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Continental aircraft engine. Maintenance and overhaul manual. -
However, the borescope inspection required by the SB must also be considered. If there is evidence of burned or over-temped valves, then yes, they do need to be pulled. Also, be sure he used a master orifice to determine the minimum and that he looked inside the cylinder with a borescope.
Service Instruction No. Below is an excerpt from A. As you can see, Lycoming views the issue very differently:. NOTE: Unless the pressure difference exceeds 15 psi the investigation should not necessarily mean removal of the cylinder; often a valve will re-seat itself and result in acceptable compression during a later check which should be made within the next 10 hours of operation. Tom Ferguson has been flying since To summarize SB, here are some of the highlights.
The compression test is a very useful tool to help determine the internal condition of cylinders, but it has limitations and must be used in conjunction with other non-invasive tests. A borescope inspection MUST be done in conjunction with a compression check. The SB gives some good guidelines to follow on this inspection.
When determining the location of leaks, listen for exhaust and intake valve leaks, and piston blow-by at the oil filer. But also look for leaks caused by cylinder cracks at the sparkplug holes and in-between the aluminum cooling fins.
Instead, a master orifice is used to determine the minimum reading. This is a different orifice than the one we talked about earlier. The master orifice is temporarily attached to the Differential Pressure Tester outlet instead of the cylinder.
Turn on the air and set the regulator to 80 psi. Whatever the outlet pressure gage reads is the minimum allowed by that specific tester. The plane should be flown again for about 1 hour. Again, this is a very simplified paraphrase of SB Its 14 pages long and you should read it. What about Lycoming engines? As you can see, Lycoming views the issue very differently: Pressure readings for all cylinders should be nearly equal; a difference of 5 psi is satisfactory; a difference of 10 to 15 psi indicates an investigation should be made.
If the pressure reading for all cylinders is equal and above 70 psi; the engine is satisfactory; less than 65 psi indicates wear has occurred and subsequent compression checks should be made at hour intervals to determine rate and amount of wear.
If the pressure reading is below 60 psi or if the wear rate increases rapidly, as indicated by appreciable decrease in cylinder pressure, removal and overhaul of the cylinders should be considered.
Legacy Product Replacement Valves Crankcase Repair Piston Replacement Crankshaft Repair Crankshaft Counterweight Inspection and Repair Crankshaft Counterweight Removal Counterweight Identification Crankshaft Counterweight Inspection Crankshaft Counterweight Bushing Bore Inspection Crankshaft Counterweight Bushing Replacement Crankshaft Hanger Blade Bushing Inspection Oil Control Plug Replacement Crankshaft Plating Overhaul Connecting Rod Replacement Connecting Rod Dimensional Inspection Connecting Rod Piston Pin Boring Crankshaft Nose Oil Seal Replacement Solid Nose Oil Seal Removal Solid Nose Oil Seal Installation Split Nose Oil Seal Removal Exhaust Flange to Cylinder Installation Non-Destructive Inspection Gear Tooth Inspection Fluorescent Penetrant Inspection Magnetic Particle Inspection Connecting Rod Magnetic Particle Inspection Ultrasonic Inspection Ultrasonic Inspection Certification Crankshaft Ultrasonic Inspection Engine Cleaning Engine and Component Cleaning Cylinder Cleaning Piston Cleaning Cleaning Exhaust Parts Cleaning Aluminum Alloy Parts Dry Blasting Vapor Blasting Protective Coatings Aviation Oil Appendix A.
Glossary A A-1 A Terms and Definitions Appendix B. Torque Specifications B General Information B-1 B Torque Tips B-2 B B-3 B Torque Wrench and Extension Calculations Appendix C. Maintenance Standards C Handling Parts C-1 C Replacement Parts C-3 C Acceptable Replacement Parts Know Your Supplier C-4 C Mandatory Overhaul Replacement Parts C-5 C C-7 C Engine Data Plate Replacement C-8 C Removal and Installation of Engine Data Plate Special Instructions C-9 C Safety Wiring Hardware C C Tab Washer Installation Heli-Coil Removal Heli-Coil Insertion Stud Replacement Stud Removal Stud Installation Cotter Pin Installation Fuel System Service Fuel System Purge Gasket Installation Hose and Tubing Installation Harness Routing Table Service Documents Incorporated in Manual Special Tools List Tools, Accessories, and Supply Vendors Common Tools Break-in Oil Preservative Oil Authorized Adjustments and Replacements Engine Inspection and Maintenance Schedule Engine Operation Prerequisites Fuel System Adjustment Values Static Ground Setup Compensation Table Magneto Timing Specifications - Geared Engines Spark Plug Application Chart Spark Plug Rotation Chart VAPC Parameters Cylinder Inspection Tasks and References Additional Cylinder Service Document References Differential Pressure Test Results Borescope Inspection Objectives and Corrective Actions Crankcase Casting Numbers Exhaust Inspection Criteria Overspeed Categories Engine Operational Checklist Cylinder Inspection Checklist Aviation Fuel Specifications Authorized Fuels by Aircraft Model Non-Overhaul Parts Replacement Reference Parts Repair Reference Parts Handling Guidelines Alternator Drive Hub Slippage Alternator Cross Reference Cylinder Repair vs.
Replacement Guidelines Piston to Cylinder Clearance Ring Gap Specifications Engine to Piston Cross Reference Engines Serial Number Applicability Cylinder Part Number Conversion Engine Power Train Crankshaft Assembly Part Number History Crankshaft Assemblies Crankshaft Hanger Blade Bushing Sizes Wide Rod Crankshaft Counterweight Supersedure Counterweight Bushing Bore Dimensions Counterweight Hanger Blade Bushing Dimensions Crankshaft Oil Plug Installation Specifications Connecting Rod Specifications Parts Requiring Fluorescent Penetrant Inspection Magnetic Particle Inspection Reference Aircraft Engine Parts Cleaning Guidelines Cleaning Tips Painting External Parts Appendix B, Quick Table Reference B-1 Table B Component Specific Torque Specifications B-6 Table B B Table B General Torque Specifications Hydraulic Line Torque Specifications Straight Thread Fitting Torque Specifications B Table C C-5 Table C Figure Figure and Index Reference Change Page Identification List of Effective Pages Pulley Alignment Tool Alternator Drive Hub Torque Tool Needle Bearing Installation Tool - Part Bearing Installation Tool Valve Guide Seal Installation Tool O-Ring Installation Tool Oil Seal Tool Helical Coil Extraction Tool Helical Coil Insertion Tool Helical Coil Expanding Tool Anti-Seize Lubricant Application Fuel Injection Sealant Application Crankcase Threading Diagram - O Scavenge Pump Body Threading Diagram Oil Pump Assembly Threading Diagram Starter Adapter Assembly Threading Diagram Accessory Drive Cover Threading Diagram Part No.
MSB4 Swivel Tee Typical Turbocharged Fuel System Schematic IO Oil Servicing Points typical O Oil Servicing Points typical Disposable Oil Filter and Integral Screen Crankshaft Positioned at TDC Cylinder No. Spark Plug Inspection Criteria Elbow Kit Assembly Throttle and Metering Assembly Throttle and Control Assembly, Front View Throttle and Control Assembly, Side View Fuel Pressure Regulator, Turbocharged Engine Altitude Leaning Schedule Adjustment Example Altitude Leaning after Correction Fixed Wastegate Typical Sloped Controller Variable Absolute Pressure Controller Air Conditioning Compressor Belt Tensioning Optional Compressor Belt Tensioning Typical Alternator Belt Tensioning Front Mount Belt Driven Alternator Cylinder Power Stroke Areas Differential Pressure Test Equipment Usage Normal Combustion Chamber Burned Exhaust Valve Phosphated Cylinder Bore Cylinder Barrel Scoring and Piston Rub Typical Wear in Upper Ring Travel Typical Cylinder Wear Improperly Positioned Baffle Seals Aft and Side Baffles with Air Gaps Crack in Non-Critical Area of Crankcase, typical O Engine Crankcase Induction Tube Bead Location Throttle and Control Assembly Lubrication Points Throttle and Metering Assembly Lubrication Points Induction Port Drain Connectors Exhaust Slip joint Inspection V-band Clamp Inspection Alternator Drive Hub Alternator and Coupling Assembly Fuel Injector Nozzle Identification typical Turbo Fuel Injector Nozzle Assembly typical Alternator and Drive Hub Alternator Drive Hub Spanner Wrench Multi-Part Alternator Drive Hub One Piece Alternator Drive Hub Continental Motors Ignition System Champion Slick Ignition System Cylinder Torque Sequence Cylinder Position Number Location Ring Gap Measurement Location Intake Valve Angle Crankshaft Counterweight Bump Service Inspection Counterweight Bushing Bore Inspection Counterweight Inspection, Repair and Installation Crankshaft Hanger Blade Bushing Replacement Crankshaft Helix Pattern Connecting Rod Dimensions Retainer Plate and Screws on Front of Crankcase Crankshaft Nose Oil Seal Parts Split Nose Oil Seal Parts Gear Inspection Criteria Crankshaft Ultrasonic Inspection Method Location Torque Wrench B-4 Figure B Drive extensions Extension increases applied torque B-5 Figure B Extension decreases applied torque B-5 Figure C Right-hand-thread safety wire installation C Figure C Safety wire Patterns for Right-Hand Threads Heli-Coil Extraction Tool Installing a Helical Coil Insert Stud Sizes Minimum Material Thickness for Helical Coil insertion Installing Hoses and Fittings Scope and Purpose of This Manual This manual provides maintenance instructions for spark ignition, Standard Practices operating on aviation gasoline AvGas.
For information specific to the Continental Motors engine series, accessories, or the airplane, refer to the appropriate manual. A list of tools for all applicable engines is provided in Chapter 2. Consumables items, such as lubricants, sealants, and adhesives are listed in Chapter 3. Airworthiness limitations are in Chapter 4. Chapter 5 contains generic installation instructions applicable to our engines.
Chapter 6 provides schedule inspection and service intervals and instructions, as well as unscheduled maintenance instructions. Chapter 7 contains general engine operating instructions, applicable to all models.
Chapter 8 contains engine troubleshooting instructions. Engine preservation and storage instructions are in Chapter 9. Non-overhaul engine part replacement instructions are in Chapter Chapter 11 contains Non- Destructive Inspection guidelines.
Chapter 12 contains part cleaning instructions. Appendix A contains a glossary of common terms and acronyms used throughout the manual; Appendix B provides torque specifications, and Appendix C contains maintenance standards.
Together, this manual and those listed below comprise the instructions for continued airworthiness for applicable engines. This manual, and the overhaul manuals and component service manuals as applicable to engine specification listed below are delivered to the customer with the engine.
Refer to Section Advisories This manual utilizes three types of advisories; defined as follows: WARNING A warning emphasizes information which, if disregarded, could result in severe injury to personnel or equipment failure. NOTE: Provides special interest information, which may facilitate performance of a procedure or operation of equipment. Warnings and cautions precede the steps to which they apply; notes are placed in the manner which provides the greatest clarity.
Warnings, cautions, and notes do not impose undue restrictions. Failure to heed advisories will likely result in the undesirable or unsafe conditions the advisory was intended to prevent. Advisories are inserted to ensure maximum safety, efficiency, and performance. Abuse, misuse, or neglect of equipment can cause eventual engine malfunction or failure. Effectivity Symbols Variations in engine configuration may require specific instructions or illustrations.
When information pertains to only a subset of the applicable engine models, an effectivity symbol will precede the information. We prepared this manual in a user-friendly format suited equally for electronic viewing and print.
Illustrations in this manual are for reference only, depicting the most prominent configuration in the engine series. Consult the electronic illustrated parts catalog for engine model-specific illustrated parts breakdowns. The current information available from Continental Motors must be used to perform engine service, repair or overhaul. Installation of aftermarket parts on a Continental Motors engine constitutes a deviation from type-design criteria.
Installation of aftermarket parts on a Continental Motors engine must be performed using Instructions for Continued Airworthiness prepared by the manufacturer and approved by the FAA for the subject installation.
For work with the engine installed in the aircraft, the aircraft maintenance manual may also be required to gain access to, perform maintenance, or install some items. Use only the current information from the aircraft manufacturer.
Exploded assembly illustrations accompany instructions throughout the manual. Parts in illustrations Figure are identified with either alpha or numerical callouts indexes. Corresponding parts listings follow the illustrations for reference. The first time instructions refer to an illustration, the figure number is identified in parentheses, followed by the callout.
In subsequent parts references, only the callout will be specified unless the referenced illustration changes. Failure to comply may void the engine warranty. WARNING Prior to authorizing engine maintenance, the owner must ensure the facility or mechanic meets the Federal Aviation Administration or equivalent authority regulatory requirements.
The engine owner must verify the repair facility or mechanic uses the most current revision, including change pages of the applicable ICA. Use of Instructions for Continued Airworthiness which have been designated as obsolete, superseded, or inactive is prohibited.
Continental Motors ICAs are written for use by maintenance personnel who possess and apply the knowledge, training, and experience commensurate with persons holding a valid license or certification granted by the governing airworthiness authority to return the engine to an airworthy condition.
Each person performing maintenance, alteration or preventive maintenance on an engine or accessory must use methods, techniques and practices set forth in the Instructions for Continued Airworthiness or other methods, techniques, and practices found acceptable to the Administrator. Order of Precedence Continental Motors engine operating instructions are generated prior to and independently of the aircraft operating instructions. Prior to commencing engine maintenance, consult the Continental Motors web site to verify the current status of the ICAs relating to the intended procedure.
Publications This most current approved version of this manual is delivered to the customer at time of purchase. Contact an authorized Continental Motors distributor to discuss publication or service subscription options and pricing or visit our web site. Using superseded information may jeopardize engine airworthiness. Service documents, published by the manufacturer, or Airworthiness Directives, published by the FAA, may alter or provide supplemental information to the Maintenance and Overhaul Manual.
Verify and use only the current versions of all instructions. 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. Continental Motors issues service documents in the form of Service Bulletins on a wide variety of topics.
Some service documents may affect or supplement information in this manual and should be reviewed prior to performing maintenance. All active service documents applicable to the Standard Practice have been incorporated in these instructions as of the date of publication.
Printed publication subscribers receive printed changes and revisions as they are released. 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.
A change page replaces only the previous edition of the affected page. In the event a change page forces repagination, a new page will be inserted with a decimal extension added to the page number.
For example, if additional pages are required between pages 1- 6 and , the inserted page numbers will be Page A of the manual contains the original publication date and an itemized list of changes issued for the technical manual Figure The list of effective pages, itemizes the pages in each section, by change number.
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:. The service document cover page indicates the engine models affected by the service document. Insert a copy of applicable Service Documents in affected manuals until the service document instructions are incorporated in the manual, or the service document is canceled or superseded.
May contain updates to Instructions for Continued Airworthiness to address a safety issue. May contain updates to Instructions for Continued Airworthiness in the form of maintenance procedures or specifications. May contain updates to Instructions for Continued Airworthiness for optional component installations, which are not covered in the Applicable Operator, Maintenance, or Overhaul Manuals.
SSIs will not be included in the general service document set but will be made available through our Customer Service Department to owners of the affected engines only. Service Documents Incorporated in this Manual Applicable technical maintenance and service information contained in the Service Documents listed below, relevant to the engine models covered by this engine manual, have been incorporated in this M-0 Standard Practice Maintenance Manual.
The full content of active Continental Motors Service Documents is available at www. 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 Section As service documents are received, note the service document number, release date, title, and applicable section affected by the service document in the blank cells below and insert a copy of the service document behind the last page of this section. Related Publications The table below lists the publications, source, and accessibility relevant to Standard Practice installation, maintenance and overhaul.
Using superseded information jeopardize engine airworthiness. Our web site continentalmotors. If you are an Internet service subscriber, you can access our web site to confirm and review the latest revision of this manual. Suggestions and Corrections Continental Motors solicits and encourages user comments regarding suggested changes to this manual.
Notify our Customer Service Department immediately if you discover incorrect information which adversely affects safety. Contact Information Continental Motors factory representatives are available to answer technical questions and encourages suggestions regarding products, parts, or service. If customers have an inquiry or require technical assistance, they should contact their local Continental Motors distributor or field representative.
Service Parts Continental Motors engineering staff develops a complete bill of materials for every engine model specification manufactured. While many parts fit multiple engine model specifications, interchangeability of parts from one engine model, or model specification, to another is not guaranteed.
Service Part Applicability and Availability Major engine assemblies and components are permanently identified steel stamped, engraved, laser etched, or ink-stamped with a unique part number during the manufacturing process. An electronic parts catalog for all current production engine model specifications is available on the Continental Motors web site see Section Some parts of assemblies are not available for aftermarket sale for various reasons.
Some assemblies are not intended to be disassembled, such as cylinder heads and barrels. For this reason, only the next higher assembly NHA is available for aftermarket sales. Part Supersedure One of Continental Motors engineering core values is continuous improvement.
The original part numbers used to manufacture your aircraft engine may or may not be available at the time replacement parts are necessary to restore the engine to an airworthy condition.
The simplest way to determine the part number required is to locate the part or assembly in the illustrated parts catalog and compare part number s to the markings on the existing part s.
Through design improvements, it may be necessary to assign a new part number to a part or assembly that supersedes the part number used to build earlier specifications of your engine model because the form, fit or function of the parts differ. To determine if a part number used to assemble your engine has been superseded, consult the Parts Supersedure History under the Support Materials heading on our web site.
Special Tools NOTE: Tools listed in Table are for reference only, not for the purpose of promoting a particular vendor or requiring the customer to purchase from the indicated sources. The providers listed are potential sources for the items based on information available at the time of printing. Customers are free to obtain equivalent items from alternate sources which meet or exceed specifications of the listed tools.
Box aircraft-tool. Bunker Ct. Federal Mogul Southfield, MI federal-mogul. Mansville Dr. Technologies P. Starrett Company Crescent Street starrett. Before Knurl 2. Material Case Harden. SAE J is the specification for aircraft piston engine ashless-dispersant oil. SAE J is the specification for aircraft piston engine non-dispersant mineral oil. Lubricating oil meeting these specifications is acceptable; proof of conformity is the responsibility of the lubricant manufacturer.
If oil consumption has not stabilized in this time, drain the mineral oil, replace the oil filter and replace the discarded mineral oil with SAE J aviation oil.
Motorstor Engine Protectant Sprayed in cylinders Section 9. Oil change intervals published in this manual are minimum requirements. Continental Motors believes more frequent oil and filter changes enhance engine service life. Drain and replenish engine oil every 25 hours of operation or 4 months for engines that incorporate a reusable oil screen. Inspect oil screens and oil filter elements for contaminates at each oil change.
Oil analysis may be used in addition to the oil screen or filter element inspection, but not as a replacement for it. Most of these additives and concentrates are not compatible with air-cooled, light aircraft engines in their operating environments.
With the exception of the use of isopropyl alcohol or diethylene glycol monomethyl ether DiEGME compound described in the following paragraph , we do not recommend the use of additives or concentrates in any of our aircraft engines. The use of unapproved additives may void the engine warranty.
Use only recommended fuels and lubricants. Under certain ambient conditions of temperature and humidity, sufficient quantities of water may exist in the fuel to create restrictive ice formation in the fuel supply.
To alleviate this occurrence, it is permitted to add no more than three percent Isopropyl Alcohol to the fuel supply. DiEGME compound must be carefully mixed with the fuel in concentrations not to exceed 0.
Sealants CM Part Number Type Application Remarks Non-beaded gaskets; Apply both sides of starter gasket, oil cooler adapter gasket, vacuum pump adapter gasket, and fuel pump pad cover gasket. Beaded gasket; Apply to non-beaded D, X side of starter gasket, oil cooler adapter gasket, vacuum pump adapter gasket, and fuel pump pad cover gasket.
All press type plugs Hubbard etc. Only apply sealants or lubricants to fitting tapered ends up to the first two threads. Never apply to the first two threads to prevent contaminating fuel supply. Never use Teflon tape on fluid fittings of fuel injector nozzles. The use of RTV, silicone, Gasket Maker or any other sealant on the areas listed above during engine assembly will cause a loss of cylinder deck stud or through-bolt torque. The result will be cylinder separation, main bearing movement, oil starvation and catastrophic engine failure.
Shake or mix well before using. Do not apply gasket sealant to crankshaft nose seal area. When applying, use short light brush strokes until an even thin coat is obtained. The gasket sealant should be viscous enough that most of the brush marks disappear; if not, discard the old gasket sealant and reapply with new gasket sealant. NOTE: Allow the gasket sealant to air dry to a tacky condition before applying silk threading. Apply gasket maker in all areas that will mate against areas where gasket sealant was applied on the matching case half except the through bolt bosses.
Ensure the free ends of the thread will be covered by gasket material except at the nose oil seal. Assemble crankcase halves; install and torque all crankcase hardware in proper sequence in accordance with the applicable overhaul manual as soon as possible. NOTE: Take care to prevent displacement or damage to the crankshaft oil seal and silk thread. Ensure thrust washer halves and bearing halves remain in place. After crankcase torque, follow the instructions in Section to install the nose oil seal.
The gasket sealant should be viscous enough that most of the brush marks disappear; if not, discard the old gas- ket sealant and reapply with new gasket sealant. Scavenge Pump Body Sealant and Threading 1. NOTE: Apply gasket sealant and threading a continuous, single piece only as illustrated.
Assemble and torque as soon as possible in accordance with the applicable overhaul manual. Oil Pump Assembly Sealant and Threading 1. NOTE: Allow gasket sealant to air dry to a tacky condition before applying silk threading.
Assemble and torque as soon as possible according to the overhaul manual instruc- tions. Starter Adapter Assembly Sealant and Threading 1. When apply- ing, use short light brush strokes until an thin, even coat is obtained. The gasket seal- ant should be viscous enough that most of the brush marks disappear; if not, discard the old gasket sealant and reapply with new gasket sealant.
Temporarily install the starter adapter to make an impression of the silk thread on the accessory case. Carefully remove the starter adapter so that the shaft gear does not pull out. Install and torque the starter adapter according to the instructions in the applicable overhaul manual as soon as possible. Wipe excess sealant from the accessory case and starter adapter.
When apply- ing, use short light brush strokes until an even thin coat is obtained. The gasket seal- ant should be viscous enough that most of the brush marks disappear; if not, remove old gasket sealant and reapply with new gasket sealant. Chapter 4.
Consult Section Continental Motors engine Instructions for Continued Airworthiness with an initial publication date later than contain an Airworthiness Limitation Section. Engine Removal Engine Hoist rated for lbs. Two 2 engine slings rated for lbs. Engine Transport Stand 4. Catch Basins oil and fuel 5.
Tank Sprayer with Stoddard Solvent exterior engine cleaning Engine Installation Ashless dispersant oil conforming to SAE J 5. MIL-P, Grade 1 oil 6. Approved fuel for the engine model see Section Spark plugs and copper gaskets 8. Cable ties or nylon lacing cord Bladder-type pressure pot at least 1 gallon capacity Type 1 flammable fuel container at least one gallon capacity Clean fuel hoses fuel system setup AN union fittings fuel system setup Rubber grommets bulkhead and baffle pass-through Loctite Part No.
Engine Receipt and Handling When the engine arrives, inspect the crating for damage. If the engine crating appears damaged, notify the freight shipping company for resolution. If the crating appears intact, proceed to Section Uncrating the Engine 1. Remove the lag screws attaching the wooden cover to the base.
Lift the wooden cover and remove it. Open the plastic bag wrapped around the engine. 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. Crating an Engine for Shipping 1. Lower the engine onto the container base. Attach the engine using shock mounts and bolts. Cover the engine with a plastic bag. Install and attach the container cover to the base. 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.
Inspect the engine for signs of damage or corrosion. If the engine exhibits no sign of damage or corrosion, proceed with installation. If damage or corrosion is discovered, contact the supplier of the engine for disposition. Ensure the area is clear when lifting the engine. Do not allow the front, rear, sides or bottom of the engine to strike any obstructions as the extreme weight may damage the engine or its components.
Attach a hoist to the engine lifting eyes located at the top of the crankcase backbone. Take up slack on the hoist prior to loosening the engine mount bolts; remove the bolts from the shipping shock mounts.
Lift the engine and install it on a transportation stand or dolly. Engine Installation Procedures Refer to the engine installation instructions in the primary ICA for the engine being installed when installing a like engine as a replacement. For engines being installed for the first time in a new aircraft, refer to the engine installation manual.
NOTE: The installer is authorized to reposition engine component fittings, if necessary, to mate with the aircraft interfaces, See Section NOTE: Fitting orientation is determined at the time engine model specification is designated for the aircraft application.
If fitting orientation adjustment is required for every engine installation, a model specification change request may be more appropriate than repeated repositioning of fittings. Normally, only minor adjustments to the engine fuel system will be necessary at engine installation Reference Section Occasionally, minor adjustment may be necessary to other engine systems, components, or to position fittings for best routing and fit.
Personnel performing the specified adjustment and component replacements must be a licensed Airframe and Power Plant mechanic or be approved by the OEM or STC Converter facilities quality assurance to be capable of performing the specific task.
Work shall be performed in accordance with applicable continued airworthiness instructions including but not limited to the engine Installation Manual, Maintenance and Overhaul or Overhaul Manual, Service Documents. Adjustments and or replacements accomplished in accordance with these instructions must be documented by the OEM on the aircraft production paper work. Additionally, the OEM must provide Continental Motors notification of adjustments and replacements accomplished in accordance with these instructions.
If a component part is replaced, the OEM must provide the part number and serial number of the component removed and the part number and serial number of the component installed. Persistent engagement of the starter to rotate the crankshaft will exceed the starter duty cycle and may result in premature starter failure. Verify lubrication lines, fittings, hoses, screens, and filters are in place prior to pre- oiling. Obtain a 1-gallon capacity bladder-type pressure pot with an output pressure of 50 psi not to exceed 60 psi.
Connect the pre-oiler supply hose to the engine oil pressure output fitting. It may be necessary to disconnect the aircraft oil pressure sensor fitting according to the aircraft manufacturer's instructions. Remove the rocker covers. Open the pre-oiler valve and monitor the rocker arms for oil flow.
Depending upon oil temperature, it may take several minutes to see an indication of oil flow. Close the pre-oiler valve upon verification of oil flow at the rocker arms. Torque the rocker cover fasteners to Appendix B specifications.
Disconnect the pre-oiler supply hose and cap; connect the aircraft oil pressure sensor to the engine oil pressure output according to the aircraft manufacturer's instructions.
Check the oil level in the sump using the oil gauge rod dip stick. Verify the engine oil is at the proper level according to instructions in the primary ICA Section Engine Inspection Introduction Inspections described in this chapter apply only to the Continental Motors engines covered by this manual. Perform the engine inspections according to the instructions provided.
Perform aircraft inspections according to the aircraft manufacturer's instructions. NOTE: Discrepancies discovered by the person conducting the scheduled or unscheduled inspections, even if the discrepancy is not an itemized inspection item, should be corrected upon discovery.
Fuel and oil system contamination affects engine performance and service life. If oil or fuel system contamination is discovered, do not limit the correction to the symptom; isolate and correct the source of the contamination, including any residual material left in the engine by the source of the contamination.
Inspection and Maintenance Schedule Unless another FAA-approved Inspection Program is established, the Engine Inspection and Maintenance Schedule shows the inspections for the subject engines covered by this manual in their original type design. The inspections described in this chapter apply to the engine and not to the aircraft. The inspections are progressive; commencing from the date the engine is placed in service. The inspection intervals are tracked by Engine Log entries and designated by hours of operation or calendar time, whichever occurs first.
Inspection techniques must be executed consistently for reliability. Time Between Overhaul Continental Motors CM provides operational limitations and instructions for your engine along with the requirements for continued airworthiness as specified in the engine Operator Manuals, Maintenance Manuals, Overhaul Manuals, and Service Documents. The Time Between Engine Overhaul provided in this document applies only to engines that have been operated and maintained in accordance with these instructions.
Engine mounted components and accessories require overhaul at the same hourly and calendar intervals as the engine, unless otherwise specified by the component or accessory manufacturer. TBO periods were established on most CM engines beginning in the s. Since that time, CM has made significant engineering improvements to virtually all major engine components. CM has refined manufacturing processes and implemented computer numerical controlled CNC machining tools enabling CM factory engines to meet higher standards than possible when the engines were originally granted FAA Type Certificates.
Environmental corrosion occurs internally and externally on an engine. This naturally occurring process can affect continued airworthiness of the engine and engine mounted components or accessories. Regardless if the engine has been operated regularly or has been in storage; gaskets, seals, and synthetic and natural rubber goods deteriorate over time.
- Continental m-o manual
Post-Overhaul Test and Adjustments Post-Overhaul Testing Prerequisites Post-Overhaul Test Operating Limits Standard Acceptance Test Oil Consumption Test Drive Belt Tension Check Appendix A. Glossary A A-1 A Terms and Definitions Appendix B. Torque Specifications B General Information B-1 B Torque Tips Cylinder Torque Procedure B-3 B Torque Wrench and Extension Calculations Appendix C. Standard Practices C Handling Parts C-1 C Replacement Parts C-2 C Acceptable Replacement Parts Know Your Supplier C-3 C Mandatory Overhaul Replacement Parts C-4 C Safety Wiring Hardware C-5 C Tab Washer Installation C-7 C Helical Coil Insert Replacement C-8 C Helical Coil Removal C-9 C Helical Coil Insertion C C Stud Replacement Stud Removal Size-on-Size Rosan Stud Removal Step-Type Rosan Stud Removal Stud Installation Rosan Stud Installation Cotter Pin Installation Fuel System Service Fuel System Purge Gasket Maker Application Gasket Installation Hose and Tubing Installation Harness Routing Appendix D.
Overhaul Dimensional Limits D D-1 D D-2 D Throttle and Mixture Control Lever D-3 D Starter and Starter Adapter D-4 D D-9 D D D Engine Cylinder Overhaul Dimensions Crankshaft Counterweight Assemblies Counterweight Pins Connecting Rod Dimensions Stud Height Settings Starter Adapter Stud Height Settings Lubrication System Stud Height Settings Accessory Drive Adapter Stud Height Cylinder Stud Height Settings Crankcase Plugs and Fittings Crankcase Stud Height Settings Table Legend for Figure Accessory Drive Ratios Special Tools List Tool, Accessory and Supply Vendors Break-in Oil Preservative Oil Engine Inspection and Maintenance Schedule Engine Operation Prerequisites IO Engine Operating Limits Static Ground Setup Compensation Table Cylinder Inspection Tasks and References Differential Pressure Test Results Borescope Inspection Objectives and Corrective Actions Overspeed Categories Engine Operational Checklist Cylinder Inspection Checklist Non-Overhaul Parts Replacement Reference Parts Handling Guidelines Parts Repair Reference Fuel Pump Drive Coupling Dimensions Basic Starter Adapter Dimensions Shaft Gear Drum Service Limits Worm Wheel Drum Dimensions Lubrication System Component Service Limits Cylinder Barrel Service Limits Engine Removal and Disassembly Checklist Engine Overhaul Visual Inspection Checklist Fluorescent Penetrant Inspection Checklist Magnetic Particle Inspection Checklist Ultrasonic Inspection Checklist Dimensional Inspection Checklist Engine Cylinder Overhaul Inspection Checklist Engine Drive Train Inspection Checklist Replacement Parts Inventory Aircraft Engine Parts Cleaning Guidelines Cleaning Tips Painting External Parts Parts requiring Fluorescent Penetrant Inspection Magnetic Particle Inspection Reference Alternator Drive Hub Slippage Cylinder Repair vs.
Replacement Guidelines Mandatory Cylinder Overhaul Replacement Parts Engine Drive Train Parts Replacement Standard Acceptance Test Requirements Oil Consumption Test Requirements General Torque Specification B-6 Table B Tube Fitting Torque Specifications B-7 Table B Component Specific Torque Specifications B-8 Table B Specific Torque for Non-Lubricated Hardware B Table C C Table D D-2 Table D Basic Starter Adapter Overhaul Dimensions D-5 Table D D-7 Table D D-8 Table D Ignition System Dimensional D-9 Table D Lubrication System Dimensions D Table D Lubrication System Components Dimensions Cylinder Assembly Dimensions Updraft Engine Cylinder Assembly Dimensions Crossflow Cylinder Assembly Dimensions Cylinder Barrel Dimensions Additional Crankcase Dimensions Crankcase Dimensions Additional Engine Drive Train Dimensions Engine Drive Train Dimensions Crankshaft, Camshaft, and Idler Gear Backlash Counterweight Pin Part Numbers Crankshaft Counterweight Blade Bushing Dimensions Basic Starter Adapter Stud Heights Cylinder Stud Heights Crankcase Plugs Figure Figure and Index Reference Change Page Identification List of Effective Pages Engine Model Definition Cylinder Number Designation Permold Crankcase Features Connecting Rod Updraft Cylinder Features Crossflow Cylinder Features Piston Features Lubrication Schematic Oil Cooler Continental Motors Ignition System Schematic Champion Slick Ignition System Schematic Typical Updraft Induction System Typical Cross-flow Induction System IOA Fuel Flow vs.
Brake Horsepower IOB Fuel Flow vs. IOC Fuel Flow vs. IOG Fuel Flow vs. Borescope Autoscope Pulley Alignment Tool Alternator Drive Hub Torque Tool Oil Control Plug Installation Tool Needle Bearing Installation Tool -Part Bearing Installation Tool Crankcase Needle Bearing Installation Tool Valve Guide Seal Installation Tool O-Ring Installation Tool Oil Seal Tool Helical Coil Extraction Tool Helical Coil Insertion Tool Helical Coil Expanding Tool Rosan Stud Removal Tool Exhaust Port Dimensions Propeller Flange Dimensions Gear Driven Alternator Detail Gear Driven Alternator Detail, cont.
Belt Driven Alternator Detail Crankshaft Positioned at TDC Cylinder No. Spark Plug Inspection Criteria Spark Plug Rotation Chart Champion Slick Ignition Harness Routing Continental Motors Ignition Harness Routing Fuel Pump Adjustments Refrigerant Compressor Belt Tensioning Cylinder Power Stroke Areas Differential Pressure Test Equipment Usage Normal Combustion Chamber Burned Exhaust Valve Phosphated Cylinder Bore Cylinder Barrel Scoring and Piston Rub Typical Wear in Upper Ring Travel Typical Cylinder Wear Improperly Positioned Baffle Seals Aft and Side Baffles with Air Gaps Crankcase Critical white and Non-critical Shaded Area Mount Boss with Thick Rib Mount Boss with Thin Rib General Inspection Area Suspect Crack Indication Induction Tube Bead Location Alternator Drive Hub ES Alternator ES Alternator Assembly Fuel Pump Assembly Original Fuel Injector Nozzles Position Tuned Fuel Injector Nozzle Fuel Injector Assemblies Starter Motor and Starter Adapter Basic Starter Adapter Shaft Gear Drum Dimensions Starter Adapter with Scavenge Pump Gear Driven Alternator Assembly Alternator Cotter Pin Installation Continental Motors Ignition System Champion Slick Ignition System Accessory Drive Adapter Dimensions Accessory Drive Assembly Rear View of Engine Oil Pressure Relief Valve Valve Seat in the Oil Pump Housing Oil Temperature Control Valve Lubrication System Service Limits Updraft Cylinder Assembly Crossflow Cylinder Assembly Updraft Cylinder Pushrod Tube Assembly Crossflow Cylinder Pushrod Tube Assembly Packing Installed to Stabilize Connecting Rods Piston, Piston Pin and Piston Rings Static Seal Pushrod Dimensions Cylinder Service Limits Intake Valve Seat Dimensions Exhaust Valve Seat Dimensions Valve Service Limits Single Cylinder Torque Sequence Pushrod Spring Compressor Rocker Arm to Retainer Clearance Rocker Arm Side Clearance Retainer Plate and Screws on Front of Crankcase Crankshaft Nose Oil Seal Parts Crankshaft Plated Area Magneto Tachometer Sensor Continental Ignition System Accessory Drive Adapter Assembly IOA Induction Assembly IOB Induction Assembly IOC Induction Assembly IOC Oil Cooler ION Oil Cooler Direct Drive Alternator Belt Driven Alternator Bracket Assembly Optional Alternator Bracket Assembly Optional Refrigerant Compressor Mount Assembly Starter and Adapter IOP Oil Sump Piston Assembly Cylinder Base Packing support Connecting Rods Inter-Cylinder Baffle Assembly Cylinder Drain Tube Fitting IOA Engine Mounts IOC Engine Mounts Fitting Orientation Guide Standard Oil Pump Starter and Adapter with Accessory Drive Miscellaneous Crankcase Hardware Crankcase Fastener Locations Keyed Camshaft Refrigerant Compressor Mounting Kit Gear Inspection Criteria Crankshaft Ultrasonic Inspection Method Location Crankcase Critical White Stress Areas Crankcase Dimensional Inspection Torque Sequence Crankshaft Journals Crankshaft Counterweight Bump Surface Inspection Refrigerant Compressor Sheave Induction Manifold Fittings Oil Filter Adapter Stud M Compliance Stamp Part No.
Cylinder Position Number Rocker Arm Single Bushing Replacement Radius Cut Distance from Camshaft Centerline Overhead View of Radius Cut Depth Counterweight Inspection, Repair and Installation Crankshaft Hanger Blade Bushing Replacement Crankshaft Helix Pattern Connecting Rod Assembly Worm Wheel Gear Installation Tool Starter with Accessory Drive Oil Seal Retainer Clip Position Basic Starter and Starter Adapter Assembly Secure Baffle with Spring Piston Ring Installation Order Valve and Spring Installation Connecting Rod Position Number Refrigerant Compressor Mounting Assembly Crankcase Sealant and Threading Timing Mark Alignment Left Crankcase Assembled on Stand Cylinder Base O-ring supporting the Connecting Rods Permold Crankcase Fasteners Cylinder Drain Fitting Permold Crankcase Torque Sequence Miscellaneous Crankcase Fasteners Pushrod Housing Installation Oil Sump Torque Sequence Starter and Adapter Assembly Alternator Drive End Housing Modification Alternator Brace Shim Location Anti-Seize Application Continental Ignition Assembly Magneto Sensor Slick Ignition Assembly Sheave Alignment Starter Adapter Belt Sheave Alignment Belt Tension Adjustment Torque Wrench B-4 Figure B Drive extensions Extension increases applied torque B-5 Figure B Extension decreases applied torque B-5 Figure C Right-hand-thread safety wire installation C-5 Figure C Safety wire Patterns for Right-Hand Threads C-6 Figure C C-7 Figure C C-9 Figure C Installing a Helical Coil Insert C Figure C Stud Sizes Minimum Material Thickness for Helical Coil insertion Rosan Stud Installation Dimensions Installing Hoses and Fittings C Figure D D-2 Figure D D-6 Figure D D-8 Figure D D-9 Figure D Oil Pump Dimensions D Figure D Intake Valve Dimensions Exhaust Valve Dimensions Counterweight Assembly Crankshaft Counterweight Bushing Bore Dimensions Crankshaft Counterweight Bushing Dimensions Crankshaft Hanger Blade Bushing Bore Crankshaft Hanger Blade Bushing Basic Starter Adapter Studs Starter Adapter with Accessory Drive Studs Accessory Drive Adapter Crankcase Stud Detail Instructions in this manual are specific to the IO Permold 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. Chapter 2 contains detailed engine model descriptions and specifications.
Chapter 5 provides engine installation instructions. Chapter 7 provides supplemental information for the airplane flight manual AFM or pilot operating handbook POH in regards to specific engine operating procedures.
Appendix A contains a glossary of common terms and acronyms used throughout the manual; Appendix B provides torque specifications, and Appendix C contains standard maintenance practices. This manual and the component manuals as applicable to engine specification listed below are delivered to the customer with the engine.
Refer to Section Effectivity Symbols Slight variations in IO Series engine models require specific instructions or illustrations. When peculiar information pertains to only a specific engine model in the series, an effectivity symbol will accompany the information. Advisories This manual utilizes three types of advisories; defined as follows: WARNING A warning emphasizes information which, if disregarded, could result in severe injury to personnel or equipment failure.
NOTE: Provides special interest information, which may facilitate performance of a procedure or operation of equipment. Warnings and cautions precede the steps to which they apply; notes are placed in the manner which provides the greatest clarity. Warnings, cautions, and notes do not impose undue restrictions. Failure to heed advisories will likely result in the undesirable or unsafe conditions the advisory was intended to prevent. Advisories are inserted to ensure maximum safety, efficiency, and performance.
Abuse, misuse, or neglect of equipment can cause eventual engine malfunction or failure. Using this Manual This manual, the accessory manuals listed in Table , and certain service documents that are incorporated into the manuals as revisions constitute the Instructions for Continued Airworthiness ICAs prepared by Continental Motors and accepted by the Federal Aviation Administration FAA. Continental Motors prepared this manual in a user- friendly format suited equally for electronic viewing and print.
Illustrations in this manual are for reference only, depicting the most prominent configuration in the engine series. Consult the parts catalog for engine model-specific illustrated parts breakdowns. Continental Motors ICAs must not be used for aftermarket parts obtained from sources other than Continental Motors or our authorized distributors.
Installation of aftermarket parts on a Continental Motors engine constitutes a deviation from FAA approved type-design criteria. Installation of aftermarket parts on a Continental Motors engine must be performed using Instructions for Continued Airworthiness prepared by the manufacturer and approved by the FAA for the subject installation. Parts in illustrations Figure 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. Engine service life is calculated based on compliance with the aircraft and engine manufacturers required instructions, inspections, and maintenance schedule.
Failure to comply may void the engine warranty. The engine owner must verify the repair facility or mechanic uses the most current revision, including change pages of the applicable ICA. Use of Instructions for Continued Airworthiness which have been designated as obsolete, superseded, or inactive is prohibited. Information and instructions contained in this manual anticipate the user possesses and applies the knowledge, training, and experience commensurate with the prerequisite FAA license and certification requirements.
Order of Precedence Continental Motors engine operating instructions are generated prior to and independently of the aircraft operating instructions. Prior to commencing engine maintenance, consult the Continental Motors web site to verify the current status of the ICAs relating to the intended procedure Publications This most current approved version of this manual is delivered to the customer at time of purchase. This manual and all subsequent revisions or changes are published in Adobe portable document format filename.
Contact an authorized Continental Motors distributor to discuss publication or service subscription options and pricing or visit our web site. Using superseded information may jeopardize engine airworthiness. Service documents, published by the manufacturer, or Airworthiness Directives, published by the FAA, may alter or provide supplemental information to the Maintenance and Overhaul Manual. Verify and use only the current versions of all instructions.
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. Continental Motors issues service documents in the form of Service Bulletins on a wide variety of topics.
Some service documents may affect or supplement information in this manual and should be reviewed prior to performing maintenance. All active service documents applicable to the IO Permold Series Engine have been incorporated in these instructions as of the date of publication. Printed publication subscribers receive printed changes and revisions as they are released. 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 , referred to as a change bar in the outside margin of the page.
A change page replaces only the previous edition of the affected page. In the event a change page forces repagination, a new page will be inserted with a decimal extension added to the page number. For example, if additional pages are required between pages 1- 6 and , the inserted page numbers will be Page A of the manual contains the original publication date and an itemized list of changes issued for the technical manual Figure If change pages are issued for the manual, the change will be identified, with an effective date under the heading Effective Changes for This Manual on Page A.
The list of effective pages, itemizes the pages in each section, by change number. Original pages are designated by a 0 in the List of Effective Pages Change column. Service Documents Six categories of Service Documents may be issued by Continental Motors ranging from mandatory Category 1 to informational Category 6. Definitions of the categories are listed below:.
The service document cover page indicates the engine models affected by the service document. Service documents may alter or replace the manufacturers Instructions for Continued Airworthiness. Insert a copy of applicable Service Documents in affected manuals until the service document instructions are incorporated in the manual, or the service document is canceled or superseded.
May contain updates to Continental Motors Instructions for Continued Airworthiness to address a safety issue. Category 2: Critical Service Bulletin CSB This category identifies a condition that threatens continued safe operation of an aircraft, persons or property on the ground unless some specific action inspection, repair, replacement, etc. Category 3: Service Bulletin SB Information which the product manufacturer believes may improve the inherent safety of an aircraft or aircraft component; this category includes the most recent updates to Instructions for Continued Airworthiness.
May contain updates to Continental Motors Instructions for Continued Airworthiness in the form of maintenance procedures or specifications. May contain updates to Continental Motors Instructions for Continued Airworthiness for optional component installations, which are not covered in the Applicable Operator, Maintenance, or Overhaul Manuals. Continental Motors will distribute SSI notification directly to the affected engines owners. SSIs will not be included in the general service document set but will be made available through our Customer Service to owners of the affected engines only.
Service Documents Incorporated in this Manual Applicable technical information in the service documents listed below, relevant to the engine models covered by this engine manual, have been incorporated in this manual. 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 until the new information is incorporated in the manual text. As service documents are received, note the service document number, release date, title, and applicable section affected by the service document in the blank cells below and insert a copy of the service document behind the last page of this section.
For paragraphs or entire sections, draw an X through the affected information in the manual and reference the service document containing the correction. Related Publications The table below lists related publications, source, and accessibility relevant to IO Permold Series engine installation, operation, maintenance and overhaul.
Using superseded information jeopardize engine airworthiness. Our web site continentalmotors. If you are an Internet service subscriber, you can access the web site to confirm and review the latest revision of this manual. If you have not subscribed to Internet service and are using printed materials, contact a customer service representative using the Contact Information on page As applicable to engine model specification 3.
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 , Contact Information or send comments via e-mail to CM. Notify Continental Motors Customer Service department immediately, using our toll-free number, if you discover incorrect information which adversely affects safety.
Contact Information Continental Motors service representatives are available to answer technical questions and encourages suggestions regarding products, parts, or service. If customers have an inquiry or require technical assistance, they should contact their local authorized Continental Motors distributor or Continental Motors field representative.
Our mailing address, telephone numbers and Internet address are listed below: Continental Motors, Inc. The cubic inch displacement is achieved using a 5. Basic engine weights, minus accessories, are listed in Section Engine weights vary by model specification, refer to the engine Detailed Model Specification for installed engine weights, including accessories. The engine is provided with four engine mounts designed for a focalized bed mount. A crankcase breather port is located on the oil filler neck on the side of the crankcase between number 2 and number 4 cylinders.
Engine lubrication is provided by a wet sump, high pressure oil system. The engine lubrication system includes the engine driven pressure oil pump, engine mounted oil cooler, oil sump, full flow oil filter, oil pressure relief valve, and provisions for aircraft pressure and temperature instrumentation. An oil cooler is mounted on the left crankcase half behind the number 2 cylinder.
An oil temperature control valve, called a Vernatherm restricts oil flow through the oil cooler until normal operating temperatures are reached.
During engine warm up, a cavity in the base of the oil cooler allows free flow of oil back to the crankcase, bypassing the vernatherm. Engine manifold pressure is controlled by the throttle plate and is measured at the 0. IO Permold Series engines are equipped with a Continuous Flow Fuel Injection system that meters fuel flow as a function of engine speed, throttle angle and mixture control angle. The metered fuel is fed to continuous flow air bled injector nozzles located at each cylinder intake port.
IO engines with updraft cylinders feature fuel drains located in the induction tubes. IO engines with crossflow cylinders feature fuel drains at the bottom of each cylinder. Engine Model Number Definition The engine model number indicates key features of the engine.
Each alphanumeric character in the engine model number has a specific meaning, Figure depicts the significance of each character in the IOB1B engine model designation. Engine Model Definition Cylinder Number Designations Refer to Figure The front of the engine is the end closest to the propeller and the rear of the engine is the accessory end Viewed from the rear of the engine, the left-side cylinders are designated by even num- bers , with Cylinder 2 being closest to the rear.
The right side cylinders have odd number sequential designation , with Cylinder 1 being closest to the rear. Firing order of the engine is Detailed Engine Description Crankcase The crankcase is composed of two aluminum alloy castings joined along the center vertical plane. The individual castings with studs and inserts will be referred to as left and right crankcases throughout the manual. Bosses molded in the castings are line bored in the assembled casting to form bearings for the camshaft and saddles for precision main bearing inserts.
Guides are bored through lateral bosses for hydraulic tappets and on the left crankcase half for the governor drive shaft gear. A needle bearing bore is located on the right crankcase half at the rear main bearing saddle for the starter adapter and needle bearing. Cylinder mounting pads on the left crankcase are farther forward than the corresponding pads on the right crankcase to permit each connecting rod to work on a separate crankpin.
There are seven studs and two through bolts for attaching cylinder base flanges. The propeller governor mount pad is located on the lower front corner of the left crankcase half. An alternator pad is located on the right crankcase forward of the number five cylinder mount pad. The crankcase interior is ventilated by an integral breather in the oil filler adapter inserted in a machined hole between the number two and four cylinders on the left crankcase half.
Engine Drive Train When starting the engine, torque is transmitted from the starter through the starter adapter components to the large crankshaft gear. As the worm gear in the adapter is turned, the spring mounted on the hub tightens to grip the knurled drum of the shaft gear. After starting, the spring returns to its normal position releasing the shaft gear and disengaging the starter.
Torque is transmitted to the alternator by a face gear mounted on the crankshaft. Crankshaft torque is transmitted by the small crankshaft gear directly to the idler gear and the camshaft gear. The idler gear rotates in a counter-clockwise direction to drive the magneto drive gears. Optional accessories mounted on the aft side of the accessory case are driven by the internal splines of the magneto drive gears. The fuel pump coupling mates directly with the square drive machined in the center of the small crankshaft gear.
Share Embed Flag. TAGS inlet aircraft filter teledyne continental installation fitting motors revision hose tcmlink. You also want an ePaper? This battery should be inspected at the airframe manufacturers recommended interval, using procedures contained in the latest revision of the Airframe Maintenance Manual. In addition, the start vibrator backup battery must be replaced at least every 12 months. CAUTION: Low voltage to the start vibrator below 8 volts will cause loss of start vibrator boost voltage output and possible reversion of the magneto to the advanced timing mode.
Engine damage may result from improper start vibrator operation. Reference Figure 1. Correct any discrepancies before proceeding. Make adjustments as necessary to meet specifications published in the latest revision of SID Install a protective cover on the fuel supply line to prevent contamination. Install a protective cover on the fuel pump inlet fitting to prevent contamination.
Blow the filter cone dry with clean, filtered dry compressed air. If any physical damage is noted to the filter, it must be replaced. Temporarily restore power to the aircraft and open the fuel selector valve. Placing the end of the fuel supply hose into a proper container, use the aircraft boost pump to flush the hose to remove any contaminants. Turn the fuel selector valve back to the off position and remove power from the aircraft.
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