3-17. Throttle Lever Installation

0.12

73.00°

0.1885

0.1875

1.90

IDLE SPEED ADJUSTMENT

0.3125-24 UNF-3B

LEVER MAY BE POSITIONED BY CUSTOMER. FORMED SERRATIONS ON THE LEVER SHOULD INTERLOCK WITH THE FORMED SERRATIONS ON THE SHAFT. APPLY CLEAN 50-WEIGHT AVIATION ENGINE OIL TO THE SHAFT THREADS AND LOCK NUT PRIOR TO TORQUE. HOLD LEVER AWAY FROM LEVER PIN WHEN TORQUING NUT. TORQUE NUT 100-120 IN/LBS.

0.12

73.00°

0.1885

0.1875

1.90

IDLE SPEED ADJUSTMENT

0.3125-24 UNF-3B

TO OIL FILTER AND COOLER FOR Ø 0.50 TUBE WITH 37° FLARED FITTING

0.750-16 UNF-2A THDS.

OUT

26°

OIL PRESSURE

0.125-27 NPTF

OIL TEMPERATURE

0.4375-20 UNJF -3B

ALTERNATE OIL PRESSURE

0.125-27 NPTF

1.01

3.88

CRANKSHAFT

0.44

1.80

2.80

FROM OIL FILTER AND COOLER FOR Ø 0.50 TUBE WITH 37° FLARED FITTING

0.750-16 UNF-2A THD S.

CRANKCASE FINISHED SURFACE

TO OIL FILTER AND COOLER FOR Ø 0.50 TUBE WITH 37° FLARED FITTING

0.750-16 UNF-2A THDS.

OUT

26°

OIL PRESSURE

0.125-27 NPTF

OIL TEMPERATURE

0.4375-20 UNJF -3B

ALTERNATE OIL PRESSURE

0.125-27 NPTF

CLC

1.01

3.88

CRANKSHAFT

0.44

1.80

2.80

FROM OIL FILTER AND COOLER FOR Ø 0.50 TUBE WITH 37° FLARED FITTING

0.750-16 UNF-2A THD S.

CRANKCASE FINISHED SURFACE

Engine Installation

IO-240 Series Engine Installation & Operation Manual 3-25 31 October 2011

Figure 3-18. Oil Cooler Adapter Connections

Engine Installation

CRANKSHAFT

1.88

0.94

1.77

45°

1.14

0.11

0.48

0.55

1.29

OIL TEMPERATURE SENSOR 0.125-27 NPTF

OIL PRESSURE SENSOR 0.125-27 NPTF

OIL PRESSURE SWITCH 0.125-27 NPTF

1.57

FROM OIL COOLER 37° FLARED FITTING

0.750-16 UNF-2A THDS.

TO OIL COOLER 37° FLARED FITTING

0.750-16 UNF-2A THDS.

CRANKSHAFT

1.88

0.94

1.77

45°

1.14

0.11

0.48

0.55

1.29

OIL TEMPERATURE SENSOR 0.125-27 NPTF

OIL PRESSURE SENSOR 0.125-27 NPTF

OIL PRESSURE SWITCH 0.125-27 NPTF

1.57

FROM OIL COOLER 37° FLARED FITTING

0.750-16 UNF-2A THDS.

TO OIL COOLER 37° FLARED FITTING

0.750-16 UNF-2A THDS.

Figure 3-19. Oil Cooler Adapter Connections

3-26 IO-240 Series Engine Installation & Operation Manual

Figure 3-20. Oil Cooler-Filter Adapter Connections

31 October 2011

Engine Installation

Ø 0.28-0.31 4 HOLES

4X R .31

2.505

2.495

1.255

1.245

2.169

2.165

1.255

1.245

2.505

2.495

Ø 0.28-0.31 4 HOLES

4X R .31

2.505

2.495

1.255

1.245

2.169

2.165

1.255

1.245

2.505

2.495

BATTERY TERMINAL

0.25-20 UNC-2A

FIELD TERMINAL #10-24 UNC-2A

GROUND TERMINAL #10-24 UNC-2A

STATOR TERMINAL #10-24 UNC-2A

BATTERY TERMINAL

0.25-20 UNC-2A

FIELD TERMINAL #10-24 UNC-2A

GROUND TERMINAL #10-24 UNC-2A

STATOR TERMINAL #10-24 UNC-2A

Figure 3-21. IO-240-A Air Intake Flange

Figure 3-22. Alternator Connections

IO-240 Series Engine Installation & Operation Manual 3-27 31 October 2011

Engine Installation

1 REQUIRED

SEAT 2 REQUIRED

BUSHING LORD

# J3608-1 2 REQUIRED

CUP 2 REQUIRED

CRANKCASE

0.19

REAR CRANKCASE

FINISH

0.70

HOLE FOR

O 0.375 BOLT

SPACER

1 REQUIRED

3.00

ENGINE MOUNT ASSEMBLY

4 ASSEMBLIES REQUIRED BUSHINGS ARE SUPPLIED

WITH ENGINE

1 REQUIRED

SEAT 2 REQUIRED

BUSHING LORD

# J3608-1 2 REQUIRED

CUP 2 REQUIRED

CRANKCASE

0.19

REAR CRANKCASE

FINISH

0.70

HOLE FOR

O 0.375 BOLT

SPACER

1 REQUIRED

3.00

ENGINE MOUNT ASSEMBLY

4 ASSEMBLIES REQUIRED BUSHINGS ARE SUPPLIED

WITH ENGINE

2X 0.10

0.19

CRANKCASE

ACCESSORY END

2XO 1.34

2X 0.03 X 45°

2XO 1.12

ENGINE MOUNT LEG

2X 0.10

0.19

CRANKCASE

ACCESSORY END

2XO 1.34

2X 0.03 X 45°

2XO 1.12

ENGINE MOUNT LEG

3-28 IO-240 Series Engine Installation & Operation Manual

Figure 3-23. Engine Mounts

31 October 2011

Engine Installation

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6:,7&+

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Figure 3-24. Continental Motors Magneto Ignition Schematic

IO-240 Series Engine Installation & Operation Manual 3-29

Figure 3-25. Champion (Slick) Magneto Ignition Schematic

31 October 2011

Engine Installation

Slick Magneto

#10-32 TO IGNITION SWITCH

OPTIONAL IGNITION SWITCH SHIELD CONN.

“P” LEAD

TORQUE

13-15 IN LBS

“P” LEAD

TORQUE

13-15 IN LBS

111

GND

Slick Magneto

#10-32 TO IGNITION SWITCH

OPTIONAL IGNITION SWITCH SHIELD CONN.

“P” LEAD

TORQUE

13-15 IN LBS

111

“P” LEAD

TORQUE

13-15 IN LBS

1111

GND

#10-32 TACH SENSOR

TERMINAL

OPTIONAL IGNITION SWITCH SHIELD CONN.

#10-32 TO IGNITION SWITCH

#10-32 TACH SENSOR

TERMINAL

OPTIONAL IGNITION SWITCH SHIELD CONN.

#10-32 TO IGNITION SWITCH

3-30 IO-240 Series Engine Installation & Operation Manual

Figure 3-26. Airframe Ignition Switch Connections to Magneto

31 October 2011

Chapter 4. Engine Operation

4-1. Introduction

This chapter contains IO-240 engine operating instructions to supplement the AFM/POH.

• Flight Prerequisites

• Normal Operation

• Emergency Operation

• Operation in Abnormal Environments

This chapter provides IO-240 engine operating instructions with fixed pitch propellers and supplements information in the Airplane Flight Manual (AFM) or Pilot's Operating Handbook (POH) provided by the airframe manufacturer or supplemental type certificate holder as required by the Federal Aviation Regulations (FAR) for aircraft operating procedures.

CAUTION: This section pertains to engine operations under various operating conditions. Normal operations are presented first, followed by emergency and abnormal operating conditions. The pilot must read and thoroughly understand Section 4-4 and Section 4-5 prior to the occurrence of such conditions. Whenever abnormal conditions arise, timely response is critical.

Engine Operation

4-2. Flight Prerequisites

If the engine is newly installed and/or has been repaired/overhauled, perform the sequential tasks listed in the “Engine Operational Check” instructions in Section 6-3.6 of the Maintenance and Overhaul Manual (M-6) prior to releasing the engine for normal operation.

The “Engine Operational Check” in Section 6-3.6 of the Maintenance and Overhaul Manual (M-6) must be completed on an engine that has been installed, inspected, repaired, or overhauled before the aircraft can be released for normal operation.

DO NOT FLY THE AIRCRAFT UNTIL ALL FLIGHT PREREQUISITES HAVE BEEN MET.

NOTE: Environmental conditions (humidity), seasonal changes, and engine usage influence susceptibility to corrosion. Engines that are flown occasionally (less than one time per week) are more vulnerable to corrosion under these conditions. The best method of reducing the risk of corrosion is to fly the aircraft weekly for at least one hour. The owner/ operator is ultimately responsible for recognizing corrosion and taking appropriate corrective action.

WARNING

After successful completion of the Engine Operational Check, perform a Flight Check according to instructions in Section 4-2.3.

IO-240 Series Engine Installation & Operation Manual 4-1 31 October 2011

Engine Operation

4-2.1. Oil Change Interval

NOTE: After the first 25 hours of operation, perform an oil change according to the “Engine Oil Servicing” instructions in Section 6-3.7 of the Maintenance and Overhaul Manual (M-6).

The Oil Change Interval is specified in Table 6-1, “Engine Inspection and Maintenance Schedule.” in the Maintenance and Overhaul Manual (M-6).

4-2.2. Engine Fuel Requirements

The engine is certified for operation with 100 or 100-LL aviation fuel. If the minimum fuel grade is not available, use the next higher grade. Never use a lower grade fuel. The use of lower octane fuel may result in damage to, or destruction of, an engine the first time high power is applied.

If the aircraft is inadvertently serviced with the incorrect grade of aviation fuel or jet fuel, the fuel system must be completely drained and the fuel tanks serviced in accordance with the aircraft manufacturer's recommendations. After the fuel system is decontaminated, inspect the engine according to the “Contaminated Fuel System Inspection” instructions in Section 6-4.5 in the Maintenance and Overhaul Manual (M-6).

4-2.3. Flight Check and Break-In

WARNING

New and factory rebuilt Continental Motors engines are adjusted to meet product specifications prior to shipment. A flight check ensures the engine meets operational specifications after installation in the airframe, prior to release for normal service. Section 2-3, “Engine Specifications and Operating Limits” contains the engine specifications and operating limits for each engine model.

Perform an Engine Operational Check and a normal preflight ground run-up in accordance with the Airplane Flight Manual (AFM) or Pilot's Operating Handbook (POH), before releasing the engine for a Flight Check. Engines with an altitude compensating fuel pump requires a Flight Check after engine installation, fuel system repairs or adjustments, significant changes in geographic location from the last operational check, if the autoleaning function is suspect, and at twelve month intervals, in conjunction with the Annual/ 100-hour inspection. Engines equipped with a standard fuel pump flight check requirements are the same as the engines with an altitude compensating fuel pump except geographic location and auto-leaning functions do not apply. A flight check is also required for engines with a standard fuel pump if rated, full power RPM cannot be verified during a ground run-up.

Perform an “Engine Operational Check” according to instructions in Section 6-3.7 of the Maintenance and Overhaul Manual (M-6) and a normal preflight, engine start and ground run-up, according to the AFM/POH, before the A&P mechanic can approve the airplane for a Flight Check.

Follow the instructions in Section 4-2.3.1 to completed the recommended break-in period for Continental Motors engines. Perform a flight check after engine installation, inspection, repairs, or adjustments on engine models equipped with a standard fuel pump

4-2 IO-240 Series Engine Installation & Operation Manual

31 October 2011

according to instructions in Section 4-2.3.2.1; see Section 4-2.3.2.2 for engine models with an altitude compensating fuel pump.

4-2.3.1. Engine Break-In

Avoid long descents at high engine RPM to prevent undesirable engine cooling. If outside air temperature is extremely cold, it may be desirable to increase drag to maintain engine power without gaining excess airspeed. Do not permit cylinder head temperature to drop below 300°F (149°C).

CAUTION: High power ground operation resulting in cylinder and oil temperatures exceeding normal operating limits can be detrimental to cylinders, pistons, valves, and rings.

1. Start the engine according to “Engine Start” instructions in Section 4-3.2.

2. Conduct a normal ground run-up and take-off according to the AFM/POH instructions.

3. Monitor the following engine instrument panel indications: a) engine RPM, b) fuel flow and pressure, c) Oil pressure and temperature, d) cylinder head temperature, and e) exhaust gas temperature to verify the engine is operating within the parameters specified in Section 2-3.

Engine Operation

WARNING

4. Reduce the engine speed to climb power according to the AFM/POH instructions. Maintain a shallow climb attitude to achieve optimum airspeed and cooling airflow.

5. At cruise altitude:

a. Maintain level flight cruise at 75% power with best power or richer mixture for

the first hour of operation.

NOTE: Best power mixture setting is 100°-150°F (38°-66°C) rich of peak exhaust gas temperature. Adjust engine controls or aircraft attitude to maintain engine instrumentation within specification.

b. For the second and subsequent hours of flight, alternate cruise power settings

between 65% and 75% power with appropriate best power mixture settings.

WARNING

Long descents at high engine RPM or low manifold pressure may cause undesirable engine cooling. If outside air temperature is extremely cold, it may be desirable to increase drag to maintain engine power without gaining excess airspeed. Do not permit cylinder head temperature to drop below 300° F (149° C).

6. Descend at low cruise power settings. Avoid long descents or descents at cruise power RPM with manifold pressure below 18 in. Hg. If necessary, reduce engine RPM to the lower limit of the specified operating range to maintain sufficient

IO-240 Series Engine Installation & Operation Manual 4-3 31 October 2011

Engine Operation

manifold pressure. Carefully monitor engine instrumentation to maintain levels above the minimum specified cylinder head temperature and oil temperature.

7. Comply with the scheduled maintenance intervals specified in Table 6-1, “Engine Inspection and Maintenance Schedule.” in the Maintenance and Overhaul Manual (M-6).

Table 4-1. IO-240 Operating Limits

Observe the following limits during normal engine operation, flig ht check and break-in

ITEM SPECIFICATION

IO-240-A IO-240-B

Full Throttle Speed 2800 ±25 RPM 2800 ±25 RPM Idle Speed-RPM 1000 ±25 RPM 900-1000 ±25 RPM

(propeller dependent) Rated Manifold Air Pressure 29.5 in. Hg. 2 9.5 in. Hg. Engine Intake Air Temperature Ambient Ambient Engine Intake Air Pressure Ambient Ambient Fuel Grade (Octane) 100-LL or 100 100-LL or 100 Maximum Oil Temperature Limit 240° F (116° C) 240° F (116° C) Oil Pressure (Max. Oil Cold) 100 psig 100 psig Minimum Oil Pressure at Idle 10 psig at or below

200° F (93° C) Oil Sump Capacity (Quarts) 6 Quarts 6 Quarts Ignition Timing 22° BTC +/- 1° 26° BTC +/- 1° Cylinder Head Temperature

with Bayonet Thermocouple (Limit) Oil Consumption 0.006 x (rated power of engine) x (%power at which

460° F (238° C) Max. 460° F (238° C) Max.

measured/100) x (hours duration) = oil consumed

1 quart of oil = 1.875 lbs

10 psig at or below 200° F (93° C)

4-4 IO-240 Series Engine Installation & Operation Manual

31 October 2011

4-2.3.2. Flight Check

Flight Check procedures vary for IO-240 engines based on fuel system configuration. For IO-240 engines with a standard fuel pump, perform the Flight Check according to instructions in Section 4-2.3.2.1. On IO-240 engines with an altitude compensating fuel

pump , perform the Flight Check according to instructions in Section 4-2.3.2.2.

4-2.3.2.1. Flight Check w/Standard Fuel Pump

1. Start the engine according to the “Engine Start” instructions in Section 4-3.2.

2. Conduct a normal ground run-up and take-off according to the AFM/POH.

3. Monitor the following engine instrument panel indications: a) engine RPM, b) fuel flow, c) oil pressure and temperature, d) cylinder head temperature and e) exhaust gas temperature (4) to verify the engine is operating within the parameters specified in Section 2-3.

4. If the engine fails to reach the rated full throttle RPM during ground operations, ascend to cruise altitude (>2000' above field elevation) and verify the engine achieves full throttle, full rich, rated RPM at cruise altitude and operates within the limits specified in Section 2-3; If full power, rated RPM is achieved, proceed to step

5. If the aircraft indicated values fail to meet the published limits, repeat the Engine Operational Check and Flight Check.

Engine Operation

WARNING

All abnormal conditions must be corrected prior to releasing the aircraft for normal operation.

5. Release the engine to normal service.

IO-240 Series Engine Installation & Operation Manual 4-5 31 October 2011

Engine Operation

Exhaust

Gas Temperature

Rise?

Less than 50°F (10°C)

IO-240-B Altitude Compensating Fuel Pump Flight Check

Ascend to a minimum of 3000 ft above airfield elevation. Ad just aircraft attitude to maintain 2450 RPM, wide open throttle (WOT). Retard the mixture control from Full Rich to Peak EGT while monitoring EGT indication. Note EGT rise from Full Rich to Peak EGT on the Engine Operational Checklist.

Greater than 250°F (121°C)

Maintenance Complete.

50°F-250°F

(10°C-121°C)?

WOT fuel pump pressure is too low.

WOT fuel pump pressure is too high.

Select two different additional altitudes at least 2000 ft. above the initial test altitude. Repeat and record the leaning authority test.

NOTE:

Adjust the fuel mixture control for Peak EGT in a slow, deliberate movement while monitoring the EGT indicator. Leaning from FULL RICH EGT to PEAK EGT requires no less than 30 seconds. Abruptly chopping the fuel mixture control will yield an inaccurate PEAK EGT indication.

Troubleshoot Fuel System according to instructions in

Chapter 8 of the

Maintenance and Overhaul

Manual (M-6)

Perform a normal takeoff according to AFM/POH. Monitor engine instruments; Observe operating limits in Section 2-3.

Recheck Metered

Pressure setting vs.

Figs. 6-7 or 6-8 in the

Maintenance

Manual (M-6).

Increase Metered Fuel Pressure setting.

Less than

Maximum Limit

Reduce Metered Fuel Pressure setting.

Greater than

Minimum Limit

Equal to or Greater than

Maximum

Metered Pressure

Limit.

Recheck Metered

Pressure setting vs.

Figs. 6-7 or 6-8 in the

Maintenance

Manual (M-6).

Equal to or Less than

Minimum

Metered Pressure

Limit.

4-2.3.2.2. Flight Check w/Altitude Compensating Fuel Pump

4-6 IO-240 Series Engine Installation & Operation Manual

31 October 2011

4-3. Normal Operation

Information in this section supplements instructions for normal operation found in the AFM/POH. Adhere to the aircraft AFM/POH operating procedures.

Before flying the aircraft, ensure all tasks listed in “Flight Prerequisites” in Section 4-2 have been completed, in addition to those required aircraft manufacturer's instructions in the AFM/POH.

Operation of a malfunctioning engine can result in additional damage to the engine, bodily injury or death.

Supplemental instructions for normal operation in this section are:

• Pre-operational Requirements

• Engine Start

• Ground Engine Run-up

• Taxi Preparation

• Take-off

• Climbing/Ascent

• Cruising

• Descent

Engine Operation

WARNING

• Landing/Approach

• Engine Shutdown

4-3.1. Pre-operational Requirements

1. Check the oil level, and verify the quantity is within specified limits.

2. Verify oil fill cap and dipstick are secure.

3. Drain the fuel sumps and strainers in accordance with airframe manufacturer's recommendations.

4. Check the fuel system according to the POH and verify compliance with the “Engine Fuel Requirements” in Section 4-2.2.

5. Check propeller and propeller hub for cracks, oil leaks, and security.

6. Check engine nacelle for signs of damage, leaks, and debris.

IO-240 Series Engine Installation & Operation Manual 4-7 31 October 2011

Engine Operation

4-3.2. Engine Start

Do not attempt to start an engine with an over-primed or flooded induction system. Starting an engine with a flooded induction system can result in hydraulic lock and subsequent engine malfunction or failure. Allow excess fuel to drain from the intake manifold and/or cylinder prior to attempting to start the engine.

Refer to the aircraft POH for detailed engine starting procedures. Complete Section 4-3.1, “Pre-operational Requirements” prior to engine start. Be familiar with the quantity and location of the engine fuel system drains.

CAUTION: Attempting to start an engine with a partially discharged aircraft battery may result in damage to the starter relay or possible engine kick-back resulting in a broken starter adapter clutch spring.

When starting the engine, ensure the battery is completely charged, especially in subfreezing temperatures.

Verify the tasks listed in Table 4-2, “Flight Prerequisites,” have been completed in addition to those required by the aircraft POH, aircraft manufacturer, or Supplemental Type Certificate (STC) holder. Note the following:

WARNING

• If the engine is being started in extreme cold, preheating may be required. Refer to

Section 4-5.1, “Engine Operation in Extreme Cold.”

• If the engine is started in hot weather, refer to Section 4-5.2, “Engine Operation in Hot

Weather.”

• If the engine is being started at high altitude, refer to Section 4-5.3, “Ground Operation

at High Density Altitude.”

WARNING

Ensure the propeller arc is clear of personnel and obstructions before starting the engine.

CAUTION: If the engine is hot, engage starter first, then turn on the auxiliary fuel pump as instructed by the airframe manufacturer.



Release the starter as soon as the engine fires. Never engage the starter while the propeller is turning.



Engine operation without oil pressure will result in engine malfunction and probable failure.

NOTE: Check oil pressure frequently. Oil pressure indication must be noted within 30 seconds in normal weather. If no oil pressure is observed , stop the engine and investigate the cause.

1. Propeller............................................................Clear

2. Master Switch ................................................... ON

4-8 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Operation

3. Fuel Selector Valve ...........................................ON or Fullest Tank

4. Aircraft Fuel Boost Pump .................................According to AFM/POH

5. Ignition Switch..................................................L, R or BOTH

CAUTION: If the engine is hot, engage starter first, then turn on the auxiliary fuel pump as instructed by the airframe manufacturer.



Release starter switch as soon as engine fires. Never engage the starter while the propeller is still turning. If the starter has been engaged for 30 seconds and the engine has not started, release the starter switch and allow the starter motor to cool for 3-5 minutes before another starting attempt is made.

6. Mixture Control.................................................FULL RICH

7. Throttle..............................................................1/4 OPEN

WARNING

Ensure the propeller plane of rotation is clear before engaging the starter.

8. Ignition Switch..................................................START

RESULT: Engine starts and runs smoothly at idle; indicated oil pressure is greater than 10 psi. If the engine fails to start, refer to the troubleshooting instructions in Section 8 of the Maintenance and Overhaul Manual (M-6).

NOTE: Check oil pressure frequently. Oil pressure indication must be noted within 30 seconds in normal weather. If no pressure is observed, stop the engine and investigate the cause.

9. Oil Pressure.......................................................Check

Indicated Oil Pressure is greater than 10 psi. If oil pressure is low or no oil pressure is indicated, shut down the engine immediately and investigate the cause.

10. Proceed to Section 4-3.3, “Ground Run-up.”

4-3.2.1. Cold Start

Follow the AFM/POH instructions, using the same procedure as for a normal start. After the engine starts, it may be necessary to operate the boost pump intermittently for a few seconds in order to prevent the engine from stalling.

IO-240 Series Engine Installation & Operation Manual 4-9 31 October 2011

Engine Operation

4-3.2.2. Flooded Engine

Do not operate the engine if hydraulic lock is suspected. Engine damage may occur. Perform a “Hydraulic Lock Inspection” according to instructions in Section 6-4.2 in the Maintenance and Overhaul Manual (M-6). If no fuel drainage is observed, discontinue starting attempts until the cause is determined.

If starting difficulty is experienced, verify fuel is running from the cylinder drains. Persistent starting attempts, with no fuel venting overboard may be an indication of either fuel starvation or hydraulic lock. Hydraulic lock is a condition where fluid accumulates in the Induction System or the cylinder assembly.

4-3.2.3. Hot Start

NOTE: For several minutes after stopping a hot engine, heat soaked fuel injection components, (especially the fuel pump, if equipped) may cause fuel vaporization, making engine start difficult.

Supplement the AFM/POH normal starting instructions with the following steps:

1. Fuel Selector Valve ..........................................ON

WARNING

2. Throttle..............................................................CLOSED

3. Mixture Control ................................................IDLE CUT OFF

4. Boost Pump.......................................................ON (15-20 seconds)

5. Boost Pump.......................................................OFF

6. Allow fuel to drain from intake prior to engine start; follow AFM/POH starting instructions.

4-3.3. Ground Run-up

CAUTION: DO NOT operate the engine at run-up speed unless the oil temperature is at least 75° F (24° C) and the oil pressure is within the 30-60 psi range. Operating the engine above idle before reaching minimum oil temperature may cause a loss of oil pressure and engine damage.

1. Maneuver aircraft nose into wind

2. Throttle..............................................................IDLE

CAUTION: Avoid prolonged idle at low RPM to prevent spark plug fouling.

3. Mixture..............................................................FULL RICH

4. Throttle..............................................................900-1200 RPM

5. Maintain engine RPM between 900 and 1000 RPM for at least one minute or until engine oil temperature exceeds 75° F (24° C).

6. Cowling Flaps ................................................... FULL OPEN (if equipped)

4-10 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Engine Operation

WARNING

Absence of RPM drop during the magneto check may be an indication of a faulty ignition circuit resulting in a condition known as “Hot Magneto.” Should the propeller be turned by hand, the engine may inadvertently start and cause personal injury or death. This condition must be corrected prior to continued aircraft operation.

CAUTION: Do not underestimate the importance of the magneto check. When operating on single ignition, some RPM drop should be noted. Normal indications are 25-75 RPM drop and slight engine roughness as each magneto is switched off. RPM drop exceeding 150 RPM may indicate a faulty magneto or fouled spark plugs.

NOTE: If the engine runs roughly after single magneto operation, increase engine speed to 2200 RPM in the BOTH position and lean the mixture control until the RPM peaks for ten seconds before returning to the full rich position to clear the spark plugs and smooth operation before returning to single magneto operation.

Limit ground operation to time necessary to complete engine warm-up and pre-flight checkout.

7. Throttle..............................................................1700 RPM

a. Magneto Checkout

1) Ignition Switch......................................R

RESULT: Noticeable RPM (not to exceed 150 RPM) drop and slight engine roughness; record Left Magneto channel drop results. Maximum allowable RPM drop spread between magneto channels is 50 RPM.

2) Ignition Switch......................................BOTH

RESULT : Engine speed returns to normal. Allow Ignition switch to remain in BOTH for approximately 30 seconds to clear engine.

3) Ignition Switch......................................L

RESULT: Noticeable RPM (not to exceed 150 RPM) drop and slight engine roughness. The difference between magnetos individual operation should not exceed 75 RPM. Maximum RPM drop for either magneto is 150 RPM. Observe engine smoothness during magneto switching.

CAUTION: Do not operate the engine at speeds in excess of 2000 RPM longer than necessary to complete ground checks. Proper engine cooling depends upon forward motion of aircraft. Discontinue testing if temperature or pressure limits are approached.

b. Minor spark plug fowling can be cleared as follows:

1) Ignition Switch......................................BOTH

2) Throttle..................................................2200 RPM

IO-240 Series Engine Installation & Operation Manual 4-11 31 October 2011

Engine Operation

3) Mixture Control .................................... lean until RPM peaks for 10 seconds.

4) Mixture Control .................................... FULL RICH

8. Throttle..............................................................1200 RPM

4-3.4. Taxi Preparation

Before taxiing, refer to the AFM/POH for detailed taxi preparation procedures applicable to your aircraft. Check the following items:

CAUTION: DO NOT operate the engine at run-up speed unless the oil temperature is at least 75°F (24°C) and the oil pressure is within the 30-60 psi range. Operating the engine above idle before reaching minimum oil temperature may cause a loss of oil pressure and engine damage.

NOTE: For taxi operation during high ambient temperature or from fields at higher altitudes, the mixture control may require leaning for smooth engine operation. A FULL RICH mixture must be used for takeoff.

1. Cowling Flaps ................................................... FULL OPEN (if equipped)

2. Instrument Checkout.........................................Refer to AFM/POH

4-3.5. Power Control

When increasing power: enrich the mixture, then advance the throttle to increase RPM. When decreasing power: reduce the RPM, then adjust the mixture setting.

4-12 IO-240 Series Engine Installation & Operation Manual

31 October 2011

4-3.6. Take-Off

If, during preflight check or engine warm-up, any operational abnormalities occur, do not takeoff. Determine the cause and take corrective action necessary to maintain airworthiness.

Supplement the AFM/POH take-off procedures with these engine settings:

1. Mixture..............................................................FULL RICH

2. Cowl Flaps ........................................................Refer AFM/POH

3. Throttle..............................................................Advance for rated takeoff power

CAUTION: Cylinder head and oil temperatures must never be allowed to exceed limits. Near maximum temperatures should occur only when operating under adverse conditions such as high power settings, low airspeed, extreme ambient temperatures, etc. Take remedial steps to reduce such temperatures as soon as possible. If excessive temperatures are noted and cannot be explained, or if abnormal cowl flap and/or mixture settings are required to maintain temperatures, inspect to determine cause. Possible causes are broken or missing baffles, inoperative cowl flaps, sticking oil temperature control unit, or restricted fuel flow. Faulty instruments or thermocouples may cause erroneously high (or low) indications. Refer to troubleshooting procedures in Section 8 of the Maintenance and Overhaul Manual (M-6).

Engine Operation

WARNING

4. Monitor Engine Gauges not to exceed operating limits a. Manifold Pressure b. Tachometer c. Fuel Flow d. Cylinder Head Temperature e. Oil Temperature and Pressure

IO-240 Series Engine Installation & Operation Manual 4-13 31 October 2011

Engine Operation

4-3.7. Climb

For climbing or ascent procedures at full power, supplement the AFM/POH with these settings:

At power settings above 75% normal rated power, do not use the EGT gauge as an aid to mixture adjustment. Attempts to determine “peak” EGT at high power will result in burned valves, detonation and engine failure.

1. Throttle..............................................................Greater than 75% rated power

2. Mixture Control ................................................FULL RICH

3. Cowl Flaps ........................................................Set to maintain CHT/Oil Temp

NOTE: Maintain mixture and throttle settings until climb is complete. Upon completion of climb, power settings may be reduced to desired settings.

4. Immediately after takeoff, monitor engine gauges not to exceed operating limits. a. Manifold Pressure

WARNING

b. Tachometer c. Fuel Flow d. Cylinder Head Temperature e. Oil Pressure f. Oil Temperature

4-14 IO-240 Series Engine Installation & Operation Manual

31 October 2011

4-3.8. Cruise

When the desired altitude has been reached, supplement the AFM/POH instructions with these steps:

1. Adjust the throttle for the desired cruise power settings.

2. Monitor Engine Instruments - Allow engine temperatures to stabilize (approximately five minutes after cruise settings).

3. Adjust the mixture control to lean cruise condition in accordance to AFM/POH.

4. If using the exhaust gas temperature gauge to monitor cruise fuel flow, adjust the fuel mixture to 75° to 100°F (24° to 38°C) rich of peak for best power setting.

Engine Operation

CAUTION: Do not lean the fuel mixture beyond the “Best Power” setting. Excessive mixture leaning will increase engine temperatures and may damage the engine.

NOTE: When increasing power, enrich mixture, then advance the throttle to increase RPM. When reducing power, retard throttle, then adjust the mixture control. 



Changes in altitude or air temperature will require adjustments in manifold pressure and fuel flow.

IO-240 Series Engine Installation & Operation Manual 4-15 31 October 2011

Engine Operation

4-3.9. Descent

Avoid rapid descents at high RPM and idle manifold pressure.

Supplement the AFM/POH with the following:

1. RPM .................................................................. Reduce from cruise

2. Mixture..............................................................Adjust for smooth engine operation

Avoid long descents at high RPMs or low manifold pressure to prevent the engine from excessive cooling. If power must be reduced for long periods, set the manifold pressure no lower than necessary to obtain desired performance. If the outside air is extremely cold, it may be desirable to add drag to maintain engine power without gaining excess airspeed. Do not permit the cylinder temperature to drop below 300° F (149° C).

CAUTION: Monitor engine RPM during descent to ensure maximum rated engine RPM is not exceeded. If engine RPM approaches maximum rated RPM, reduce the angle of descent to increase drag and maintain engine operation within rated specifications. If the engine exceeds rated engine RPM for more than one minute, refer to “Engine Overspeed Inspections” in Section 6-4.3 of the Maintenance and Overhaul Manual (M-6).

WARNING

3. Cylinder Head Temperature.............................. 300°-460° F (149°-238° C)

4. Oil Temperature................................................75°-240° F (24°-116° C)

5. Engine Gauges ..................................................within operating limits

6. Manifold pressure ............................................. above 18.5 in.Hg

7. Engine gauges ................................................... within operating limits

4-3.10. Landing

Supplement the AFM/POH landing procedure with the following:

NOTE: If engine roughness occurs with the mixture at full rich, as may occur at very low throttle settings and high RPM, moderate leaning of the mixture is required to maintain smooth engine operation.

1. Mixture Control ................................................FULL RICH

2. Boost Pump.......................................................According to AFM/POH

4-16 IO-240 Series Engine Installation & Operation Manual

31 October 2011

4-3.11. Engine Shutdown

Supplement the AFM/POH engine shutdown procedures with the following:

1. Boost Pump.......................................................OFF

2. Throttle..............................................................1700 RPM

CAUTION: When operating on single ignition, some RPM drop should be noted. Normal indications are up to 150 RPM drop and slight engine roughness as each magneto is switched off. RPM drop in excess of 150 RPM may indicate a faulty magneto or fouled spark plugs. Avoid prolonged single magneto operation to preclude spark plug fouling.

Engine Operation

WARNING

NOTE: If the engine runs roughly after single magneto operation, increase engine speed to 2200 RPM in the BOTH position and lean the mixture control until the RPM peaks for ten seconds before returning to the full rich position to clear the spark plugs and restore smooth operation before returning to single magneto operation.



The difference between magnetos individual operation should not exceed 50 RPM. Maximum RPM drop for either magneto is 150 RPM. Observe engine smoothness during magneto switching.

3. Ignition Switch..................................................R

RESULT: 25-75 RPM drop (not to exceed 150 RPM) and slight engine roughness. Maximum allowable RPM drop spread between magneto channels is 50 RPM.

4. Ignition Switch..................................................BOTH

RESULT: Engine speed returns to normal. Allow Ignition switch to remain in BOTH for approximately 30 seconds to clear engine.

5. Ignition Switch..................................................L

RESULT: 25-75 RPM drop (not to exceed 150 RPM) and slight engine roughness. Maximum allowable RPM drop spread between magneto channels is 50 RPM.

6. Throttle..............................................................IDLE

7. Mixture Control.................................................IDLE CUTOFF

8. Ignition Switch..................................................OFF

IO-240 Series Engine Installation & Operation Manual 4-17 31 October 2011

Engine Operation

4-4. Emergency Operation

Information in this section supplements instructions for emergency operations found in the aircraft POH. Perform the following engine-specific steps in addition to the POH requirements when responding to emergency conditions.

If a malfunction should occur in-flight, certain remedial actions may eliminate or reduce the severity of the condition. Some malfunctions which might occur are listed in this chapter. Recommended corrective action is also included. However, no single procedure will be applicable in every situation.

Thorough aircraft and engine familiarity are invaluable assets in assessing a given situation and responding accordingly.

Maintain control of the aircraft at all times. Do not stall the airplane attempting to extend the gliding distance.

The following terms are used throughout Section 4-4

Land as Soon as Practical: Land at the nearest airport suitable for the aircraft.

Land at the best available landing area within aircraft

Land as Soon as Possible:

gliding distance, following instructions in the AFM/POH

WARNING

4-4.1. Engine Fire During Start

Maintain control of the aircraft at all times. Do not stall the airplane attempting to extend the gliding distance.

Supplement the AFM/POH instructions if possible with the following if flames are observed in the induction or exhaust system during engine start:

1. Mixture Control ................................................IDLE CUT-OFF

2. Throttle..............................................................FULL OPEN

3. Starter Switch.................................................... Hold in cranking position to

.......................................................................... extinguish fire

4-4.2. Engine Fire During Flight

1. Fuel Selector ..................................................... OFF

2. Mixture..............................................................IDLE/CUTOFF

3. Throttle..............................................................CLOSED

4. Magneto Switches.............................................OFF

5. Perform emergency/forced landing per AFM/POH and LAND AS SOON AS

POSSIBLE.

WARNING

4-18 IO-240 Series Engine Installation & Operation Manual

31 October 2011

Continental Refrigerator IO-240-A, IO-240-B Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Chapter 1 . Introduction

1-1. Scope and Purpose of This Manual

1-1.1. Effectivity Symbols

1-1.2. Advisories

1-1.3. Using this Manual

Figure 1-1. Figure and Index Reference

1-2. Publications

1-2.1. Service Documents

1-2.2. Related Publications

Table 1-1. Related Publications

1-2.3. Publication Access

1-2.4. Publication Changes

1-2.4.1. Update/Change Distribution

Figure 1-2. Change Page Identification

Figure 1-3. List of Effective Pages

1-2.4.2. Suggestions and Corrections

1-3. Contact Information

Chapter 2 . Engine Description

2-1. General Engine Description

2-1.1. Engine Model Number Definition

Figure 2-1. Engine Model Definition

2-1.2. Cylinder Number Designations

Figure 2-2. Cylinder Number Designation

2-2. Detailed Engine Description

2-2.1. Crankcase

Figure 2-3. IO-240 Crankcase Features

2-2.2. Engine Drive Train

Figure 2-4. Engine Drive Train

2-2.2.1. Crankshaft

Figure 2-5. Crankshaft

2-2.2.2. Connecting Rods

Figure 2-6. Connecting Rod

2-2.2.3. Camshaft

Figure 2-7. Camshaft

2-2.3. Accessory Case

2-2.4. Cylinders

Figure 2-8. Accessory Case Features

Figure 2-9. Cylinder Features

2-2.4.1. Pistons

2-2.4.2. Hydraulic Valve Tappets

Figure 2-10. Piston Features

2-2.5. Lubrication System

Figure 2-11. IO-240-A Lubrication

2-2.5.1. Oil Pump

Figure 2-12. IO-240-B Lubrication

Figure 2-13. Oil Pump

2-2.5.2. Oil Sump

2-2.5.3. Oil Pressure Relief Valve

2-2.5.4. Oil Cooler Adapter

Figure 2-14. IO-240-A Oil Cooler Adapter

Figure 2-15. IO-240-B Oil Cooler Adapter

Figure 2-16. IO-240-B Oil Cooler/Filter Adapter

2-2.6. Ignition System

Figure 2-17. Continental Motors Magneto Part Number Structure

Figure 2-18. Continental Motors Ignition Distribution

Figure 2-19. Slick Ignition Distribution

2-2.7. Fuel System

Figure 2-20. IO-240 Standard Fuel Injection System

2-2.7.1. Fuel Pump

Figure 2-21. Standard Fuel Pump

Figure 2-22. Altitude Compensating Fuel Pump

2-2.7.2. Fuel Injectors

Figure 2-23. Fuel Injector

2-2.8. Starter Assembly

2-2.9. Alternator

2-2.10. Engine Cooling

Figure 2-24. Engine Cooling

2-2.11. Induction System

Figure 2-25. IO-240-A Induction System

Figure 2-26. IO-240-B Crossflow Induction System

2-3. Engine Specifications and Operating Limits

Table 2-1. IO-240-A Specifications and Operating Limits

Table 2-2. IO-240-B Specifications and Operating Limits

2-3.1. Accessory Drive Ratios

Tab le 2-3 . Acc es sory Drive Ratios

2-3.2. Performance Data