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CONTINENTAL AIRCRAFT ENGINE A-65 Maintenance Manual

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CONTINENTAL AIRCRAFT ENGINE
MAINTENANCE
MANUAL
STANDARD PRACTICE
FOR SPARK IGNITED ENGINES
Technical Portions Accepted by the Federal Aviation Administration
Publication M-0
©
2017 CONTINENTAL MOTORS
JUL 2017

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Summary of Contents for CONTINENTAL AIRCRAFT ENGINE A-65

  • Page 1 CONTINENTAL AIRCRAFT ENGINE MAINTENANCE MANUAL STANDARD PRACTICE FOR SPARK IGNITED ENGINES Technical Portions Accepted by the Federal Aviation Administration Publication M-0 CHANGE 4 © 2017 CONTINENTAL MOTORS JUL 2017...

  • Page 2: Table Of Contents

    Supersedure Notice This manual incorporates maintenance and service information contained in Continental Motors Service Documents common to the horizontally opposed, spark ignition, AvGas aircraft engines conforming to Type Certificate held by Continental Motors. This document is supplemental to the Instructions for Continued Airworthiness provided in the manuals listed in Section 1-1.1.

  • Page 3: Table Of Contents

    List of Effective Pages, cont. Page Change Page Change Page Change Page Change 6-140 ......1 7-24......1 10-94 thru 10-95 ..3 6-141 ......0 7-25 thru 7-30 ....0 10-96 thru 10-99 ..0 6-142 ......3 8-1 thru 8-15 ....0 10-100 thru 10-101 ..
  • Page 4 Intentionally Left Blank Standard Practice Maintenance Manual CHANGE 1 30 May 2016...

  • Page 5: April

    (ICA) are supplied to the owner with the engine. Instructions in this manual are standard practices, with differences identified by model, for A-65, A-75, C-75, C-85, C-90, C-125, C- 145, E-165, E-185, E-225, O-200, GO-300, O-300, IO-240, IOF-240, IO-346, IO-360,...

  • Page 6: Change

    Overhaul Manual TSIOL-550-C OH-24 Overhaul Manual IOF-550 OMI-15 Operation, Maintenance and TSIOL-550-C Installation Manual X30008 Overhaul Manual A-65, A-75 X30010 Overhaul Manual C-75, C,85, C90, O-200-A, B X30013 Overhaul Manual C-125, C-145, O-300 X30016 Overhaul Manual E-165, E-185, E-225 X30019...
  • Page 7 Introduction X30596S1 Overhaul Manual LTSIO-360-RB, TSIO-360-RB X30600 Overhaul Manual TSIOL-550-A X30601 Maintenance and Operator’s Manual TSIOL-550-A X30605 Maintenance Manual IO-550-D, E, F & L X30607 Overhaul Manual IO-550-D, E, F & L X30645 Maintenance Manual LTSIO-360-RB TSIO-360-RB X30672 Maintenance Manual TSIO-360-MB, SB 1-1.2.
  • Page 8 Introduction 1-1.4. Using this Manual This manual, the primary engine ICA listed in Section 1-1.1, applicable FAA ADs and Continental Motors service documents, the accessory manuals listed in Table 1-2, and all changes incorporated in the ICAs as revisions constitute the Instructions for Continued Airworthiness (ICAs) prepared by Continental Motors and accepted by the FAA.
  • Page 9 Introduction 1-2.4.1. Service Documents Incorporated in this Manual Applicable technical maintenance and service information contained in the Service Documents listed below, relevant to the engine models covered by this engine manual, have been incorporated in this M-0 Standard Practice Maintenance Manual. This manual supersedes and retires these older Service Documents (where applicable) excluding Mandatory Service Bulletins (MSBs) and Critical Service Bulletins (CSBs) identified with an asterisk below.
  • Page 10 Introduction Table 1-1. Service Documents Incorporated in Manual Service Document Subject Affected Chapter SB96-11B, Propeller Strikes and Hydraulic Lock Unscheduled Inspection SB96-12, Cylinder Continued Airworthiness Scheduled Inspection 6 & 10 SID97-2B, Design, Operation Maintenance and Engine Maintenance Warranty of Cylinders SID97-3G, Continuous Flow Fuel Injection Systems O p e r a t i o n a l C h e c k s...
  • Page 11 Lubricants, Sealants, and Adhesives Table 3-4. Sealants Part Number Type Application Remarks Crankcase parting face Starter adapter to accessory case Loctite 30516 Gasket Sealant Apply according to assembly 654663 Accessory drive adapter (with P/N 641543 Silk Thread) instructions Pressure oil pump covers Pressure scavenge pump covers Use on all pipe threads to oil coolers All models (use sparingly on...
  • Page 12 Lubricants, Sealants, and Adhesives Table 3-5. Lubricants Part Type Application Remarks Number Starter worm gear & bevel gear teeth All models during engine Needle bearings and ball bearings assembly Valve stems Accessory drive splines and couplings Where applicable Idler gear and pin 470, 520, 550 Magneto rubber drive bushings All models...
  • Page 13 Engine Inspection and Service Table 6-4. Fuel System Adjustment Values Idle and FULL POWER Fuel Pressures and Flows Manifold Metered Absolute Unmetered Nozzle Fuel Fuel Prop. Pressure Engine (MAP) Pump PSI (lbs/hr) (gal/hr) TSIO-520-BE 5.5 - 7.0 2600 38.0 25.0 - 28.0 12.7 - 14.1 214 - 224 36.5 - 38.2...
  • Page 14 Engine Inspection and Service Table 6-4. Fuel System Adjustment Values Idle and FULL POWER Fuel Pressures and Flows Manifold Metered Absolute Unmetered Nozzle Fuel Fuel Prop. Pressure Engine (MAP) Pump PSI (lbs/hr) (gal/hr) 8.0 -10.0 IO-550-C 2700 31.6 - 37.8 17.6 - 19.6 152 - 160 25.9 - 27.3...
  • Page 15 Engine Inspection and Service 6-4.7.5. Magneto RPM Drop Check WARNING Absence of RPM drop during magneto check may be an indication of a faulty ignition circuit (Hot Magneto). Should the propeller be turned by hand (as in during preflight), the engine could inadvertently start and cause personal injury or death.

  • Page 16: Added

    Engine Inspection and Service 6-4.7.6. Engine Shutdown Procedure 1. Perform a normal engine shutdown according to the “Engine Shutdown” instructions in Section 7-3.4. 2. Remove installed test equipment. a. Disconnect the metered fuel pressure test hose from the aircraft fittings. b.

  • Page 17: Standard Practice Maintenance Manual 31 Jul

    Engine Inspection and Service 6-4.8.2. Oil Change Perform an oil change within 30 minutes of engine shutdown (to obtain a useful oil sample) according to the oil changes intervals specified in Section 6-2. NOTE: More frequent oil changes are recommended under extreme usage (flight training, shuttle service, or crop dusting) or adverse (desert or arctic climates) weather conditions.
  • Page 18 Engine Inspection and Service 2) New, rebuilt, or overhauled engines exhibit more wear material during the break-in period; material found in the filter media will diminish over time. If wear material in the oil filter does not diminish, or increases, note the characteristics of the wear material (Section 6-4.8.5, “Oil Trend Monitoring and Spectrographic Oil Analysis”...

  • Page 19: C-19

    Engine Inspection and Service 5. Reinstall the oil drain plug with a new crush washer (gasket) according to instructions in Appendix C-10.1; torque the drain plug to Appendix B specifications and safety wire the drain plug according to instructions in Appendix C-3. 6.
  • Page 20 Engine Inspection and Service Intentionally Left Blank 6-50.2 Standard Practice Maintenance Manual CHANGE 4 31 Jul 2017...
  • Page 21 I C A f o r amplification. A-65, A-75 80/87...
  • Page 22 Engine Operation Table 7-2. Authorized Fuels by Engine Model Certified Fuel Current Engine Model on Type Certificate Alternate Authorization NOTE: Engine operation with RH95/130 and UL94 fuel may limit engine performance, operating ceiling, and/or maximum recommended cruise power. Consult the engine specifications a n d o p e r a t i n g l i m i t s s e c t i o n o f t h e p r i m a r y I C A f o r amplification.
  • Page 23 100/100LL. Engines most affected by the higher octane include the A-65, A-75, C-75, C-85, C-90, C-125, C-145, O-200, O-300 and GO-300 engine series. Compliance with the instructions in Section 10-6.10 on these engines will improve engine operation with the higher grade fuels.
  • Page 24 Engine Operation 7-2.3. Engine Operation after Cylinder Replacement and/or Major Overhaul NOTE: Instructions within this section apply to steel, nitrided, through- hardened, or chrome plated cylinders. For engine operating instructions with nickel silicon carbide (NiC3) plating, refer to the operating instructions in the latest revision of SB15-6.
  • Page 25 Non-Overhaul Repair and Replacement CAUTION: Piston ring reinstallation is not recommended. If the piston rings are removed for any reason, discard the removed piston rings and install a new set of piston rings, with end gaps adjusted for the destination cylinder. 12.
  • Page 26 Non-Overhaul Repair and Replacement 10-6.1.2. Cylinder Installation Replace worn or out of tolerance components based on the following criteria: Only allow parts that meet the service limits may remain in service. • If a part has reached a service limit tolerance, it must be replaced with a part that con- •...
  • Page 27 Non-Overhaul Repair and Replacement 8. Remove the ring compressor and push the cylinder assembly against the crankcase cylinder deck with the stud holes aligned. CAUTION: Engine crankcases featuring the seventh stud and associated hardware use beveled seat brackets, part numbers 646297 and 646298 in combination with a self-aligning nut, part number 646312.
  • Page 28 Non-Overhaul Repair and Replacement determine the cause. Verify crankshaft end play (end clearance) is within the tolerance specified in the primary ICA. If no end play is present, disassemble the engine to determine the cause. 12. Install the valve train and pushrods according to the instructions in the primary ICA. 13.
  • Page 29 Non-Overhaul Repair and Replacement Intentionally Left Blank Standard Practice Maintenance Manual 10-35 31 Jul 2017 CHANGE 4...
  • Page 30 Non-Overhaul Repair and Replacement 10-6.1.3. Cylinder Torque CAUTION: This cylinder torque procedure is for individual cylinder installation. For complete engine assembly and torque, refer to instructions in the primary ICA. 1. Lubricate the cylinder base stud threads, through-bolt threads and nut threads on BOTH sides of the engine with clean, 50-weight aviation oil.
  • Page 31 Non-Overhaul Repair and Replacement 7. Remove the crankshaft nose oil seal, reinforcing ring (if used), and spring as shown in Figure 10-44). Gentle force may be required to remove the nose oil seal parts from the counterbore. 8. Inspect the propeller mounting flange carefully to insure that no nicks, burrs or sharp edges are present which could damage the oil seal surface during installation.
  • Page 32 Non-Overhaul Repair and Replacement 6. Turn the spring ends in a winding direction and allow one end to wind into the other end. 7. Apply Part No. 654561 Grease to the lip of the new seal and the propeller flange. 8.
  • Page 33 Non-Overhaul Repair and Replacement 10-10.3. Split Nose Oil Seal Removal Follow same procedures listed for stretch type oil seals except it is not necessary to remove the propeller. With the propeller installed, any removal of plating or blending of the 1” area referred to in Section 10-10.1 will have to be accomplished manually without engine rotation.
  • Page 34 Non-Overhaul Repair and Replacement 14. Using thumb pressure, work the seal and spring into the crankcase counterbore. Ensure the seal is in the deepest part of the recess all the way around. Figure 10-45. Split Nose Oil Seal Parts 15. After the seal is in place, wipe any remaining sealant from the seal and crankshaft. 16.
  • Page 35 Torque Specifications Table B-2. Component Specific Torque Specifications Torque Value Models Affected (Non-standard, see Size Fastener In.-Lbs. Ft.-Lbs. General Torque Specification) .44-20 Nut, Cylinder to Crankcase 400-450 33.3-37.5 A Series, C-75, C-85 & C-90 Through Studs .44-20 Nut, Front & Rear Crankcase 490-510 40.8-42.5 O-200 Bearing Through Studs...
  • Page 36 Torque Specifications Table B-2. Component Specific Torque Specifications Torque Value Models Affected (Non-standard, see Size Fastener In.-Lbs. Ft.-Lbs. General Torque Specification) 31.7-35.0 O-470, IO-470, TSIO-470, IO-520,  .31-24 Bolt, Gear to Crankshaft (Bolt 380-420 L/TSIO-520, GTSIO-520, IO-550, IOF-550, Hardness RC 38-42) TSIO-550, TSIOF-550, &...

  • Page 37: Maintenance Standards

    Maintenance Standards C-2.4. Mandatory Overhaul Replacement Parts In addition to the items listed in Section C-2.3, mandatory replacement parts must be discarded and replaced with new parts during engine overhaul. Table C-1. Mandatory Overhaul Replacement Parts MANDATORY REPLACEMENT SPECIAL 100% AT ENGINE REPLACEMENT ITEMS CONDITIONS...
  • Page 38 Maintenance Standards Table C-1. Mandatory Overhaul Replacement Parts MANDATORY REPLACEMENT SPECIAL 100% AT ENGINE REPLACEMENT ITEMS CONDITIONS REPLACEMENT OVERHAUL Crankshaft Gears, continued • Crankshaft Alternator Face Gear Bolts • Crankshaft Alternator Face Gear Lock Plates Cylinder Deck Stud Nuts and Through Bolt Nuts Engine Baffles (see Baffles) Repairable Replace On...
  • Page 39 Maintenance Standards ® C-9. 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 40 Maintenance Standards C-10. Gasket Installation WARNING Apply Gasket Maker only as directed. 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, main bearing bosses, or cylinder fastener threads.

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