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

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IO-240-A
B
®
CONTINENTAL
AIRCRAFT ENGINE
INSTALLATION
AND
OPERATION
MANUAL
FAA APPROVED
Publication OI-6
©
2011 CONTINENTAL MOTORS, INC.
OCT 2011

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Summary of Contents for Continental Refrigerator IO-240-A

  • Page 1 IO-240-A ® CONTINENTAL AIRCRAFT ENGINE INSTALLATION OPERATION MANUAL FAA APPROVED Publication OI-6 © 2011 CONTINENTAL MOTORS, INC. OCT 2011...
  • Page 2 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 &...
  • Page 3 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”...
  • Page 4 Service Document Subject Affected Chapter SIL93-15, General Practices for Installation of Lock Wire, Tab Standard Practices Appendix C Washers, and Cotter Pins CSB94-1, TCM Ignition CSB641 Magneto Coil SIL94-5, Mobil AV-1 Oil Authorized Lubricants MSB94-8D, Magneto to Engine Timing Service SB95-2, Inspection and Maintenance of Engine Control Cables Inspection and Linkage...
  • Page 5 Service Document Subject Affected Chapter SIL00-11B, Release of new Cylinder Induction Port Drain Cylinder Assembly Connector CSB02-8, TCM Ignition Systems CSB664 SIL03-1, Cold Weather Operation – Engine Preheating Preheating procedures SIL03-2B, Currently Active Approved Spark Plug Application Spark plugs 2 & 3 SIL03-3, Differential Pressure Test and Borescope Inspection Inspection Criteria SIL03-7, IO-240 Series Magneto Drive Gear...
  • Page 6 Service Document Subject Affected Chapter I n d u c t i o n S y s t e m SB08-13, Induction System Hose and Clamp Installation Appendix C Inspection & Assembly SB09-14, Camshaft Corrosion Treatmen Engine Inspection SIL640, Service Document Format Service Documents Preface &...
  • Page 7 Service Bulletins Release After This Manual Bulletin Number: Release Date: Affected Sections: Title: Bulletin Number: Release Date: Affected Sections: Title: Bulletin Number: Release Date: Affected Sections: Title: Bulletin Number: Release Date: Affected Sections: Title: Bulletin Number: Release Date: Affected Sections: Title: Bulletin Number: Release Date:...
  • Page 8 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).

  • Page 9: Table Of Contents

    TABLE OF CONTENTS 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 ......................1-2. Publications...................... 1-2.1. Service Documents ...................... 1-2.2. Related Publications..................... 1-2.3. Publication Access ....................... 1-2.4. Publication Changes..................... 1-2.4.1.
  • Page 10 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 ................... 3-1.1. Common Tools and Consumable Supplies Required ..........3-1.2. Engine Receipt and Handling ..................3-1.2.1. Uncrating the Engine..................3-2 3-1.2.2. Crating an Engine for Shipping................. 3-2 3-1.2.3.
  • Page 11 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.
  • Page 12 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.
  • Page 13 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.
  • Page 14 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.

  • Page 15: 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).

  • Page 16: Figure 1-1. Figure And Index Reference

    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. WARNING Continental Motors ICAs are applicable only to Continental Motors engines conforming to the approved, type certified engine model configuration.

  • Page 17: Publications

    Introduction 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.

  • Page 18: 1-2.2. Related Publications

    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 Printed Manual Available...

  • Page 19: 1-2.3. Publication Access

    Introduction 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.
  • Page 20 Introduction Change Bar Change Bar Change Bar Change Change Change Change Change Change Date Date Date Number Number Number 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.).

  • Page 21: 1-2.4.2. Suggestions And Corrections

    Introduction Effective Manual Effective Manual Changes and Changes and Change Dates Change Dates Itemized List Itemized List of Effective of Effective Pages 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.

  • Page 22: Contact Information

    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....

  • Page 23: Chapter 2. Engine Description

    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.

  • Page 24: 2-1.1. Engine Model Number Definition

    Engine Description 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). I O - 240 - B 1 I O - 240 - B 1 Shipping Designation Shipping Designation Specification Number...

  • Page 25: Detailed Engine Description

    Engine Description 2-2. Detailed Engine Description 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.

  • Page 26: Engine Drive Train

    Engine Description 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.

  • Page 27: 2-2.2.2. Connecting Rods

    Engine Description 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.

  • Page 28: 2-2.2.3. Camshaft

    Engine Description 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.

  • Page 29: 2-2.4. Cylinders

    Engine Description STARTER MOUNTING MAGNETO MOUNTING MAGNETO MOUNTING OIL PRESSURE RELIEF VALVE HOUSING TACH DRIVE MOUNTING OIL SCREEN ALTERNATOR HOUSING MOUNTING MOUNTING Figure 2-8. Accessory Case Features 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.

  • Page 30: Figure 2-9. Cylinder Features

    Engine Description ROCKER COVER ROCKER SHAFT THRUST WASHER ROCKER ARM (ONE ON EACH SIDE OF EACH ROCKER ARM) RETAINER VALVE RETAINER KEYS OUTER SPRING ROTOCOIL INNER SPRING EXHAUST SPRING SEAT VALVE GUIDE INTAKE VALVE GUIDE EXHAUST VALVE INTAKE VALVE COOLING FINS SEAT INSERT CYLINDER HEAD INTAKE VALVE...

  • Page 31: 2-2.4.1. Pistons

    Engine Description 2-2.4.1. Pistons 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.

  • Page 32: 2-2.5. Lubrication System

    HYDRAULIC LIFTERS LIFTERS OIL PRESSURE OIL PRESSURE OIL FILTER OIL FILTER RELIEF VALVE RELIEF VALVE SCREEN SCREEN SUCTION SUCTION TUBE TUBE OIL SUMP OIL SUMP Figure 2-11. IO-240-A Lubrication 2-10 IO-240 Series Engine Installation & Operation Manual 31 October 2011...

  • Page 33: 2-2.5.1. Oil Pump

    Engine Description CRANKSHAFT CRANKSHAFT EXHAUST EXHAUST BEARINGS BEARINGS PUSHROD PUSHROD INTAKE INTAKE CAMSHAFT CAMSHAFT HOUSING HOUSING BOSS BOSS PUSHROD PUSHROD OIL COOLER OIL COOLER ADAPTER ADAPTER OIL PUMP GEARS OIL PUMP GEARS HYDRAULIC HYDRAULIC LIFTERS LIFTERS OIL PRESSURE OIL PRESSURE OIL FILTER AND OIL FILTER AND RELIEF VALVE...

  • Page 34: 2-2.5.2. Oil Sump

    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...

  • Page 35: Figure 2-14. Io-240-A Oil Cooler Adapter

    OIL FLOW BACK OIL FLOW BACK PORT PORT TO ENGINE TO ENGINE Figure 2-14. IO-240-A Oil Cooler Adapter Figure 2-15. IO-240-B Oil Cooler Adapter IN IN Figure 2-16. IO-240-B Oil Cooler/Filter Adapter IO-240 Series Engine Installation & Operation Manual 2-13...

  • Page 36: 2-2.6. Ignition System

    Engine Description 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.

  • Page 37: Figure 2-18. Continental Motors Ignition Distribution

    Engine Description /()7 0$*1(72 5,*+7 0$*1(72 72 /()7 72 5,*+7 0$*1(72 0$*1(72 6:,7&+ 6:,7&+ (1*,1( ),5,1* 25'(5  0$*1(72 ),5,1* 25'(5  Figure 2-18. Continental Motors Ignition Distribution /()7 0$*1(72 5,*+7 0$*1(72 72 /()7 72 5,*+7 0$*1(72 0$*1(72 6:,7&+ 6:,7&+ (1*,1( ),5,1* 25'(5  0$*1(72 ),5,1* 25'(5  Figure 2-19.

  • Page 38: 2-2.7. Fuel System

    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 multi- port, continuous flow fuel injection system controls fuel flow to match engine requirements.

  • Page 39: Figure 2-21. Standard Fuel Pump

    Engine Description pressure for the higher engine speeds. This combination of mechanical control circuits ensures proper pump pressure and delivery for all engine operating speeds. Figure 2-21. Standard Fuel Pump 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).

  • Page 40: 2-2.7.2. Fuel Injectors

    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.

  • Page 41: 2-2.10. Engine Cooling

    Engine Description 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.

  • Page 42: 2-2.11. Induction System

    Engine Description 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. INDUCTION SYSTEM INDUCTION SYSTEM...

  • Page 43: Engine Specifications And Operating Limits

    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 Firing Order 1-3-2-4 Time Between Overhaul (TBO) 2000 accumulated hours or 12 years Bore 4.43 in.
  • Page 44 Engine Description Table 2-1. IO-240-A Specifications and Operating Limits Cylinder Head Temperature 360° to 420°F 182° to 215°C Maximum Cruise Operational Temperature 460°F 238°C Maximum Allowable Operational Temperature 240°F 116°C Minimum Takeoff Temperature Exhaust Exhaust System back pressure, maximum, measured at port, in Hg (kPa) 2.0 (6.75)

  • Page 45: Table 2-2. Io-240-B Specifications And Operating Limits

    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 Firing Order 1-3-2-4 Time Between Overhaul (TBO) 2000 accumulated hours or 12 years Bore 4.43 in.
  • Page 46 Engine Description Table 2-2. IO-240-B Specifications and Operating Limits Cylinder Head Temperature 360° to 420°F 182°to 215°C Maximum Cruise Operational Temperature 460°F 238°C Maximum Allowable Operational Temperature 240°F 116°C Minimum Takeoff Temperature 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.

  • Page 47: 2-3.1. Accessory Drive Ratios

    Engine Description 2-3.1. Accessory Drive Ratios Accessory drive ratios are the same for all of the IO-240 series engines, except as noted. Table 2-3. Accessory Drive Ratios Maximum Torque Maximum (in. lbs.) Overhang Direction of Drive Ratio Moment, Accessory Rotation to Crankcase Cont.

  • Page 48: 2-3.2.1. Io-240-A Performance Charts

    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...

  • Page 49: Figure 2-28. Io-240-A Sea Level Performance

    Engine Description Figure 2-28. IO-240-A Sea Level Performance IO-240 Series Engine Installation & Operation Manual 2-27 31 October 2011...

  • Page 50: 2-3.2.2. Io-240-B Performance Charts

    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...

  • Page 51: Figure 2-30. Io-240-B Sea Level Performance

    Engine Description Figure 2-30. IO-240-B Sea Level Performance IO-240 Series Engine Installation & Operation Manual 2-29 31 October 2011...
  • Page 52 Engine Description Intentionally Left Blank 2-30 IO-240 Series Engine Installation & Operation Manual 31 October 2011...

  • Page 53: Chapter 3.Engine Installation

    Engine Installation 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-C- 6529 Type II (Fly-away oil) 3.

  • Page 54: 3-1.2.1. Uncrating The Engine

    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.
  • Page 55 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.

  • Page 56: Installation Procedures

    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.

  • Page 57: 3-2.3. Installation Sequence

    Engine Installation NOTE: If corrosion or abnormal conditions are discovered during the borescope inspection, contact the supplier (If the engine was obtained “Contact Information” in Section 1- from Continental Motors, refer to ) for disposition instructions. 6. Inspect the cylinder bores with a borescope for rust and contamination according to the “Cylinder Borescope Inspection”...
  • Page 58 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.

  • Page 59: 3-2.3.1. Engine Pre-Oiling

    Engine Installation 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 WARNING Do not operate the engine until all hardware, spark plugs,...

  • Page 60: 3-2.3.2. Fuel Purge And Leak Check

    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.

  • Page 61: 3-2.4. Installation Inspection

    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.
  • Page 62 Engine Installation normal service to ensure the installed engine meets the manufacturer’s performance and operational specifications. WARNING 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.

  • Page 63: Engine Installation Drawings

    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.

  • Page 64: Figure 3-2. Io-240-A Left Side View

    EXHAUST PORT CYLINDER HEAD CYLINDER HEAD 4X 2.47 4X 2.47 C L C L TEMPERATURE (CHT) TEMPERATURE (CHT) THERMOCOUPLE THERMOCOUPLE 0.375-24 UNF-2A 0.375-24 UNF-2A Figure 3-2. IO-240-A Left Side View 3-12 IO-240 Series Engine Installation & Operation Manual 31 October 2011...

  • Page 65: Figure 3-3. Io-240-A Front View

    (4 Places) (CW TO INCREASE) (CW TO INCREASE) FUEL PUMP FUEL PUMP FUEL DRAIN FUEL DRAIN 0.4375-20 UNF-2A 0.4375-20 UNF-2A 8.30 8.30 12.12 12.12 Figure 3-3. IO-240-A Front View IO-240 Series Engine Installation & Operation Manual 3-13 31 October 2011...

  • Page 66: Figure 3-4. Io-240-A Rear View

    RETURN 0.250-18 NPTF RETURN 0.250-18 NPTF OIL SUMP OIL SUMP OIL DRAIN PLUG OIL DRAIN PLUG 5.25 5.25 5.25 5.25 0.88 HEX, 0.625-18 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...

  • Page 67: 3-3.2. Io-240-B Installation Drawings

    Engine Installation 3-3.2. IO-240-B Installation Drawings 12.93 12.93 C L CYL.#3 [328.42] C L CYL.#3 [328.42] 4.76 4.76 9.281 9.281 [120.90] [120.90] [235.74] [235.74] C L CYL.#1 C L CYL.#1 2.968 2.968 1.38 1.38 [35.05] [35.05] [75.39] [75.39] AND 20000 PAD AND 20000 PAD VAC PUMP DRIVE VAC PUMP DRIVE...

  • Page 68: Figure 3-6. Io-240-B Left Side View

    Engine Installation Figure 3-6. IO-240-B Left Side View 3-16 IO-240 Series Engine Installation & Operation Manual 31 October 2011...

  • Page 69: Figure 3-7. Io-240-B Front View

    Engine Installation Figure 3-7. IO-240-B Front View IO-240 Series Engine Installation & Operation Manual 3-17 31 October 2011...

  • Page 70: Figure 3-8. Io-240-B Rear View

    Engine Installation Figure 3-8. IO-240-B Rear View 3-18 IO-240 Series Engine Installation & Operation Manual 31 October 2011...

  • Page 71: Figure 3-9. Io-240-B W/Optional Oil Cooler-Filter Adapter Top View

    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...

  • Page 72: Figure 3-10. Io-240-B W/Optional Oil Cooler-Filter Adapter Left Side View

    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...

  • Page 73: Figure 3-11. Io-240-B W/Optional Oil Cooler-Filter Adapter Rear View

    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...

  • Page 74: 3-3.3. Io-240 Common Installation Drawings

    Engine Installation 3-3.3. IO-240 Common Installation Drawings Ø 0.508-0.521 Ø 0.508-0.521 6 HOLES 6 HOLES Ø 0.500-0.501 Ø 0.500-0.501 2 HOLES 2 HOLES Ø 4.000 Ø 4.000 30° 30° 30° 30° 4.880 4.880 Ø ---------- Ø ---------- 4.870 4.870 ARP 502 MODIFIED ARP 502 MODIFIED PROP FLANGE PROP FLANGE...

  • Page 75: Figure 3-13. Exhaust Flange Dimensions

    Engine Installation Ø 1.50 Ø 1.50 R 0.97 R 0.97 0.06 0.06 2X R 0.31 2X R 0.31 Ø 2.50 B.C. Ø 2.50 B.C. 15° 15° 0.3125-24 UNF-3A STUD 0.3125-24 UNF-3A STUD 0.78 EXTENSION HEIGHT 0.78 EXTENSION HEIGHT EXHAUST MOUNTING FLANGE EXHAUST MOUNTING FLANGE Typical 4 Places Typical 4 Places...

  • Page 76: Figure 3-15. Standard Fuel Pump Adjustments

    Engine Installation VAPOR RETURN (LOCATED ON OPPOSITE VAPOR RETURN (LOCATED ON OPPOSITE SIDE ON MOST FUEL PUMPS) SIDE ON MOST FUEL PUMPS) VAPOR RETURN VAPOR RETURN METERED POWER METERED POWER CW = INCREASE CW = INCREASE FUEL INLET FUEL INLET FUEL INLET FUEL INLET PRESSURE...

  • Page 77: Figure 3-17. Throttle Lever Installation

    Engine Installation 0.12 0.12 1.90 1.90 0.1885 0.1885 0.1875 0.1875 0.3125-24 UNF-3B 0.3125-24 UNF-3B LEVER MAY BE POSITIONED BY CUSTOMER. LEVER MAY BE POSITIONED BY CUSTOMER. FORMED SERRATIONS ON THE LEVER SHOULD FORMED SERRATIONS ON THE LEVER SHOULD INTERLOCK WITH THE FORMED SERRATIONS INTERLOCK WITH THE FORMED SERRATIONS ON THE SHAFT.

  • Page 78: Figure 3-19. Oil Cooler Adapter Connections

    Engine Installation Figure 3-19. Oil Cooler Adapter Connections OIL PRESSURE OIL PRESSURE SENSOR 0.125-27 NPTF SENSOR 0.125-27 NPTF 1.77 1.77 OIL PRESSURE OIL PRESSURE OIL TEMPERATURE OIL TEMPERATURE 0.94 0.94 SWITCH 0.125-27 NPTF SWITCH 0.125-27 NPTF SENSOR 0.125-27 NPTF SENSOR 0.125-27 NPTF 0.48 0.48 45°...

  • Page 79: Figure 3-21. Io-240-A Air Intake Flange

    1.245 1.245 2.505 2.505 2.495 2.495 2.169 2.169 Ø Ø 2.165 2.165 Figure 3-21. IO-240-A Air Intake Flange STATOR TERMINAL STATOR TERMINAL #10-24 UNC-2A #10-24 UNC-2A BATTERY TERMINAL BATTERY TERMINAL 0.25-20 UNC-2A 0.25-20 UNC-2A FIELD TERMINAL FIELD TERMINAL #10-24 UNC-2A...

  • Page 80: Figure 3-23. Engine Mounts

    Engine Installation CRANKCASE CRANKCASE 1 REQUIRED 1 REQUIRED REAR CRANKCASE REAR CRANKCASE FINISH FINISH SEAT 2 REQUIRED SEAT 2 REQUIRED 0.19 0.19 BUSHING LORD BUSHING LORD 0.70 0.70 # J3608-1 2 REQUIRED # J3608-1 2 REQUIRED CUP 2 REQUIRED CUP 2 REQUIRED HOLE FOR HOLE FOR O 0.375 BOLT...

  • Page 81: Figure 3-24. Continental Motors Magneto Ignition Schematic

    Engine Installation /()7 0$*1(72 5,*+7 0$*1(72 72 /()7 72 5,*+7 0$*1(72 0$*1(72 6:,7&+ 6:,7&+ (1*,1( ),5,1* 25'(5  0$*1(72 ),5,1* 25'(5  Figure 3-24. Continental Motors Magneto Ignition Schematic /()7 0$*1(72 5,*+7 0$*1(72 72 /()7 72 5,*+7 0$*1(72 0$*1(72 6:,7&+ 6:,7&+ (1*,1( ),5,1* 25'(5  0$*1(72 ),5,1* 25'(5 ...

  • Page 82: Figure 3-26. Airframe Ignition Switch Connections To Magneto

    Engine Installation Slick Magneto Slick Magneto 1 1 1 1 1 1 1 1 1 1 “P” LEAD “P” LEAD “P” LEAD “P” LEAD TORQUE TORQUE TORQUE TORQUE 13-15 IN LBS 13-15 IN LBS 13-15 IN LBS 13-15 IN LBS OPTIONAL OPTIONAL IGNITION SWITCH...

  • Page 83: Chapter 4. Engine Operation

    Engine Operation 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...

  • Page 84: 4-2.1. Oil Change Interval

    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.”...

  • Page 85: 4-2.3.1. Engine Break-In

    Engine Operation 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 WARNING 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.

  • Page 86: Table 4-1. Io-240 Operating Limits

    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, flight 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...

  • Page 87: 4-2.3.2. Flight Check

    Engine Operation 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.
  • Page 88 Engine Operation 4-2.3.2.2. Flight Check w/Altitude Compensating Fuel Pump IO-240-B Altitude Compensating Fuel Pump Flight Check Perform a normal takeoff according to AFM/POH. Monitor engine instruments; Observe operating limits in Section 2-3. NOTE: Ascend to a minimum of 3000 ft above airfield elevation. Adjust Adjust the fuel mixture control aircraft attitude to maintain 2450 RPM, wide open throttle (WOT).

  • Page 89: Normal Operation

    Engine Operation 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. WARNING 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.

  • Page 90: 4-3.2. Engine Start

    Engine Operation 4-3.2. Engine Start WARNING 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.

  • Page 91: 4-3.2.1. Cold Start

    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 ...

  • Page 92: 4-3.2.2. Flooded Engine

    Engine Operation 4-3.2.2. Flooded Engine WARNING 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.
  • Page 93 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.

  • Page 94: 4-3.4. Taxi Preparation

    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.

  • Page 95: 4-3.6. Take-Off

    Engine Operation 4-3.6. Take-Off WARNING 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.

  • Page 96: 4-3.7. Climb

    Engine Operation 4-3.7. Climb For climbing or ascent procedures at full power, supplement the AFM/POH with these settings: WARNING At power settings above 75% normal rated power, do not use the EGT gauge as an aid to mixture adjustment. Attempts to determine “peak”...

  • Page 97: 4-3.8. Cruise

    Engine Operation 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). CAUTION: Do not lean the fuel mixture beyond the “Best Power”...

  • Page 98: 4-3.9. Descent

    Engine Operation 4-3.9. Descent WARNING 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 WARNING Avoid long descents at high RPMs or low manifold pressure to prevent the engine from excessive cooling.

  • Page 99: 4-3.11. Engine Shutdown

    Engine Operation 4-3.11. Engine Shutdown Supplement the AFM/POH engine shutdown procedures with the following: 1. Boost Pump ............OFF 2. Throttle.............. 1700 RPM 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.”...

  • Page 100: Emergency Operation

    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.

  • Page 101: 4-4.3. In-Flight Restart

    Engine Operation 4-4.3. In-Flight Restart CAUTION: Do not shut down an engine for practice or training purposes. Whenever engine failure is simulated, do so by reducing  power.  A few minutes exposure to temperatures and airspeed at flight altitudes can have the same effect as on an inoperative engine with hours of cold-soaking in sub-Arctic conditions.

  • Page 102: 4-4.6. High Oil Temperature

    Engine Operation 4-4.6. High Oil Temperature CAUTION: If these steps do not restore oil pressure to normal, an engine failure or severe damage is imminent. Follow the AFM/POH emergency instructions and Land As Soon As Possible. NOTE: Prolonged high oil temperature indications are accompanied by reduced oil pressure.

  • Page 103: Engine Operation In Abnormal Environments

    Engine Operation 4-5. Engine Operation in Abnormal Environments The anticipated types of abnormal environments are: Extreme cold weather • Extreme hot weather • High density altitude ground operation • 4-5.1. Engine Operation in Extreme Cold Engine starting during extreme cold weather is more difficult than in moderate temperatures.

  • Page 104: 4-5.1.1. Engine Preheating

    Engine Operation blocking proper oil flow through the engine. The amount of damage will vary and may not become evident for many hours. However, the engine may be severely damaged and may fail shortly after application of high power. Prior to operation and/or storage in cold weather, ensure the engine is serviced with the correct viscosity oil for the ambient air temperature.
  • Page 105 Engine Operation 3. Periodically feel the top of the engine for warmth. Apply heat directly to the induction tubes and cylinders to promote fuel vaporization and ease starting. Alternately heat the sump and engine cylinders until engine start. 4. Start the engine immediately after completion of the preheating process. Since the engine will be warm, follow the normal start instructions in Section 4-3.2.
  • Page 106 Engine Operation NOTE: The use of an approved thermal blanket or cover will help reduce the effects of wind and cold air circulation when the aircraft is not stored in a hangar. The preheating system manufacturer should have thermal blankets available. 3.
  • Page 107 Engine Operation 4-5.1.1.3. Cold Weather Starting Without Preheating At ambient temperature between 20° to 40º F (-7°to 4° C), perform the following: CAUTION: Attempting to start an engine with a partially discharged aircraft battery may result in damage to the starter relay or possible engine kickback, resulting in a broken starter adapter clutch spring.

  • Page 108: 4-5.2. Engine Operation In Hot Weather

    Engine Operation 4-5.2. Engine Operation in Hot Weather “Hot weather” is defined as ambient temperature exceeding 90° F (32° C). After an engine is shutdown, the temperature of various components will begin to stabilize. The hotter parts such as cylinders and oil will cool, while other parts will begin to heat up due to lack of air flow or heat convection from those engine parts that are cooling.

  • Page 109: 4-5.2.2. Engine Restart In Hot Weather

    Engine Operation 4-5.2.2. Engine Restart in Hot Weather Restarting attempts will be the most difficult between 30 to 60 minutes after shutdown. Following that interval, fuel vapor will decrease and present less of a restart problem. WARNING Allow excess fuel to drain from the induction system prior to starting the engine.

  • Page 110: 4-5.3. Ground Operation At High Density Altitude

    Engine Operation 4-5.3. Ground Operation at High Density Altitude CAUTION: Reduced engine power will result from higher density altitude associated with high temperature. Idle fuel mixture may be rich during high density altitude conditions. Lean the fuel mixture to sustain operation at low RPM. When practical, operate the engine at higher idle speed.
  • Page 111 Glossary Appendix A. Glossary A-1. Acronyms The following acronyms are commonly used throughout Continental Motors publications. Acronym Definition A & P Airframe & Powerplant Airworthiness Directive Airplane Flight Manual Authorized Oversize Auxiliary Power Unit As Required Authorized Undersize Brake Horsepower BSOC Brake Specific Oil Consumption Before Top Dead Center...

  • Page 112: Glossary

    Glossary Acronym Definition Pilot’s Operating Handbook Parts Manufacture Approval Root Mean Square Revolutions per Minute Service Bulletin Service Information Directive Service Information Letter STANAG Standardization Agreement (STANAG) Supplemental Type Certificate Time Between Overhauls Type Certificate Top Dead Center Turbine Inlet Temperature Technical Standard Order TSMOH Time Since Major Overhaul...
  • Page 113 Glossary Term Definition Dynamic Seal Vital seal in the engine cylinder that consists of valve-to-valve seat seals, spark plug-to-spark plug port seals, and cylinder head-to-barrel seal. Elongate To stretch out or lengthen. Erosion Wearing away of material due to flow, hot gases, grit, or chemicals. Fretting Surface erosion caused by slight movement between two parts that are fastened together.
  • Page 114 Glossary Term Definition Service Bulletin Service document that contains information considered by the product manufacturer to constitute a substantial improvement to the inherent safety of an aircraft or component of an aircraft; also includes updates of instructions for continued airworthiness. Service Information Directive Service document that contains information determined by the manufacturer to be of value to an owner/operator in the use of a product...

  • Page 115: Appendix B.torque Specifications

    Torque Specifications Appendix B.Torque Specifications B-1. General Information Tables in this appendix list torque values for Continental Motors aircraft engine hardware. Refer to the appropriate manufacturer’s overhaul instructions for airframe or engine accessory torque specifications. Table B-1 is for bolts, nuts, screws, driving studs, and pipe plugs;...

  • Page 116: Cylinder Torque Procedure

    Torque Specifications If a nut slot cannot be aligned with a cotter pin hole within the specified limits, • substitute another serviceable nut to attain alignment. If the cotter pin hole in a stud lies beyond the nut slots, when the nut has been torqued •...

  • Page 117: Torque Wrench And Extension Calculations

    Torque Specifications B-3. Torque Wrench and Extension Calculations Torque wrenches measure the force applied to the fastener on the axis of the square drive socket adapter. Torque Setting/Reading = Force x Distance Torque Setting/Reading = Force x Distance Torque Wrench Square Drive Distance = A Torque Wrench Square Drive Distance = A Figure B-1.

  • Page 118: Figure B-3. Extension Increases Applied Torque

    Torque Specifications Extension Extension Torque Wrench Square Drive Distance = A Torque Wrench Square Drive Distance = A Length = B Length = B Fastener Torque Distance Fastener Torque Distance Fastener Torque Fastener Torque Fastener Torque Set Torque= Set Torque= Set Torque= A + B A + B...

  • Page 119: Table B-1. General Torque Specification

    Torque Specifications Table B-1. General Torque Specification Bolts, Nuts, Screws Torque Size In. lbs. Ft. lbs. #2-56 1.4-2.6 #4-40 2.9-5.5 #6-32 5.3-10.1 #8-32 17.5-22.5 1.5-1.9 #10-32 36-50 3.0-4.2 #10-24 21-25 1.7-2.0 .250-20 75-85 6.3-7.1 .250-28 90-100 7.5-8.3 .3125-18 155-175 12.9-14.6 .3125-24 180-220 15.0-18.3...

  • Page 120: Table B-3. Hose Fitting ("B" Nut) Torque Specification

    Torque Specifications Table B-2. Tube Fitting Torque Specifications Size Hose Assembly Tube O.D. Torque (In-lbs) .31-24 #2 Brass / Aluminum .125 15-30 .31-24 #2 Steel .125 15-50 .38-24 #3 Brass / Aluminum .188 40-65 .38-24 #3 Steel .188 50-90 .44-20 #4 Brass / Aluminum .250 60-80...

  • Page 121: Table B-4. Component Specific Torque Specifications

    Torque Specifications Table B-4. Component Specific Torque Specifications Torque Value Size Fastener In-Lbs Ft-Lbs Models Affected Crankcase .25-28 Nut-Crankcase Flange 100-125 8.3-10.4 All Models (AR) .31-24 Nut-Crankcase Flange 240-280 20.0-20-3 (AR) Stainless Steel hardware Only .31-24 Nut, Magneto Flange 100-120 8.3-10.0 All Models (AR) .38-24...
  • Page 122 Torque Specifications Table B-4. Component Specific Torque Specifications Torque Value Size Fastener In-Lbs Ft-Lbs Models Affected Miscellaneous Fuel Injection #8-32 Screw, Aneroid Body Hold 17.5-22.5 1.5-1.9 All Fuel Injected Model (AR) Down (AN500-8-14) #8-32 Screw, Manifold Cover Hold 22-26 1.8-2.2 All Fuel Injected Model (AR) Down (AN503-8-12) .125-27...
  • Page 123 Torque Specifications Table B-4. Component Specific Torque Specifications Torque Value Size Fastener In-Lbs Ft-Lbs Models Affected 1.75-16 Oil Filter Screen (w new 500-520 41.6-43.3 All Models (AR) crush gasket) (Install Gasket with parting line against screen face) Miscellaneous Cylinder Hardware .071 300-360 25.0-30.0...

  • Page 124: Table B-5. Specific Torque For Non-Lubricated Hardware

    Torque Specifications Table B-5. Specific Torque for Non-Lubricated Hardware Torque Value Size Fastener In-lbs Ft-lbs Model Affected #8-32 Screw, Throttle Lever 17.5-22.5 1.5-1.9 #10-32 Nut, Magneto Ground Terminal 17-19 1.41-1.58 S-1200 Magnetos #10-32 Nut, Magneto Ground Terminal 15-17 1.25-1.41 S-20/200 Magnetos Various Nut, Magneto Ground Terminal 13-15...

  • Page 125: Appendix C.standard Practices

    Standard Practices Appendix C.Standard Practices C-1. Handling Parts When removing, replacing, or re-installing parts, heed the following precautions, warnings, and tips: WARNING Turn the Ignition Switch OFF and disconnect engine electrical power before commencing maintenance or inspections. Confirm continuity between the magneto capacitor and aircraft ground to prevent accidental engine start during maintenance.

  • Page 126: Replacement Parts

    Standard Practices Do not re-install any worn, deformed, or single use fasteners. • Torque hardware to Appendix B torque specifications. • WARNING Do not apply any form of sealant to the crankcase cylinder deck, chamfer, cylinder mounting flange, cylinder base O-ring, or cylinder fastener threads.

  • Page 127: C-2.2.1. Know Your Supplier

    Standard Practices has not participated in design, test, or certification in regards to aftermarket parts manufacturers and has no experience with respect to such parts. FAA regulations require only FAA-approved parts be used on a type certified product. FAA-approved parts may be identified in accordance with the information given below. Continental Motors does not play any role in the FAA approval of such parts;...

  • Page 128: C-2.4. Mandatory Overhaul Replacement Parts

    Standard Practices system must be overhauled. All engine baffles must be repaired or replaced and all flexible baffle seals replaced. Items such as spark plugs, alternator drive belts and air-conditioning drive belts are replaced on condition. C-2.4. Mandatory Overhaul Replacement Parts In addition to the items listed in Section C-2.3 on page C-3, the following parts must be discarded and replaced with new parts during engine overhaul.

  • Page 129: Safety Wiring Hardware

    Standard Practices C-4. Safety Wiring Hardware Safety wiring secures two or more parts together so any tendency of the parts to loosen will be counteracted by increasing the tension on the safety wire attached to the other part(s). The only way to loosen the fasteners is to remove the safety wire. Always use new safety wire to secure hardware.

  • Page 130: Figure C-2. Safety Wire Patterns For Right-Hand Threads

    Standard Practices the loop and the loop is under the protruding strand that will wrap around the opposing piece of hardware to ensure the loop is held in place on the first device. Pull the protruding strand of safety wire with pliers until it is taut (but not overstressed). 4.

  • Page 131: Tab Washer Installation

    Standard Practices C-5. Tab Washer Installation Tab washers are used in various locations in Continental Motors engines. Do not re-use tab washers. Always install new tab washers. 1. Insert the locator tab (bent part of the tab washer) in the predrilled hole. 2.

  • Page 132: Helical Coil Insert Replacement

    Standard Practices C-6. Helical Coil Insert Replacement Helical coil inserts are made of wire with a diamond-shaped cross section forming both a male and female thread. Helical coil inserts are factory-installed in various tapped holes of some engine components. Stainless steel helical coil inserts of special design are installed in all spark plug holes.

  • Page 133: C-6.1. Helical Coil Removal

    Standard Practices C-6.1. Helical Coil Removal 1. Use the proper size extracting tool (Figure C-4) for the nominal thread size. 2. Tap the extracting tool into the helical coil insert until the sharp edges of the tool dig firmly into the helical coil insert. 3.

  • Page 134: C-6.2. Helical Coil Insertion

    Standard Practices C-6.2. Helical Coil Insertion 1. Blow all debris and liquid out of the tapped hole. 2. Use a proper size installation tool and slide the new helical coil insert over the slotted end of the driving mandrel of the tool. 3.

  • Page 135: Stud Replacement

    Standard Practices C-7. Stud Replacement ® Studs that are damaged or broken must be replaced. Rosan ring-locked studs are installed in the cylinder exhaust ports. These studs are either “size-on-size” or “step type.” The step type captive lock ring studs have a larger lock ring than the size-on-size type. The size-on-size captive lock ring studs utilize a small external diameter lock ring for applications where edge distance is a factor.

  • Page 136: C-7.1.2. Step-Type Rosan® Stud Removal

    Standard Practices ® Table C-1. Rosan Stud Primary & Secondary Bore Specifications Cylinder Exhaust Port Stud Primary Removal Drill Secondary Removal Drill Minimum (+0.015) Basic Stud Number Diameter Depth Diameter Depth (0.164 dia.) SFC164 1/16(0.062) 0.250 3/16(0.188) 0.080 (0.190 dia.) SFC190 1/16(0.062) 0.250...

  • Page 137: C-7.2. Stud Installation

    Standard Practices ® C-7.1.2.2. Step-Type Rosan Stud Removal Method 2 1. Follow the “Size-on-Size Rosan® Stud Removal” instructions in Section C-7.1.1. 2. Select the appropriate removal drill sizes with regard to the stud end dimension. NOTE: Example: To remove a step-type stud with a 0.250-inch diameter nut end and a 0.312- inch diameter stud end, use the appropriate removal drill for a 0.312-inch “size-on-size”...

  • Page 138: C-7.2.1. Rosan® Stud Installation

    Standard Practices Figure C-9. Minimum Material Thickness for Helical Coil insertion 5. If the hole is blind or if the hole goes through to a cavity subject to leakage, coat the new stud’s course thread with High Strength Adhesive (Part No. 646941). 6.

  • Page 139: Cotter Pin Installation

    Standard Practices C-8. Cotter Pin Installation Cotter pins are not reusable. Replace used cotter pins with the specified new cotter pins made of corrosion-resistant steel. 1. Install the nut on the bolt. 2. Verify that the nut where the cotter pin is to be inserted has been torqued to the lower limit of the torque specification in Appendix B.

  • Page 140: Fuel System Service

    Standard Practices C-9. Fuel System Service CAUTION: Fuel system contamination may lead to component damage, erratic engine operation, loss of power, or engine shutdown. Flush new fuel system parts, hoses and test equipment prior to connection to the system. Fuel system service includes any inspection, service or repair action which requires opening fuel system connections, including engine operational checks.

  • Page 141: C-10. Gasket Maker® Application

    Standard Practices ® C-10. Gasket Maker Application Gasket Maker is an easily workable tacky gel which can be applied onto one side of a flange surface from a tube and evenly spread. WARNING Apply Gasket Maker only as directed. The improper use of sealants may cause engine malfunction or failure.

  • Page 142: C-11. Gasket Installation

    Standard Practices C-11. Gasket Installation WARNING The improper use of sealants may cause engine malfunction or failure. Do not apply any form of sealant to the crankcase cylinder deck, chamfer, cylinder mounting flange, cylinder base O-ring, or cylinder fastener threads. The use of RTV, silicone, Continental Motors 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.

  • Page 143: C-12. Hose And Tubing Installation

    Standard Practices C-12. Hose and Tubing Installation Hoses and tubing to fuel, induction, lubrication, and turbocharger system fittings must be properly installed. WARNING Failure to properly support component fittings can result in fitting and/or component damage and a resulting loss of system pressure or fluid.

  • Page 144: C-13. Harness Routing

    Standard Practices C-13. Harness Routing 1. Inspect all proposed harness routes. Consider normal movement and relative motion of the various engine or aircraft parts that will be attached to the harness. 2. Do not route harnesses near belts or pulleys without the use of belt guards; belt failure may damage the wiring harness.
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