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Continental Refrigerator IOF-240-B Maintenance Manual

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IOF-240-B
®
CONTINENTAL
AIRCRAFT ENGINE
MAINTENANCE
MANUAL
TECHNICAL PORTIONS OF THIS MANUAL ARE FAA APPROVED
Publication M-22
Change 2
© 2007 TELEDYNE CONTINENTAL MOTORS INCORPORATED
DEC 2007

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Summary of Contents for Continental Refrigerator IOF-240-B

  • Page 1 IOF-240-B ® CONTINENTAL AIRCRAFT ENGINE MAINTENANCE MANUAL TECHNICAL PORTIONS OF THIS MANUAL ARE FAA APPROVED Publication M-22 Change 2 © 2007 TELEDYNE CONTINENTAL MOTORS INCORPORATED DEC 2007...

  • Page 2: List Of Effective Pages

    Teledyne Continental Motors, Inc. Supersedure Notice This manual is a revision of TCM IOF-240-B Maintenance Manual, M-22, dated July 2003. Instructions previously referred to in the F-4 FADEC System Manual, dated July 2003, have been incorporated in this manual. This manual supersedes both the M-22 and F-4 Manuals.
  • Page 3 Teledyne Continental Motors, Inc. Service Document and Technical References Service Documents and technical information cited in this edition of TCM’s Maintenance Manual (M-22) are listed in the chart below. Information relevant to this engine series from these Service Documents has been incorporated in this manual. The full content of all TCM and supplier service documents is available on TCMLINK.
  • Page 4 Teledyne Continental Motors, Inc. Service Documents Incorporated in this Manual Service Document Subject Section Affected Chapter SIL95-5, Hose and Tubing Installation Hose and tubing Standard Practices Appendix C installation CSB96-1, Starter Gear and Clutch Assembly, P/N 653575 SB96-7C, Torque Limits Specific torque values Torque Values Appendix B...
  • Page 5 Teledyne Continental Motors, Inc. Service Documents Incorporated in this Manual Service Document Subject Section Affected Chapter SIL00-11B, Release of new Cylinder Cylinder Assembly Cylinder Assembly Chapter 10 Induction Port Drain Connector SIL02-6A, Production Release of optional intake and exhaust valves SIL03-1, Cold Weather Operation –...
  • Page 6 Teledyne Continental Motors, Inc. Mandatory and Critical Service Bulletins Published After this Manual Document Number Title Affected Section(s) in this Manual Other Service Documents Published After This Manual Document Number Title Affected Section(s) in this Manual IOF-240 Series Engine Maintenance Manual 29 November 2006...
  • Page 7 Teledyne Continental Motors, Inc. PREFACE Teledyne Continental Motors (TCM) provides Instructions for Continued Airworthiness based on the design, testing, and certification of engines and parts for which TCM is the holder of the Type Certificate (TC) or Parts Manufacturing Approval (PMA) issued by the Federal Aviation Administration (FAA).

  • Page 8: Table Of Contents

    Teledyne Continental Motors, Inc. CONTENTS Chapter 1 - Introduction....................... 1-1 Chapter 2 - Engine Description....................2-1 Chapter 3 - Special Tools and Supplies ..................3-1 Chapter 4 - Airworthiness Limitations ..................4-1 Chapter 5 - Engine Removal and Installation ................5-1 Chapter 6 - Operational Performance Tests.................
  • Page 9 Teledyne Continental Motors, Inc. Introduction Chapter 1. INTRODUCTION CONTENTS Chapter 1. Introduction......................1-1 1-1. Scope and Purpose of This Manual ..................1-2 1-1.1. Advisories..............................1-3 1-1.2. Using this Manual............................1-3 1-1.3. Compliance..............................1-4 1-1.4. Order of Precedence ..........................1-5 1-2. Publications .......................... 1-6 1-2.1.

  • Page 10: Scope And Purpose Of This Manual

    Teledyne Continental Motors, Inc. Introduction 1-1. Scope and Purpose of This Manual This manual provides instructions for installing and operating IOF-240 aircraft engines, equipped with Full Authority Digital Engine Control (FADEC), manufactured by Teledyne Continental Motors (TCM). Instructions in this manual are specific to IOF-240 engines. For information specific to other TCM engine series, accessories, or the airplane, refer to the appropriate manual.

  • Page 11: 1-1.1. Advisories

    Teledyne Continental Motors, Inc. Introduction 1-1.1. 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. CAUTION: Emphasizes certain information or instructions, which if disregarded, may result in damage to the engine or accessories.

  • Page 12: 1-1.3. Compliance

    Teledyne Continental Motors, Inc. Introduction 1-1.3. Compliance The owner/operator and designated mechanic are responsible for ensuring the engine is maintained in an airworthy condition, including compliance with applicable service documents and FAA Airworthiness Directives. Engine service life is calculated based on compliance with the aircraft and engine manufacturer’s required instructions, inspections and maintenance schedule.

  • Page 13: 1-1.4. Order Of Precedence

    Teledyne Continental Motors, Inc. Introduction 1-1.4. Order of Precedence Teledyne Continental Motors (TCM) engine operating instructions are generated prior to and independently of the aircraft operating instructions. TCM operating instructions are developed using factory controlled parameters that are not necessarily the same as those specifications required to satisfy a specific aircraft/engine installation.

  • Page 14: Publications

    Teledyne Continental Motors, Inc. Introduction 1-2. Publications 1-2.1. Service Documents Six categories of Service Documents may be issued by TCM ranging from mandatory (Category 1) to informational (Category 6). Definitions of the categories are listed below: NOTE: Upon FAA approval, all TCM service documents are published and available on TCMLINK.

  • Page 15: 1-2.2. Related Publications

    Teledyne Continental Motors, Inc. Introduction Category 6: Special Service Instruction (SSI) This category is used to address an issue limited to specific model and/or serial number engines. TCM will distribute SSI notification directly to the affected engine’s owners. SSIs will not be included in the general service document set but will be made available through TCM Customer Service to owners of the affected engines only.

  • Page 16: 1-2.3. Publication Access

    Teledyne Continental Motors, Inc. Introduction 1-2.3. Publication Access TCMLINK Alpha Services, Information Services, Aviator Services, and FBO Services programs provide an array of benefits including access to electronic versions of TCM technical publications (manuals, service documents, and parts catalogs) via the Internet. Aviator Services and Alpha Services memberships are free to TCM engine owners.

  • Page 17: Tcm Contact Information

    Teledyne Continental Motors, Inc. Introduction 1-2.4.2. Suggestions and Corrections Teledyne 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 TCM address listed in Section 1-3, “TCM Contact Information.” Notify TCM Customer Service immediately, using our toll-free number, if you discover incorrect information which adversely affects safety.
  • Page 18 Teledyne Continental Motors, Inc. Introduction This Page Intentionally Left Blank 1-10 IOF-240 Series Engine Maintenance Manual 29 November 2006...

  • Page 19: Chapter 2. Engine Description

    2-3.2. Oil Specifications ............................ 2-23 2-3.3. Performance Data ............................ 2-24 LIST OF TABLES Table 2-1. IOF-240-B Specifications and Operating Limits ............. 2-21 Table 2-2. Accessory Drive Ratios, Rotation, Speed, Torque & Moments....... 2-23 Table 2-3. Engine Oil Type Requirements ................2-23...
  • Page 20 Figure 2-16. Starting System ..................... 2-18 Figure 2-17. Engine Cooling Airflow..................2-19 Figure 2-18. Typical Crossflow Induction Airflow ..............2-20 Figure 2-19. IOF-240-B Fuel Flow vs. Brake Horsepower ............2-25 Figure 2-20. IOF-240-B Sea Level Performance............... 2-26 IOF-240 Series Engine Maintenance Manual...

  • Page 21: Chapter 2. Engine Description

    Teledyne Continental Motors, Inc. Engine Description 2-1. General Engine Description The IOF-240 engines are four-cylinder, four-stroke reciprocating aircraft engines designed for fixed pitch, ground adjustable, or electric constant speed propellers. There is no provision for a hydraulic propeller governor. These horizontally-opposed, air-cooled, naturally-aspirated engines have a wet oil sump, high pressure Lubrication System, an overhead plenum intake manifold, a side-mounted accessory drive pad and provisions for a downdraft exhaust system.

  • Page 22: 2-1.1. Engine Model Number Definition

    Teledyne Continental Motors, Inc. 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 IOF-240-B1B (Figure 2-1). I O F - 240 - B 1 I O F - 240 - B 1 Shipping Designation Shipping Designation...

  • Page 23: Detailed Engine Description

    Teledyne Continental Motors, Inc. 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"...

  • Page 24: 2-2.2. Engine Drive Train

    Teledyne Continental Motors, Inc. Engine Description 2-2.2. Engine Drive Train The engine drive train consists of the crankshaft and camshaft. Crankshaft Crankshaft Starter Starter Fuel pump and Fuel pump and vacuum pump vacuum pump Oil Pump Oil Pump Camshaft Camshaft drive shaft drive shaft Driven Gear...

  • Page 25: Figure 2-6. Camshaft

    Teledyne Continental Motors, Inc. Engine Description 2-2.2.2. Connecting Rods The connecting rods halves are machined from a single forging of aircraft quality steel and cut into two pieces, splitting the center of the larger opening of the connecting rod assembly. The resulting pieces, called the rod and cap are fitted with a two piece bearing and attach to the crankpin or rod journal with special bolts and nuts.

  • Page 26: 2-2.3. Accessory Case

    Teledyne Continental Motors, Inc. Engine Description The camshaft gear (Figure 2-7) has 16 holes drilled in the outer track and one hole drilled in the inner track. The speed pulse generated by the 16 hole-outer track is the Ne Pulse and the Nc pulse is generated by the lone hole in top dead center inner track for Cylinder 1.

  • Page 27: Figure 2-8. Accessory Case

    Teledyne Continental Motors, Inc. Engine Description A semicircular opening at the accessory case bottom is a machined threaded hole to accommodate installation of the oil suction tube. Passages cast into the accessory case allow oil to flow from the oil suction tube to the oil pump gears, pressure relief valve, and main oil gallery.

  • Page 28: 2-2.4. Cylinders

    Teledyne Continental Motors, Inc. Engine Description 2-2.4. Cylinders The IOF-240 engine has four, horizontally-opposed, air cooled cylinders, two on the left side and two on the right side of the engine. The cylinders, pistons and valve drive train provide the momentum to sustain crankshaft movement. Aviation fuel and air are drawn into a cylinder during the intake stroke, compressed by the piston during the compression stroke and then ignited by a high intensity spark from each spark plug (two per cylinder).
  • Page 29 Teledyne Continental Motors, Inc. Engine Description 2-2.4.1. Pistons Pistons 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 hole and one ring groove below. Compression rings are installed in the top and second grooves.

  • Page 30: 2-2.5. Lubrication System

    Teledyne Continental Motors, Inc. Engine Description 2-2.5. Lubrication System The engine lubrication system delivers lubricating oil throughout the engine to various bearings, bushings, and engine components. The wet sump, high pressure lubrication system consists of an internal engine-driven oil pump, a non-adjustable pressure relief valve, an oil sump, oil sensing ports.

  • Page 31: Figure 2-11. Oil Pump

    Teledyne Continental Motors, Inc. Engine Description INSIDE VIEW OF INSIDE VIEW OF ACCESSORY CASE ACCESSORY CASE DRIVEN GEAR DRIVEN GEAR PUMP PUMP CAVITY CAVITY DRIVE DRIVE DRIVE GEAR GEAR GEAR Figure 2-11. Oil Pump 2-2.5.2. Oil Sump The oil sump body is a welded unit composed of front and rear halves of pressed sheet steel.

  • Page 32: 2-2.6. Ignition System

    Teledyne Continental Motors, Inc. Engine Description PLUG OIL BY-PASS FLOW OIL BY-PASS OIL FLOW OUT VALVE TO EXTERNAL OIL COOLER PLUG OIL PRESSURE PORT OIL TEMP. OIL FLOW BACK PORT TO ENGINE Figure 2-12. Oil Cooler Adapter 2-2.6. Ignition System The Ignition System consists of the high voltage harness and spark plugs.

  • Page 33: 2-2.7. Fuel System

    Teledyne Continental Motors, Inc. Engine Description 2-2.7. Fuel System The Fuel Injection System is composed of an engine-driven fuel pump, fuel filters, fuel distribution block, fuel injector assemblies, and a by-pass solenoid valve (also referred to as a “diverter valve.”). The FADEC System automatically controls the fuel supplied to each cylinder using solenoid-actuated sequential port fuel injectors.

  • Page 34: Figure 2-14. Fuel Pump

    Teledyne Continental Motors, Inc. Engine Description 2-2.7.1. Fuel Pump An engine-driven, positive displacement vane fuel pump supplies fuel as required to the fuel injectors. Fuel enters the fuel pump at the well of the swirl chamber where the fuel is centrifuged and the liquid is separated from fuel vapor.

  • Page 35: Figure 2-15. Fuel Injector Nozzle

    Teledyne Continental Motors, Inc. Engine Description 2-2.7.2. Fuel Injectors The fuel injector assembly is threaded on both ends and is made up of two parts: the control coil and the injector (Figure 2-15). The internal components of the fuel injector consist of a pintle valve and a spring.

  • Page 36: 2-2.8. Starter Assembly

    Teledyne Continental Motors, Inc. Engine Description 2-2.8. Starter Assembly The IOF-240 starter employs an electric starter motor mounted on the accessory case at the rear of the engine. The lightweight starter employs a clutch assembly which engages the crankshaft to turn the engine. TCM offers an optional rear-mounted 12-volt starter motor.

  • Page 37: 2-2.9. Alternator

    Teledyne Continental Motors, Inc. Engine Description 2-2.9. Alternator The IOF-240 engine incorporates a boss on the rear of the engine accessory case for mounting a direct drive alternator. A 12-volt, 60 amp, front gear-driven alternator is available as optional equipment by TCM. There is also a provision for mounting a belt driven alternator at the front of the engine.

  • Page 38: 2-2.11. Induction System

    Teledyne Continental Motors, Inc. Engine Description 2-2.11. Induction System The downdraft type Induction System (Figure 2-18), mounted above the engine, carries induction air to the individual cylinder intake ports. The crossflow design cylinders improve airflow efficiency through the cylinder head. Air flows from the aircraft air inlet/alternate air door to the engine cylinders through the Induction System.

  • Page 39: Engine Specifications And Operating Limits

    Teledyne Continental Motors, Inc. Engine Description 2-3. Engine Specifications and Operating Limits Table 2-1. IOF-240-B Specifications and Operating Limits Cylinders Model IOF-240-B FAA Type Certificate E7SO Installation Drawing Number 656000 Arrangement Individual cylinders horizontally opposed Compression Ratio 8.5: 1 Number of Cylinders...
  • Page 40 Teledyne Continental Motors, Inc. Engine Description Table 2-1. IOF-240-B Specifications and Operating Limits Cylinder Head Temperature Normal Operational Temperature (using bayonet 360 to 420°F 182 to 216°C thermocouple) (cruise) Maximum Allowable Operational Temperature 460°F 238°C (using bayonet thermocouple) Minimum Take-off Temperature (using bayonet 240°F...

  • Page 41: 2-3.1. Accessory Drive Ratios

    Teledyne Continental Motors, Inc. Engine Description 2-3.1. Accessory Drive Ratios Table 2-2. Accessory Drive Ratios, Rotation, Speed, Torque & Moments Direction Maximum Maximum Torque, in·lb Drive Ratio to Overhang Crankshaft Cont. Static Moment, in·lbs Accessory Rotation (1) Tachometer CW, OPT 0.5:1 Starter Motor 24.727:1...

  • Page 42: 2-3.3. Performance Data

    Teledyne Continental Motors, Inc. Engine Description 2-3.2.1. Break-in Oil NOTE: SAEJ1966 Mineral oil contains a corrosion preventive additive and must not be used for more than 25 hours or six months, whichever occurs first. If oil consumption has not stabilized within the break-in period, drain and replenish the mineral oil and replace the oil filter.
  • Page 43 Hot Head Power Power Power Power Prop Load (Max Rich) Normal Prop Load Corrected Brake Horsepower (CBHP)
  • Page 44 Speed Lines in 100 RPM Steps 2800 RPM (Full Rich Fuel Flow) 2100 RPM Absolute Dry manifold Pressure (ADMP) (in Hg)

  • Page 45: Chapter 3. Special Tools And Supplies

    Teledyne Continental Motors, Inc. Special Tools and Supplies Chapter 3. SPECIAL TOOLS AND SUPPLIES CONTENTS Chapter 3. Special Tools and Supplies..................3-1 3-1. Special Tools ........................3-3 3-1.2. Vendor Contact Information........................3-9 3-1.3. Illustrated Special Tools .......................... 3-11 3-1.4. Mechanic’s Tools ............................ 3-24 3-2.
  • Page 46 Teledyne Continental Motors, Inc. Special Tools and Supplies LIST OF FIGURES Figure 3-1. Model E2M Differential Pressure Tester (built in Master Orifice Tool) ....3-12 Figure 3-2. Model E2A Differential Pressure Tester (no Master Orifice Tool) ......3-12 Figure 3-3. Master Orifice Tool used with pressure tester E2A ..........3-13 Figure 3-4.

  • Page 47: Chapter 3. Special Tools And Supplies

    Teledyne Continental Motors, Inc. Special Tools and Supplies 3-1. Special Tools NOTE: All tool vendors in the Special Tool List are for reference only, not for the purpose of promoting a particular vendor or to require 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.
  • Page 48 Teledyne Continental Motors, Inc. Special Tools and Supplies Table 3-1. Special Tool List Special Tools* Use or Reference Suggested Part Number Providers** Alternator/Regulator/ Check Battery Eastern Technology E100 Battery Tester Corporation Alternator Drive Hub Alternator Drive Hub Slippage Inspection Fabricate per Holding Fixture specifications in Figure 3-10...
  • Page 49 Teledyne Continental Motors, Inc. Special Tools and Supplies Table 3-1. Special Tool List Special Tools* Use or Reference Suggested Part Number Providers** Oil Seal Tool Crankcase And Accessory Drive Adapter Fabricate per MT500260 Oil Seal Installation instructions in Figure 3-14 Oil Filter Can Cutter Cut Oil Filter For Inspection Federal Mogul...
  • Page 50 Teledyne Continental Motors, Inc. Special Tools and Supplies Table 3-1. Special Tool List Special Tools* Use or Reference Suggested Part Number Providers** Valve Gauge Line Grinding Intake Valve Fabricate per Inspection Fixture specifications in Figure 3-12 Common Parts Kit Valve Seat Replacement Borroughs 8116 Reamers...
  • Page 51 Teledyne Continental Motors, Inc. Special Tools and Supplies Table 3-1. Special Tool List Special Tools* Use or Reference Suggested Part Number Providers** Crankcase Splitter Crankcase Separation Kent-Moore L423 Runout Block Set Drive Train Dimensional Inspection Borroughs 8117A Polishing Tool Engine Drive Train Inspection Borroughs 8087A Connecting Rod...
  • Page 52 Teledyne Continental Motors, Inc. Special Tools and Supplies Table 3-1. Special Tool List Special Tools* Use or Reference Suggested Part Number Providers** Flaw Detector Cylinder Barrel Ultrasonic Inspection Krautkramer-Branson Krautkramer- Branson part number USL-42 or equivalent Cylinder Barrel Ultrasonic Inspection Krautkramer-Branson Krautkramer- Fixture 60°...

  • Page 53: 3-1.2. Vendor Contact Information

    Teledyne Continental Motors, Inc. Special Tools and Supplies 3-1.2. Vendor Contact Information Table 3-2. Tool, Accessory, and Supply Vendors Supplier Address Phone Web Address* Aerosance 9 Eastview Drive 860-409-7880 860-409-7885 fadec.com Farmington, CT 06032 Aircraft Tool P.O. Box 370 800-248-0638 517-739-1448 aircraft-tool.com Supply 1000 Old U.S.
  • Page 54 Teledyne Continental Motors, Inc. Special Tools and Supplies Table 3-2. Tool, Accessory, and Supply Vendors Supplier Address Phone Web Address* McMaster-Carr P.O. Box 4355 630-833-0300 630-834-9427 mcmaster.com Supply Chicago, IL 60680-4355 Company Merit 201 W. Mansville Dr. 800-421-1936 800-472-3094 meritabr.com Abrasives Compton, CA 90224 310-639-4242...

  • Page 55: 3-1.3. Illustrated Special Tools

    Teledyne Continental Motors, Inc. Special Tools and Supplies 3-1.3. Illustrated Special Tools Table 3-3. Illustrated Special Tools Tool Name Figure Model E2M Differential Pressure Tester (built in Master Orifice Tool) Figure 3-1 Model E2A Differential Pressure Tester (no Master Orifice Tool) Figure 3-2 Master Orifice Tool Figure 3-3...
  • Page 56 Teledyne Continental Motors, Inc. Special Tools and Supplies Figure 3-2. Model E2A Differential Pressure Tester (no Master Orifice Tool) FACTORY CALIBRATED ORIFICE DUST CAP DUST CAP SPARK PLUG THREADS (18mm) Figure 3-3. Master Orifice Tool used with pressure tester E2A The Master Orifice Tool restrictor orifice dimensions for these engines must be 0.040 inch orifice diameter, 0.250 inch long with 60°...
  • Page 57 Teledyne Continental Motors, Inc. Special Tools and Supplies Figure 3-4. Borescope (Autoscope ®) Figure 3-5. Helical Coil Extraction Tool IOF-240 Series Engine Maintenance Manual 3-13 29 November 2006...
  • Page 58 Teledyne Continental Motors, Inc. Special Tools and Supplies Figure 3-6. Helical Coil Insertion Tool Figure 3-7. Helical Coil Expanding Tool 3-14 IOF-240 Series Engine Maintenance Manual 29 November 2006...
  • Page 59 Teledyne Continental Motors, Inc. Special Tools and Supplies Figure 3-8. Rosan® stud Removal Tool Figure 3-9. Rosan stud removal tool installed on stud IOF-240 Series Engine Maintenance Manual 3-15 29 November 2006...
  • Page 60 Teledyne Continental Motors, Inc. Special Tools and Supplies Figure 3-10. Alternator Drive Hub Holding Fixture Figure 3-11. Alternator Drive Hub Torque Tool 3-16 IOF-240 Series Engine Maintenance Manual 29 November 2006...
  • Page 61 Teledyne Continental Motors, Inc. Special Tools and Supplies Ø 2.50” Ø 2.50” Figure 3-12. Valve Gauge Line Inspection Fixture IOF-240 Series Engine Maintenance Manual 3-17 31 August 2007 Change 1...
  • Page 62 Teledyne Continental Motors, Inc. Special Tools and Supplies Figure 3-13. Oil Seal Installation Tool Medium Knurl Stamp P/N On Flat Mill Flat 1/16 Radius 5/16 1.200 Dia. 1/8x45° 0.783 Dia. 1-1/4 Dia. 2.00 Before Knurl 1.00 3.00 0.68 1.00 Material 1020 Case Harden Figure 3-14.
  • Page 63 Teledyne Continental Motors, Inc. Special Tools and Supplies Figure 3-15. Staking Tool Figure 3-16. Staking Tool Bill of Materials IOF-240 Series Engine Maintenance Manual 3-19 29 November 2006...
  • Page 64 Teledyne Continental Motors, Inc. Special Tools and Supplies Figure 3-17. Staking Tool Dimensions (A) 3-20 IOF-240 Series Engine Maintenance Manual 29 November 2006...
  • Page 65 Teledyne Continental Motors, Inc. Special Tools and Supplies Figure 3-18. Staking Tool Dimensions (B) IOF-240 Series Engine Maintenance Manual 3-21 29 November 2006...
  • Page 66 Teledyne Continental Motors, Inc. Special Tools and Supplies Figure 3-19. Valve Guide Seal Installation Tool Figure 3-20. O-Ring Installation Tool 3-22 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 67 Teledyne Continental Motors, Inc. Special Tools and Supplies To signal conditioner Figure 3-21. FADEC Timing Tool Figure 3-22. SSA Simulator EDI Data Interface EDI Data Interface EDI Serial Data Cable EDI Serial Data Cable EDI Serial Data Cable EDI Serial Data Cable USB to Serial Adapter USB to Serial Adapter Figure 3-23.

  • Page 68: 3-1.4. Mechanic's Tools

    Teledyne Continental Motors, Inc. Special Tools and Supplies 3-1.4. Mechanic’s Tools Tools in the list below (Table 3-4) are required to perform overhaul procedures on IOF-240 engines. Table 3-4. Mechanic’s Tools Open end wrenches – ¼-inch through 1 inch 1/4-inch Slide hammer Deep socket wrenches: Ratchets: •...

  • Page 69: Lubricants, Sealants And Adhesives

    Teledyne Continental Motors, Inc. Special Tools and Supplies 3-2. Lubricants, Sealants and Adhesives Lubricating oils qualified for use in Teledyne Continental Motors engines are required to meet SAE (Society of Automotive Engineers) specifications. SAE specification J 1899 (formerly MIL-L-22851) is the approval for aircraft piston engine ashless-dispersant oil.
  • Page 70 Teledyne Continental Motors, Inc. Special Tools and Supplies Table 3-5. Qualified Ashless Dispersant Lubricating Oils SAE J 1899 SUPPLIER BRAND BP Oil Corporation BP Aero Oil Castrol Castrol Aero AD Oil Castrol Limited (Australia) Castrol Aero AD Oil Chevron USA Chevron Aero Oil Continental Oil Conoco Aero S...

  • Page 71: 3-2.2. Oil Change Intervals

    Teledyne Continental Motors, Inc. Special Tools and Supplies 3-2.2. Oil Change Intervals Refer to the engine maintenance manual and/or the aircraft manufacturers or Supplemental Type Certificate (STC) holders AFM/POH for fuel specifications, specified oil change intervals and inspection procedures. The oil change intervals published in this manual are minimum requirements. Teledyne Continental Motors believes more frequent oil and filter changes enhance engine service life.
  • Page 72 Teledyne Continental Motors, Inc. Special Tools and Supplies Table 3-8. Lubricants TYPE APPLICATION REMARKS Starter Worm Gear Drive Teeth & Bevel Gear Teeth All models during engine assembly Needle bearings and ball bearings Valve stems Molyshield Grease Accessory drive splines and All models, as applicable couplings P/N 656817-1 6 Gallon Can...
  • Page 73 Teledyne Continental Motors, Inc. Special Tools and Supplies Table 3-8. Lubricants TYPE APPLICATION REMARKS CHAMPION® - Spark Plug Thread Spark plugs All models Lubricant No. 2612 Induction system hose and flex Chesterton #995 Release agent duct connections All models or WD-40 Fuel Pump Aneroid Seal Rubber oil seal of spin-on oil filter Governor pad gaskets (both sides)
  • Page 74 Teledyne Continental Motors, Inc. Special Tools and Supplies Table 3-10. Adhesives TYPE APPLICATION REMARKS 3M™ Super 77™ Spray Adhesive EMI Gaskets All FADEC Cylinder deck studs All - breakaway torque =100 in-lbs. after 2 hrs Crankcase nose seal retainer bolts All Models Loctite 271 High Strength Adhesive Squirt nozzle...

  • Page 75: Chapter 4. Airworthiness Limitations

    Teledyne Continental Motors, Inc. Airworthiness Limitations Chapter 4. AIRWORTHINESS LIMITATIONS CONTENTS Chapter 4. Airworthiness Limitations ..................4-1 4-1. Mandatory Replacement Times.................... 4-2 4-2. Mandatory Inspection Intervals .................... 4-2 4-3. Other Related Procedures ..................... 4-2 4-4. Distribution of Changes to Airworthiness Limitations............4-2 IOF-240 Series Engine Maintenance Manual 29 November 2006...

  • Page 76: Mandatory Inspection Intervals

    Teledyne Continental Motors, Inc. Airworthiness Limitations FAA APPROVED The Airworthiness Limitations Section is FAA approved and specifies maintenance required under §§ 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. Federal Aviation Regulations §§ 43.16 and 91.403 require owner/operator compliance with all maintenance limitations in this section concerning mandatory replacement times, inspection intervals, and other related procedures that are specific to this engine.

  • Page 77: Chapter 5. Engine Removal And Installation

    Teledyne Continental Motors, Inc. Engine Removal and Installation Chapter 5. ENGINE REMOVAL AND INSTALLATION Refer to abbreviated engine removal and installation procedures in Chapter 5 of the TCM Overhaul Manual (OH-22) to remove and install the same engine for maintenance. Detailed engine installation procedures are in the TCM Installation and Operation Manual (OI-22).
  • Page 78 Teledyne Continental Motors, Inc. Engine Removal and Installation This Page Intentionally Left Blank IOF-240 Series Engine Maintenance Manual 29 November 2006...
  • Page 79 Teledyne Continental Motors, Inc. Operational Performance Checks Chapter 6. OPERATIONAL PERFORMANCE CHECKS CONTENTS Chapter 6. Operational Performance Checks ................. 6-1 6-1. Engine Operational Check....................6-2 6-1.1. Maintenance Preflight Inspection ......................6-3 6-1.2. Test Equipment Setup..........................6-4 6-1.3. FADEC Engine Operational Check......................6-7 6-2.
  • Page 80 Teledyne Continental Motors, Inc. Operational Performance Checks 6-1. Engine Operational Check Perform an operational check after any of the following: • Engine Installation • Maintenance or Troubleshooting • Engine Overhaul • Return from Storage • After each 100-Hour/Annual and 500-Hour Inspection NOTE: FADEC Health Status Annunciators vary by manufacturer.
  • Page 81 Teledyne Continental Motors, Inc. Operational Performance Checks 6-1.1. Maintenance Preflight Inspection Prior to starting the engine, complete a preflight inspection of the engine, propeller, nacelle, and aircraft. Perform the inspection prior to the first flight following engine installation, inspection, troubleshooting, maintenance, or overhaul work to determine if the aircraft and engine are in an airworthy condition.
  • Page 82 Teledyne Continental Motors, Inc. Operational Performance Checks 7. If the engine is newly installed or being returned to service after long-term storage, perform the “Engine Pre-oiling” procedure in Chapter 4 of the Installation and Operation Manual (OI-22). 8. Verify the induction air filter is clean and securely in place. Replace the filter with a clean one if it is dirty;...
  • Page 83 Teledyne Continental Motors, Inc. Operational Performance Checks 6-1.2.2. Engine Operational Check with Calibrated Gauges Setup CAUTION: Calibrated Gauges may be used to check and adjust the fuel system pressures after replacement of fuel injection system parts. For Engine Operational Checks following replacement of FADEC system parts, follow the steps in section 6-1.2.1, “Engine Operational Check with FADEC System Setup”...
  • Page 84 Teledyne Continental Motors, Inc. Operational Performance Checks Figure 6-3. 0-100 psi Gauge Installed to Check Fuel Pressure IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 85 Teledyne Continental Motors, Inc. Operational Performance Checks 6-1.3. FADEC Engine Operational Check Procedure 1. Fuel Selector Valve..........ON 2. Throttle..............Start Position 3. Avionics Master Switch........OFF 4. Master Power Switch ...........ON 5. Ignition Switch.............OFF 6. FADEC Primary Power Switch (Power A) ..ON 7.

  • Page 86: Fuel Selector Valve

    CAUTION: Operating the engine without oil pressure will result in engine malfunction or stoppage. NOTE: The IOF-240-B engine incorporates a fixed oil pressure relief valve; oil pressure is not adjustable. If oil pressure drops below the specified operating pressure at idle (10psig) or normal...

  • Page 87: Throttle

    Teledyne Continental Motors, Inc. Operational Performance Checks The maximum allowable RPM drop spread between L and R channels is 75 RPM. 18. Ignition Switch.............R RESULT: RPM drop maximum 150 RPM. FADEC CAUTION lamp is ON. 19. Ignition Switch.............BOTH RESULT: RPM returns to IDLE. FADEC CAUTION and WARN lamps are OFF. 20.
  • Page 88 Teledyne Continental Motors, Inc. Operational Performance Checks RESULT: Engine-driven fuel pump pressure corresponds to the fuel pressure vs. engine speed chart (Figure 6-4) –2/+5 psi at full throttle. If full power fuel pressure is not attained within the specified range, adjust the fuel pressure as directed in “Fuel System Adjustment”...
  • Page 89 36.00 35.75 35.50 35.25 35.00 34.75 34.50 34.25 34.00 33.75 33.50 33.25 33.00 32.75 32.50 32.25 32.00 31.75 31.50 31.25 31.00 30.75 30.50 30.25 30.00 29.75 29.50 29.25 29.00 28.75 28.50 28.25 28.00 1975 2000 2025 2050 2075 2100 2125 2150 2175 2200 2225 2250 2275 2300 2325 2350 2375 2400 2425 2450 2475 2500 2525 Engine Speed (RPM)
  • Page 90 Teledyne Continental Motors, Inc. Operational Performance Checks 6-2. Operational Checklist Make a copy of the Operational Checklist to record operational test results. NOTE: Operating limits and engine model specifications are located in Chapter 2, Engine Description of this manual. 6-12 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 91 Teledyne Continental Motors, Inc. Operational Performance Checks Table 6-2. Operational Checklist Aircraft Make & Model: Aircraft Registration #: Engine Model: Engine Position: Left Right Front Rear Engine Serial Number: Engine Total Time: Overhaul Date Location: Elevation: Outside Air Temp: Pressure Alt. Fuel System Adjustment Cylinder Head Temp- °F °F...
  • Page 92 Teledyne Continental Motors, Inc. Operational Performance Checks This Page Intentionally Left Blank 6-14 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...

  • Page 93: Chapter 7. Maintenance Inspections

    Teledyne Continental Motors, Inc. Maintenance Inspections Chapter 7. MAINTENANCE INSPECTIONS CONTENTS Chapter 7. Maintenance Inspections..................7-1 7-1. Inspection Program Introduction ..................7-3 7-2. Inspection and Maintenance Schedule ................. 7-3 7-3. Scheduled Inspections ......................7-3 7-3.2. 25-Hour Initial Operation Inspection......................7-5 7-3.3.
  • Page 94 Teledyne Continental Motors, Inc. Maintenance Inspections LIST OF FIGURES Figure 7-1. Cylinder Barrel Power Stroke Inspection Areas ............. 7-11 Figure 7-2. Model E2M Differential Pressure Tester ..............7-15 Figure 7-3. Model E-2A Differential Pressure Tester ............... 7-17 Figure 7-4. Master Orifice Tool....................7-17 Figure 7-5.

  • Page 95: Inspection And Maintenance Schedule

    Teledyne Continental Motors, Inc. Maintenance Inspections 7-1. Inspection Program Introduction The Inspection Program described in this chapter applies only to the Teledyne Continental Motors, Inc. (TCM) engines covered in this manual. Perform the engine inspections using the instructions contained in this chapter. Aircraft inspections must be performed according to the aircraft manufacturer’s instructions.

  • Page 96: Chapter 9 - Maintenance And Adjustments

    Section 7-3.11, “FADEC Backup Battery Annually Replace FADEC backup battery Inspection” Section 7-3.5“500-Hour 500-hour engine inspection Engine Inspection” Overhaul Instructions in 2000 12 years IOF-240-B Time Between Overhaul (TBO) OH-22 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 97 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.2. 25-Hour Initial Operation Inspection Frequency • Twenty-five (25) hours or six months (whichever occurs first) after: • A new, rebuilt or overhauled engine is placed in service. • One or more new engine cylinders and/or piston rings have been replaced. •...
  • Page 98 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.3. 50-Hour Engine Inspection Frequency The 50-hour Inspection is done under the following circumstances: • 25 hours after the 25-hour Initial Operation Inspection • After every 50 hours of operation WARNING When performing this inspection, turn the Ignition Switch OFF and disconnect engine electrical power.
  • Page 99 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.4. 100-Hour (Annual) Engine Inspection Frequency The 100-Hour Inspection is done under two circumstances: • After each 100 hours of accumulated engine operation. • Annually, if the engine did not accumulate 100 hours of operation during the calendar year since the last 100-hour inspection.
  • Page 100 Teledyne Continental Motors, Inc. Maintenance Inspections 16. Inspect installed accessories for mounting security, condition, and proper operation according to the aircraft maintenance manual or the accessory manufacturer’s instructions. 17. Perform an “Engine Operational Check” according to instructions in Chapter 6. 7-3.5.
  • Page 101 Teledyne Continental Motors, Inc. Maintenance Inspections 7. Check electrical connectors for signs of corrosion or contamination – if external corrosion or contamination is found, disconnect the connectors and inspect internal connector pins for corrosion or contamination. NOTE: For items 8-18 below, inspect for obvious signs of physical damage, wear or deterioration, loose or missing hardware, leaks or foreign material (liquid of solid) that may hinder normal operation.
  • Page 102 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.7. Cylinder Inspections A complete cylinder inspection entails the tasks described in respective sections in this manual referenced in Table 7-2 below. Performing all of the tasks in the table below ensures that items that can affect cylinder operation have been inspected and verified for proper operation.
  • Page 103 Teledyne Continental Motors, Inc. Maintenance Inspections Figure 7-1. Cylinder Barrel Power Stroke Inspection Areas IOF-240 Series Engine Maintenance Manual 7-11 31 August 2007 Change 1...
  • Page 104 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.7.2. Differential Pressure Test Purpose The Cylinder Differential Pressure Test is a widely used method to determine the internal condition of cylinders and cylinder components. As with any test or inspection, the Cylinder Differential Pressure Test has certain limitations that necessitate its use in conjunction with other non-invasive inspections.

  • Page 105: Test Equipment

    Teledyne Continental Motors, Inc. Maintenance Inspections • High iron content in oil analysis may be an indication. • Broken piston rings: • Scored, grooved cylinder; wall, evident via a borescope inspection. • Abnormal debris in oil filter or oil screen. •...
  • Page 106 Teledyne Continental Motors, Inc. Maintenance Inspections For aircraft fitted with constant speed propellers, operate the engine at a high enough power setting to allow the cycling of the aircraft propeller. For aircraft with fixed pitched propellers, operate the engine at full static RPM. WARNING The fuel must be shut off prior to Differential Pressure Testing to prevent accidental engine starts.
  • Page 107 Teledyne Continental Motors, Inc. Maintenance Inspections 8. Record the pressure reading on the right hand gauge on the Cylinder Inspection Checklist (Table 7-10). This reading is the Minimum Acceptable Cylinder Pressure Leakage Limit. 9. Close the Slow Fill Valve completely. (The handle is vertical and pointing down). 10.
  • Page 108 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.7.2.2. Differential Pressure Tester E2A setup To establish the acceptable pressure leakage limit for a Model E2A Differential Pressure Tester and Master Orifice Tool (Figure 7-4), perform the following procedure: Procedure 1. Make sure the Regulator Pressure Valve is backed all the way OUT. 2.
  • Page 109 Teledyne Continental Motors, Inc. Maintenance Inspections Figure 7-3. Model E-2A Differential Pressure Tester FACTORY CALIBRATED ORIFICE DUST CAP DUST CAP SPARK PLUG THREADS (18mm) Figure 7-4. Master Orifice Tool 7-3.7.2.3. Differential Pressure Tester Reliability Check Keep the Differential Pressure Tester clean and check it periodically for accuracy as follows: Procedure 1.
  • Page 110 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.7.2.4. Cylinder Differential Pressure Test Procedure 1. Perform the test as soon as possible after the engine is shut down to ensure the piston rings, cylinder walls, and other engine parts are well lubricated and at operating clearance.
  • Page 111 Teledyne Continental Motors, Inc. Maintenance Inspections 6. Continue rotating the propeller in the normal direction of rotation, against the pressure until the piston reaches top dead center (TDC) indicated by a sudden decrease in the force required to turn the crankshaft. If the crankshaft is rotated too far, back up at least one-half revolution and start over again to eliminate the effect of valve train backlash and to keep the piston rings seated.
  • Page 112 Teledyne Continental Motors, Inc. Maintenance Inspections Table 7-3. Differential Pressure Test Results Air Discharge Source Pressure Test Value Symptoms and Recommended Action Observations Cylinder Differential Normal borescope Continue engine in Pressure Test reading indications. service. Repeat Air discharge at oil above leakage limit.
  • Page 113 Teledyne Continental Motors, Inc. Maintenance Inspections Table 7-3. Differential Pressure Test Results Air Discharge Source Pressure Test Value Symptoms and Recommended Action Observations Cylinder Differential Normal cylinder Continue engine in Pressure Test reading borescope inspection service. above leakage limit. results. Cylinder Differential Normal cylinder Fly aircraft at cruise...
  • Page 114 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.7.2.5. Static and Dynamic Seal Check Procedure 1. The piston and piston rings form a dynamic seal (Figure 7-6) in the cylinder. Leakage in this dynamic seal can vary from cylinder to cylinder, based on ring gap position, wear or the amount of engine oil on the cylinder wall.
  • Page 115 Teledyne Continental Motors, Inc. Maintenance Inspections 6) Rotate the propeller again before rechecking leakage to reset the valves in the normal manner. 7) If leakage around the valve cannot be corrected by staking, remove and repair the cylinder. Refer to Table 7-4 “Summary of Seal Checks and Corrective Actions”...
  • Page 116 Teledyne Continental Motors, Inc. Maintenance Inspections Figure 7-7. Piston Ring Positions 4. To check the static seals (Figure 7-6) while the cylinder is still installed: a. For each cylinder under test, position the piston as close to bottom dead center as possible on the compression stroke, ensuring the intake and exhaust valves remain closed to allow the cylinder to hold pressure.
  • Page 117 Teledyne Continental Motors, Inc. Maintenance Inspections NOTE: If the Cylinder Borescope Inspection does not reveal a faulty condition, fly the aircraft at a cruise power setting between 65 and 75 percent power, as specified in the Airplane Flight Manual/Pilot’s Operating Handbook, for at least 45 minutes to allow the engine oil and cylinder head temperatures to stabilize.
  • Page 118 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.7.3. Cylinder Borescope Inspection Background Regular engine operation provides an oil coating for the cylinder and minimizes rust formation. New cylinders are particularly sensitive to rust formation if the engine is infrequently used or not properly preserved during storage. NOTE: Ground operation of the engine is an unacceptable substitute for in-flight engine operation.
  • Page 119 Teledyne Continental Motors, Inc. Maintenance Inspections 3. Position the piston at bottom dead center on the power stroke. The exhaust valve will be open with the piston in this position. 4. Insert the borescope probe through the upper spark plug hole and inspect the internal surfaces of each cylinder, including the exhaust valve and exhaust valve seat.
  • Page 120 Teledyne Continental Motors, Inc. Maintenance Inspections Figure 7-8. Normal Combustion Figure 7-9. Burned Exhaust Chamber Valve Exhaust valve has reddish deposit in center with dark outer Note the edge of valve face has lost all combustion residue edge. Intake valve has light brown combustion deposits. with striations moving toward center of valve.
  • Page 121 Teledyne Continental Motors, Inc. Maintenance Inspections Figure 7-12. Cylinder Barrel Scoring and Piston Rub Figure 7-13. Typical Wear in Upper Ring Travel Area Figure 7-14. Typical Cylinder Wear IOF-240 Series Engine Maintenance Manual 7-29 31 August 2007 Change 1...

  • Page 122: Chapter 10 - Non-Overhaul Repair And Replacement

    Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.7.4. Cylinder-to-Crankcase Mounting Deck Inspection Purpose Proper cylinder head torque requires a solid mounting surface. Foreign materials, such as grease or unauthorized sealants applied to the mounting base or flange distort the desired mating surface and alter torque readings. Proper torque is critical to engine operation. Frequency During 100 hour or annual inspection WARNING...
  • Page 123 Teledyne Continental Motors, Inc. Maintenance Inspections b. Perimeter ba ffles c. Cowl seals d. Cooling ducts e. Remaining seals and baffles Repair or replace worn or distorted baffles in accordance with the airframe manufacturer or Supplemental Type Certificate (STC) holder ’s information.
  • Page 124 Teledyne Continental Motors, Inc. Maintenance Inspections Figure 7-16. Improperly Positioned Baffle Seals Figure 7-17. Improperly Positioned Aft and Side Peripheral Baffle Seals 7-32 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 125 Teledyne Continental Motors, Inc. Maintenance Inspections Figure 7-18. Improperly Positioned Aft and Side Peripheral Baffle Seals Figure 7-19. Aft and Side Baffles with Air Gaps IOF-240 Series Engine Maintenance Manual 7-33 31 August 2007 Change 1...
  • Page 126 Teledyne Continental Motors, Inc. Maintenance Inspections Figure 7-20. Cooling Air Loss Due to Gaps in Baffle Seal Figure 7-21. Cooling Air Loss Due to Gaps in Baffle Seal 7-34 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 127 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.7.6. Cowling Inspection Purpose Check cowl openings for restrictions and proper operation of the cowl flap. Cowl flap operation is an integral part of engine cooling control. Frequency During 100-hour or annual inspection Procedure 1.
  • Page 128 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.8. Crankcase Inspection Purpose To verify the following: • Crankcase integrity • Crankcase hardware fasteners are torqued according to Appendix B • Crankcase is free of oil leaks, cracks, and mechanical damage Frequency During 100-hour or annual inspection Procedure 1.
  • Page 129 Teledyne Continental Motors, Inc. Maintenance Inspections c. Cracks shorter than one inch in the shaded locations of Figure 7-22 may remain in service. Identify the cracks according to instructions in Section 10-8. Perform follow-on inspections at 25 hour intervals for deterioration. Repair or replace the crankcase if the crack deteriorates to 1 inch or more in length in the shaded locations.
  • Page 130 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.9. Induction System Inspection Purpose Check the integrity of the air filter, seals, and airbox to prevent particulates from entering the engine that can abrade cylinder walls and ring faces thereby damaging the engine. Frequency During 100-hour or annual inspection Procedure...
  • Page 131 Teledyne Continental Motors, Inc. Maintenance Inspections 4. Remove spark plugs from each cylinder head. Clean and inspect the spark plugs according to “Ignition and Spark Plug Maintenance” instructions in Chapter 9, “Maintenance and Adjustments.” Rotate spark plugs from original locations during installation.
  • Page 132 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.12.1. Fuel Distribution Block Service Procedure 1. Remove the four screws (Figure 7-23) (96), lock washers (97), and washers (98) from the fuel distribution block cover (99). 2. Remove the gasket (102), filter (101), and O-ring (100); discard the gasket and O-ring (100).
  • Page 133 Teledyne Continental Motors, Inc. Maintenance Inspections Figure 7-23. Fuel Distribution Block Filter Assembly 7-3.12.2. Fuel Filter Service IOF-240 engines use two types of primary fuel filters between the fuel pump and the fuel distribution block. The IOF-240-B1 and B2 specifications feature a 20 micron, one piece fuel filter (Figure 7-24), installed inline between the fuel pump and the fuel distribution block.
  • Page 134 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.12.2.1. Inline Fuel Filter Service The inline fuel filter element is enclosed in one piece housing. The fuel filter element cannot be removed from the housing; clean the entire assembly as one unit. Procedure 1.
  • Page 135 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.12.2.2. Bypass Fuel Filter Service The bypass fuel filter assembly (Figure 7-26) contains a removable, reusable filter screen, held in place by a spring. Procedure 1. Disconnect the fuel lines from each end of the filter; place protective caps on the fuel lines.
  • Page 136 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.13. Engine Gauge Inspection CAUTION: Inaccurate aircraft engine related gauges may cause the pilot to operate the engine outside of the engine specification limits and can lead to accelerated engine wear. Engine gauge calibration errors can be particularly harmful for high horsepower engines.
  • Page 137 Teledyne Continental Motors, Inc. Maintenance Inspections 4. Consult the airframe manufacturer’s and/or their most current published instructions concerning aircraft engine control cable attach point inspection, cleaning, repair, installation, and lubrication. 5. Cycle throttle through full range of motion. a. Verify that each control has full range of travel. b.
  • Page 138 Teledyne Continental Motors, Inc. Maintenance Inspections 7-3.17. Alternator Inspection The alternator coupling is designed to slip when abnormal torque is required to rotate the alternator shaft This can prevent internal engine damage in the event of an alternator seizure. Frequency During 100-hour or annual inspection Procedure 1.
  • Page 139 Teledyne Continental Motors, Inc. Maintenance Inspections Figure 7-27. One piece coupling 7. Torque test the drive hub assembly using the Alternator Drive Hub Torque Tool (Chapter 3, Special Tools and Supplies) and a currently calibrated torque wrench. 8. Apply 100 inch pounds of torque to the drive hub with the torque tool. No slippage is allowed at or below 100 inch pounds of torque.
  • Page 140 Teledyne Continental Motors, Inc. Maintenance Inspections 7-4. Unscheduled Maintenance 7-4.1. Propeller Strike A propeller strike is any incident (whether or not the engine is operating) which either requires repair to a propeller blade (other than minor dressing of the blade) or where the propeller makes contact with any object that results in the loss of engine RPM.
  • Page 141 Teledyne Continental Motors, Inc. Maintenance Inspections 6. Check the integrity of the forward crankcase bearing support and adjacent structure. 7. Reassemble the engine as directed in the Engine Assembly chapter in the Overhaul Manual (OH-22). 8. Perform the aircraft inspection as specified in the aircraft manufacturer’s instructions. 7-4.3.
  • Page 142 Teledyne Continental Motors, Inc. Maintenance Inspections 7-4.4. Engine Overspeed Operating an engine beyond its capacity can damage the engine and result in subsequent engine failure. Overspeed conditions have three levels of severity defined in the table below: Category Engine Speed CAT I 2850 - 3000 RPM CAT II...
  • Page 143 Teledyne Continental Motors, Inc. Maintenance Inspections 7-4.4.2. Category II Overspeed Inspection If engine overspeed continues uncorrected for less than ten seconds, no action is required. For more than 10 seconds, land the plane and proceed as follows: Procedure 1. Complete Category I inspection and service requirements. 2.
  • Page 144 Teledyne Continental Motors, Inc. Maintenance Inspections 7-4.6. Contaminated Fuel System The engines described in this manual are certified for operation with 100-LL Blue or 100 Green aviation fuels. If a lower octane or incorrect grade of aviation fuel or jet fuel is used, perform the following procedure: Procedure 1.
  • Page 145 Teledyne Continental Motors, Inc. Maintenance Inspections Table 7-6. 25-Hour Initial Operation Inspection Checklist Engine Model Number: ___________________ Engine Serial Number: _________________ Total Time Engine Has Been in Service: _______________ Time Since Major Overhaul (TSMOH) __________________ Engine in Storage? ________ Date Inspection Performed: ________ Inspection Performed by:_____________________ Complete the 25-hour inspection according to the instructions in the Maintenance Manual;...
  • Page 146 Teledyne Continental Motors, Inc. Maintenance Inspections This Page Intentionally Left Blank 7-54 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 147 Teledyne Continental Motors, Inc. Maintenance Inspections Table 7-7. 50-Hour Engine Inspection Checklist Engine Model Number: ___________________ Engine Serial Number: _________________ Total Time Engine Has Been in Service: _______________ Time Since Major Overhaul (TSMOH) __________________ Engine in Storage? ________ Date Inspection Performed: ________ Inspection Performed by:_____________________ Complete the 50-hour inspection according to the instructions in the Maintenance Manual;...
  • Page 148 Teledyne Continental Motors, Inc. Maintenance Inspections This Page Intentionally Left Blank 7-56 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 149 Teledyne Continental Motors, Inc. Maintenance Inspections Table 7-8. 100-Hour Engine Inspection Checklist Engine Model Number: ___________________ Engine Serial Number: _________________ Total Time Engine Has Been in Service: _______________ Time Since Major Overhaul (TSMOH) __________________ Engine in Storage? ________ Date Inspection Performed: ________ Inspection Performed by:_____________________ Complete the 100-hour inspection according to the instructions in the Maintenance Manual;...
  • Page 150 Teledyne Continental Motors, Inc. Maintenance Inspections Table 7-8. 100-Hour Engine Inspection Checklist Engine Model Number: ___________________ Engine Serial Number: _________________ Total Time Engine Has Been in Service: _______________ Time Since Major Overhaul (TSMOH) __________________ Engine in Storage? ________ Date Inspection Performed: ________ Inspection Performed by:_____________________ Complete the 100-hour inspection according to the instructions in the Maintenance Manual;...
  • Page 151 Teledyne Continental Motors, Inc. Maintenance Inspections Table 7-9. 500-Hour Engine Inspection Checklist Engine Model Number: ___________________ Engine Serial Number: _________________ Total Time Engine Has Been in Service: _______________ Time Since Major Overhaul (TSMOH) __________________ Engine in Storage? ________ Date Inspection Performed: ________ Inspection Performed by:_____________________ Complete the 500-hour inspection according to the instructions in the Maintenance Manual;...
  • Page 152 Teledyne Continental Motors, Inc. Maintenance Inspections Table 7-9. 500-Hour Engine Inspection Checklist Engine Model Number: ___________________ Engine Serial Number: _________________ Total Time Engine Has Been in Service: _______________ Time Since Major Overhaul (TSMOH) __________________ Engine in Storage? ________ Date Inspection Performed: ________ Inspection Performed by:_____________________ Complete the 500-hour inspection according to the instructions in the Maintenance Manual;...
  • Page 153 Teledyne Continental Motors, Inc. Maintenance Inspections Table 7-10. Cylinder Inspection Checklist Engine Model Number: ___________________ Engine Serial Number: _________________ Total Time Engine Has Been in Service: _______________ Time Since Major Overhaul (TSMOH) __________________ Engine in Storage? ________ Date Inspection Performed: ________ Inspection Performed by:_____________________ Inspection Item Inspector Comments Complete the cylinder inspection according to the instructions in the Maintenance Manual;...
  • Page 154 Teledyne Continental Motors, Inc. Maintenance Inspections Table 7-10. Cylinder Inspection Checklist Engine Model Number: ___________________ Engine Serial Number: _________________ Total Time Engine Has Been in Service: _______________ Time Since Major Overhaul (TSMOH) __________________ Engine in Storage? ________ Date Inspection Performed: ________ Inspection Performed by:_____________________ Cylinder Borescope Findings (Section 7-3.7.3) Place a check mark in the column of any cylinder exhibiting the characteristics described in the left column.
  • Page 155 Teledyne Continental Motors, Inc. Maintenance Inspections Table 7-10. Cylinder Inspection Checklist Engine Model Number: ___________________ Engine Serial Number: _________________ Total Time Engine Has Been in Service: _______________ Time Since Major Overhaul (TSMOH) __________________ Engine in Storage? ________ Date Inspection Performed: ________ Inspection Performed by:_____________________ Condition Heavy bore wear Cylinder leaks...
  • Page 156 Teledyne Continental Motors, Inc. Maintenance Inspections This Page Intentionally Left Blank 7-64 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 157 8-13.1. Electrical Ground Check........................8-30 8-13.2. Enable Switch Check..........................8-32 8-13.3. Power Supply Check ..........................8-33 8-13.4. Boost Pump Relay Check ........................8-34 8-14. IOF-240-B FADEC Schematics ..................8-35 8-14.1. Connector Layout ..........................8-35 8-14.2. Schematic Symbol Legend ........................8-36 LIST OF TABLES Table 8-1.
  • Page 158 Teledyne Continental Motors, Inc. Troubleshooting LIST OF FIGURES Figure 8-1. Engine Data Interface....................8-10 Figure 8-2. Pin Connector Layout for J5 ................... 8-30 Figure 8-3. Pin Connector Layout for J6 ................... 8-31 Figure 8-4. P1 and P2 50-pin connectors................... 8-35 Figure 8-5.

  • Page 159: Chapter 8. Troubleshooting

    Teledyne Continental Motors, Inc. Troubleshooting 8-1. Overview The Troubleshooting Charts in this chapter discusses symptoms, probable causes, and appropriate corrective action to be taken. Troubleshooting procedures for specific systems and components are provided after the general troubleshooting chart. During fault isolation, mentally divide the engine into functions to identify the parts that contribute to the desired response.

  • Page 160: General Troubleshooting Chart

    Teledyne Continental Motors, Inc. Troubleshooting 8-2. General Troubleshooting Chart Although Teledyne Continental Motors, Inc. cannot anticipate every possible engine anomaly, the troubleshooting charts offers general guidelines to help expedite diagnosis. Abnormal Fuel Indication ...................... Go to Section 8-4. Abnormal FADEC HSA or EDI indication................Go to Section 8-6. Abnormal Oil Indication......................
  • Page 161 Teledyne Continental Motors, Inc. Troubleshooting Engine Runs Increase IDLE Check induction air Replace induction Rough AT IDLE speed filter air filter Correct IAW Check for induction system airframe Go to obstruction manufacturer’s Section instructions Correct IAW Check propeller for propeller imbalance manufacturer’s instructions...

  • Page 162: Induction System

    Teledyne Continental Motors, Inc. Troubleshooting 8-3. Induction System Low Manifold Pressure ......See “Engine Lacks Power or Maximum Manifold Pressure Reduced.” Loss of aircraft critical altitude....See “Engine Lacks Power or Maximum Manifold Pressure Reduced.” High oil temperature .................See “Engine Will Not Run At Idle Speed.” Engine Will Not Run at Idle Speed Inspect induction system for leaks...

  • Page 163: Figure 2-13. Fuel Injection System

    Teledyne Continental Motors, Inc. Troubleshooting 8-4. Fuel Injection System WARNING Fuel injector repairs, including disassembly and internal cleaning, are not authorized. Replace faulty fuel injectors. Engine Will Not Start-No Fuel Pressure Indication Check fuel level in tank. Correct input conditions and retry. Turn fuel selector valve ON.

  • Page 164: 8-4.1. Fuel Injector Operational Check

    Teledyne Continental Motors, Inc. Troubleshooting 8-4.1. Fuel Injector Operational Check IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 165 Teledyne Continental Motors, Inc. Teledyne Continental Motors, Inc. Troubleshooting Troubleshooting IOF-240 Series Engine Maintenance Manual IOF-240 Series Engine Maintenance Manual 31 August 2007 31 August 2007 Change 1 Change 1...

  • Page 166: Charging System

    Teledyne Continental Motors, Inc. Troubleshooting 8-5. Charging System Refer to the Aircraft Maintenance Manual for applicable Charging System troubleshooting. 8-6. FADEC System 8-6.1. FADEC Level I Diagnostic A FADEC System diagnostics check is required at the beginning of the 100-hour/Annual Inspection.
  • Page 167 Teledyne Continental Motors, Inc. Troubleshooting 2. Power-up the computer. WARNING Before engine start, ensure all personnel are standing clear of the propeller arc rotational radius to avoid injury. 3. Master Power Switch ........ON 4. BPMS............AUTO 5. Launch the FADEC Level I Diagnostic application and follow the onscreen prompts. RESULT: The Diagnostic software guides the user through the engine start sequence, specific engine RPM settings, and the ECU power and channel check.
  • Page 168 Teledyne Continental Motors, Inc. Troubleshooting 8-6.1.1. FADEC Power On Fault Isolation 8-12 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...

  • Page 169: 8-6.2. Fadec System Fault Isolation

    Teledyne Continental Motors, Inc. Troubleshooting 8-6.2. FADEC System Fault Isolation When troubleshooting the FADEC System, visualize the system as being composed of the following four major sub-systems: • Electronic Control Units (ECUs) • The ECUs are the FADEC System controllers; each ECU controls two cylinders. •...

  • Page 170: 8-6.3. Electronic Control Unit (Ecu)

    Teledyne Continental Motors, Inc. Troubleshooting 8-6.3. Electronic Control Unit (ECU) 8-14 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...

  • Page 171: 8-6.4. Speed Sensor Assembly

    Teledyne Continental Motors, Inc. Troubleshooting 8-6.4. Speed Sensor Assembly IOF-240 Series Engine Maintenance Manual 8-15 31 August 2007 Change 1...

  • Page 172: 8-6.5. Manifold Air Pressure Sensor

    Teledyne Continental Motors, Inc. Troubleshooting 8-6.5. Manifold Air Pressure Sensor Two self-contained, thread mounted sensors mounted in the throttle body or induction manifold, depending upon engine model report manifold pressure to FADEC. Sensor field repair is not authorized. The engine low voltage harness uses removable, circular connectors to interface with the Manifold Air Pressure Sensors.

  • Page 173: 8-6.6. Fuel Pressure Sensor

    Teledyne Continental Motors, Inc. Troubleshooting 8-6.6. Fuel Pressure Sensor The FADEC System uses two sensors for measuring the engine’s fuel pressure. The sensors are self-contained, non-serviceable units, thread-mounted into the fuel distribution block. The low voltage harness uses removable, circular connectors to interface with the fuel pressure sensors.

  • Page 174: 8-6.7. Manifold Air Temperature Sensor

    Teledyne Continental Motors, Inc. Troubleshooting 8-6.7. Manifold Air Temperature Sensor Two Manifold Air Temperature (MAT) sensors, hard-wired to the engine low voltage harness, are secured in the throttle body with compression fittings. The sensing element is a thermistor, which changes resistance with temperature in a linear, repeatable manner. 8-18 IOF-240 Series Engine Maintenance Manual Change 1...

  • Page 175: 8-6.8. Cylinder Head Temperature (Cht) Sensor

    Teledyne Continental Motors, Inc. Troubleshooting 8-6.8. Cylinder Head Temperature (CHT) Sensor The ECU monitors independent Cylinder Head Temperature (CHT) Sensor for each cylinder. The CHT Sensor uses a bayonet style mounting system wherein an adapter is threaded into the cylinder head and a spring-loaded locking ring on the sensor secures the attachment.

  • Page 176: 8-6.9. Exhaust Gas Temperature (Egt) Sensor

    Teledyne Continental Motors, Inc. Troubleshooting 8-6.9. Exhaust Gas Temperature (EGT) Sensor The ECU monitors independent Exhaust Gas Temperature (EGT) Sensors for each cylinder. EGT sensing elements are K-type thermocouples. Two conductors made of dissimilar metals are fused to form the sensing element which produces a small voltage proportional to the temperature.

  • Page 177: 8-6.10. Engine Diagnostic Interface

    Teledyne Continental Motors, Inc. Troubleshooting 8-6.10. Engine Diagnostic Interface IOF-240 Series Engine Maintenance Manual 8-21 31 August 2007 Change 1...

  • Page 178: Starter System

    Teledyne Continental Motors, Inc. Troubleshooting 8-7. Starter System Engine Will Not Start When Ignition Switch Engaged. Check Master Power and Repair wiring IAW Ignition Switch wiring airframe Starter motor turns? according to airframe manufacturer’s manufacturer’s instructions instructions. Engine turns with starter? Replace starter NOT OK Replace starter...

  • Page 179: Ignition System

    Teledyne Continental Motors, Inc. Troubleshooting 8-8. Ignition System Excessive RPM drop ....................See “Engine Runs Rough.” Poor acceleration....................See “Engine Runs Rough.” Continuous fouling of spark plugs........Refer to “Excessive Oil Consumption” in Section 8-9. Engine Runs Rough Perform FADEC Level I Refer to Section 8-6.2 Diagnostic (Sect.

  • Page 180: 8-8.1. Ignition Harness And Spark Plug Diagnostics

    Teledyne Continental Motors, Inc. Troubleshooting 8-8.1. Ignition Harness and Spark Plug Diagnostics Abnormal RPM or Performance Drop 1. Shut off fuel selector valve. 2. Remove spark plugs from all cylinders. 3. Remove clamps and cable ties from high voltage harness closest to cylinder.

  • Page 181: Lubrication System

    Teledyne Continental Motors, Inc. Troubleshooting 8-9. Lubrication System Excessive Oil Consumption Visually inspect engine and Correct source of leak (replace nacelle for evidence of leaks. seal, tighten fittings). Check engine log book for service and consumption history. Service Monitor oil consumption closely engine oil sump to proper level No further action required.
  • Page 182 Teledyne Continental Motors, Inc. Troubleshooting 8-26 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...

  • Page 183: Engine Cylinders

    Teledyne Continental Motors, Inc. Troubleshooting 8-10. Engine Cylinders Additional cylinder inspection information is contained in Chapter 7: • Cylinder Differential Pressure Test • Summary of Dynamic and Static Seal Checks and Corrective Action • Cylinder Borescope Inspection • “Cylinder Repair vs. Replacement Guidelines” section in Chapter 9, Overhaul Inspection and Repair in the Engine Overhaul Manual (OH-22).

  • Page 184: Crankcase Or Accessory Case

    Teledyne Continental Motors, Inc. Troubleshooting 8-11. Crankcase or Accessory Case 8-28 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...

  • Page 185: 8-11.1. Excessive Crankcase Pressure

    Teledyne Continental Motors, Inc. Troubleshooting 8-11.1. Excessive Crankcase Pressure 8-12. Exhaust System The IOF-240 Exhaust System is an airframe component. Refer to the airframe manufacturer’s troubleshooting procedures. IOF-240 Series Engine Maintenance Manual 8-29 31 August 2007 Change 1...
  • Page 186 Teledyne Continental Motors, Inc. Troubleshooting 8-13. Cabin Harness Functional Check The cabin harness functional check consists of the procedures listed below and presented in detail in subsequent subsections. Perform all of the checks and correct discrepancies prior to engine installation. •...
  • Page 187 Teledyne Continental Motors, Inc. Troubleshooting Figure 8-3. Pin Connector Layout for J6 Primary Power (Power A) Ground Secondary Power (Power B) Boost Request Ground RS485A Primary Power (Power A) RS485B Ground Fault 3 Fault 4 Primary Power (Power A) Enable 3 Ground Enable 4 *NC –...
  • Page 188 Teledyne Continental Motors, Inc. Troubleshooting 8-13.2. Enable Switch Check Refer to the plug layout diagrams in to check the Enable Switch as follows: Procedure 1. Ignition Switch..........L 2. Use a DVM to measure the resistance for the pin numbers listed in reference to aircraft ground.
  • Page 189 Teledyne Continental Motors, Inc. Troubleshooting 8-13.3. Power Supply Check Procedure 1. Master Power Switch ........ON 2. FADEC Primary Power circuit breakers..IN 3. HSA/SSA Primary Power circuit breakers ..IN 4. FADEC Secondary Power Switch ....OFF 5. FADEC Primary Power Switch ....ON 6.
  • Page 190 Teledyne Continental Motors, Inc. Troubleshooting 8-13.4. Boost Pump Relay Check Procedure WARNING Conduct this check in a well-ventilated area with no fuel present to prevent ignition and combustion. 1. Fuel Selector Valve....OFF(CLOSED) 2. Master Power Switch ........ON 3. BPMS............AUTO 4.
  • Page 191 Teledyne Continental Motors, Inc. Troubleshooting 8-14. IOF-240-B FADEC Schematics The IOF-240-B FADEC schematic diagrams are included for FADEC troubleshooting. Refer to the airframe schematics for the cabin harness schematics. 8-14.1. Connector Layout 10 11 12 13 14 15 16 17...
  • Page 192 Teledyne Continental Motors, Inc. Troubleshooting 8-14.2. Schematic Symbol Legend 8-36 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 193 Teledyne Continental Motors, Inc. Troubleshooting Teledyne Continental Motors, Inc. Figure 8-7. IOF-240 Electronic Control Unit #1 IOF-240 Series Engine Maintenance Manual 8-37 31 August 2007 Change 1...
  • Page 194 Teledyne Continental Motors, Inc. Troubleshooting Teledyne Continental Motors, Inc. Figure 8-8. IOF-240 Electronic Control Unit #2 8-38 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 195 Teledyne Continental Motors, Inc. Troubleshooting Teledyne Continental Motors, Inc. Figure 8-9. IOF-240 Fuel Control IOF-240 Series Engine Maintenance Manual 8-39 31 August 2007 Change 1...
  • Page 196 Teledyne Continental Motors, Inc. Troubleshooting Teledyne Continental Motors, Inc. Figure 8-10. IOF-240 Pressure Sensors 8-40 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 197 Teledyne Continental Motors, Inc. Troubleshooting Manifold Temperature #1 ECU1_TMAN_A_SIG RED AWG22 RED AWG22 P1-26 ECU1_TMAN_A_RTN WHITE AWG22 WHITE AWG22 P1-50 ECU2_TMAN_A_SIG BLUE AWG22 P2-26 ECU2_TMAN_A_RTN WHITE AWG22 P2-50 Manifold Temperature #2 BLUE AWG22 ECU1_TMAN_B_SIG RED AWG22 P1-32 ECU1_TMAN_B_RTN WHITE AWG22 WHITE AWG22 P1-43 ECU2_TMAN_A_SIG...
  • Page 198 Teledyne Continental Motors, Inc. Troubleshooting Teledyne Continental Motors, Inc. Figure 8-12. IOF-240 Speed Sensor Assembly 8-42 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 199 Teledyne Continental Motors, Inc. Troubleshooting ECU1_POWER_A POWER_A WHT AWG18 P1-1 WHT/BLU AWG18 P1-34 POWER_B ECU2_POWER_B WHT AWG18 P2-2 WHT/BLU AWG18 P2-35 ECU1_RS485_A RS485_A WHT AWG22 P1-38 RS485_B ECU1_RS485_B WHT/BLU AWG22 P1-22 ECU1_FAULT_1 FAULT_1 WHT AWG22 P1-20 ECU1_FAULT_2 FAULT_2 WHT/BLU AWG22 P1-36 ECU1_ENABLE_1 WHT AWG22...
  • Page 200 Teledyne Continental Motors, Inc. Troubleshooting This Page Intentionally Left Blank 8-44 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 201 Table 9-4. Approved Spark Plug List ..................9-14 LIST OF FIGURES Figure 9-1. Ground Straps and Connection Points ..............9-4 Figure 9-2. IOF-240-B Oil Servicing Points................9-9 Figure 9-3. Spark Plug Inspection Criteria ................9-13 Figure 9-4. Spark Plug Rotation Chart ..................9-14 Figure 9-5.

  • Page 202: Cleaning

    Teledyne Continental Motors, Inc. Maintenance and Adjustments 9-1. Cleaning Table 9-1. Cleaning Guidelines for Aircraft Engine Parts Part to Clean Cleaning Solvent* Guidelines Engine exterior and • Spray or brush cleaning solvent on the engine exterior or Mild detergent components component •...
  • Page 203 Teledyne Continental Motors, Inc. Maintenance and Adjustments Table 9-2. Cleaning Tips Don’ts Use a cloth to wipe off solvent or use compressed Except when removing carbon deposits and gum air to blow off the solvent. (oil varnish), do not use alkaline (caustic) cleaning solutions for external engine cleaning.

  • Page 204: 9-1.1. Ground Strap Connection Point Cleaning

    Teledyne Continental Motors, Inc. Maintenance and Adjustments 9-1.1. Ground Strap Connection Point Cleaning The integrity of electrical ground is important to the ability of the FADEC System to tolerate electromagnetic interference and lightning transients. Two ground straps, shown in Figure 9-1, are installed on the Electronic Control Unit (ECU). Ground straps are also installed between the engine and airframe.

  • Page 205: 9-1.2. Cleaning Aluminum Alloy Parts

    Teledyne Continental Motors, Inc. Maintenance and Adjustments 9-1.2. Cleaning Aluminum Alloy Parts Degrease an aluminum alloy part by spraying or brushing it with mineral spirits. Soak heavily soiled parts for 15 minutes in mineral spirits. To remove carbon and gum deposits, perform the following procedure: Procedure 1.

  • Page 206: Protective Coatings

    Teledyne Continental Motors, Inc. Maintenance and Adjustments 9-2. Protective Coatings Protective or anti-corrosive coatings include the following: • Alodine • Zinc chromate primer • Enamel paint • 50 weight aviation engine oil Apply a protective coating after any machining or repairing aluminum surfaces with an aluminum conversion coating.

  • Page 207: 9-2.3. Paint

    Teledyne Continental Motors, Inc. Maintenance and Adjustments 9-2.3. Paint When applying paint to external aluminum, ferrous, and magnesium parts, perform the following procedure: Procedure 1. Mask all connection joints and mating surfaces. 2. Follow instructions in Table 9-3 below to prepare and paint engine parts. Apply zinc chromate primer and enamel paint to the respective types of external parts.

  • Page 208: Engine Oil Servicing

    If any oil is spilled on the engine and nacelle during filling, clean up the oil spills on the engine and nacelle. Follow precautions in wiping up oil spills. IOF-240-B Oil Capacity 6 quarts (5.67 liters) Oil Type When to Use...

  • Page 209: 9-3.1. Check And Replenish Engine Oil Level

    Valve Assembly Oil Cooler Oil Cooler Adapter Adapter Oil Filter Adapter Oil Filter Adapter Oil Filter Oil Filter Oil Sump Oil Sump Drain Plug Drain Plug Figure 9-2. IOF-240-B Oil Servicing Points IOF-240 Series Engine Maintenance Manual 29 November 2006...

  • Page 210: 9-3.2. Oil Change

    Teledyne Continental Motors, Inc. Maintenance and Adjustments 9-3.2. Oil Change Perform an oil change within 30 minutes of engine shutdown (to obtain a useful oil sample). Oil changes are recommended at the intervals in “Engine Inspection and Maintenance” in Chapter 7, “Maintenance Inspections.” NOTE: More frequent oil changes are recommended under extreme usage or weather conditions.

  • Page 211: 9-3.3. Check For Oil Leaks

    Teledyne Continental Motors, Inc. Maintenance and Adjustments 6. Check for oil leaks as directed in section 9-3.3 “Check for Oil Leaks.” 9-3.3. Check for Oil Leaks Procedure WARNING Keep the engine compartment, nacelle, and fuselage adjacent to the nacelle clean to enable detection of any oil leaks before flight.
  • Page 212 Teledyne Continental Motors, Inc. Maintenance and Adjustments 9-3.5. Oil Sample Collection Generally, the oil sample can be collected at either of the following times: • During the oil change procedure, before any new oil is added • Between oil changes The oil sample must be taken after the engine has been operated during a normal flight profile (including normal cruise and maximum power settings) for at least 30 minutes at normal engine operating temperature (see “Engine Specifications and Operating...

  • Page 213: Ignition System Maintenance

    Teledyne Continental Motors, Inc. Maintenance and Adjustments 9-4. Ignition System Maintenance 9-4.1. Spark Plug Replacement Procedure 1. Remove the ignition harness leads from all spark plugs. 2. Remove the spark plug from the top and bottom of each cylinder. Mark each plug’s installed location during removal.
  • Page 214 Teledyne Continental Motors, Inc. Maintenance and Adjustments Table 9-4. Approved Spark Plug List Manufacturer Part Number TCM Part Number Barrel Size GAP CHAMPION RHM38E 630049 3/4-20 .016” - .021” REM38E 628325 5/8”-24 .016” - .021” AUTOLITE by UNISON UREM38E 655902 5/8”-24 .016”...
  • Page 215 Teledyne Continental Motors, Inc. Maintenance and Adjustments 10. Thread each spark plug by hand into the engine cylinder head within one to two threads of the gasket. If the spark plug cannot be screwed in this far, clean the cylinder or spark plug threads. 11.
  • Page 216 Teledyne Continental Motors, Inc. Maintenance and Adjustments Spark Tower Identification Spark Tower Identification Figure 9-6. Ignition Lead Wire Connections to ECUs B-NUT B-NUT COAT COAT FERRULE FERRULE Figure 9-7. Coating Insulating Sleeve: MS 122 DF Spray on Ignition Lead Wire 5.

  • Page 217: Adjustment Procedures

    Teledyne Continental Motors, Inc. Maintenance and Adjustments 9-5. Adjustment Procedures Adjustment procedures include the following sections in this chapter: • Throttle Position Switch Adjustment • Fuel System Adjustment WARNING Make all adjustments with the engine stopped and the Ignition, Master Power, and Primary/Secondary FADEC Power Switches in the OFF position.
  • Page 218 Teledyne Continental Motors, Inc. Maintenance and Adjustments 2. Insert a broad tip common screwdriver into the TPS adjustment slot to set the TPS position farthest away from the actuator cam. 3. Open the throttle valve to the WIDE OPEN position. Confirm the Wide-Open Throttle Stop Screw contacts the Wide-Open Throttle Stop Pin.
  • Page 219 36.00 35.75 35.50 35.25 35.00 34.75 34.50 34.25 34.00 33.75 33.50 33.25 33.00 32.75 32.50 32.25 32.00 31.75 31.50 31.25 31.00 30.75 30.50 30.25 30.00 29.75 29.50 29.25 29.00 28.75 28.50 28.25 28.00 1975 2000 2025 2050 2075 2100 2125 2150 2175 2200 2225 2250 2275 2300 2325 2350 2375 2400 2425 2450 2475 2500 2525 Engine Speed (RPM)
  • Page 220 4. Repeat steps 1-3 until the idle fuel pump pressure reading is 17.5 psi ±2 psi at 850 RPM with the boost pump OFF. Figure 9-10. IOF-240-B Fuel Pump NOTE: Set IDLE RPM fuel pump pressure to the minimum limit to provide slight fuel enrichment during part throttle operations.
  • Page 221 Teledyne Continental Motors, Inc. Maintenance and Adjustments 5. After final adjustment is accomplished, torque the jam nut according to Appendix B specification. Check reading again as in step 3 to ensure tightening the lock nut did not affect relief valve setting. NOTE: Operate the engine at 1500 - 1800 RPM for 15 seconds after each adjustment.
  • Page 222 Teledyne Continental Motors, Inc. Maintenance and Adjustments 16. Ignition Switch.............BOTH RESULT: Check the fuel system fittings for leaks while the boost pump is operating. If leaks are detected, recheck and torque leaking connections. If leaks persist, remove and inspect fittings, replace faulty fittings. 17.
  • Page 223 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Chapter 10. NON-OVERHAUL REMOVAL AND REPLACEMENT CONTENTS Chapter 10. Non-Overhaul Removal and Replacement............10-1 10-1. Parts Replacement ......................10-5 10-2. Fuel Pump Replacement....................10-7 10-2.1. Fuel Pump Removal ..........................10-7 10-2.2. Fuel Pump Installation........................... 10-8 10-3.
  • Page 224 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-11. FADEC Component Removal and Installation ............10-56 10-11.1. ECU or SSA Connector Installation ....................10-56 10-11.2. Ground Strap Installation........................10-59 10-11.3. Electronic Control Unit (ECU) Removal................... 10-60 10-11.4. Electronic Control Unit (ECU) Installation ..................10-61 10-11.5.
  • Page 225 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement LIST OF FIGURES Figure 10-1. Fuel Pump Drive Coupling ................... 10-7 Figure 10-2. Fuel Pump with fittings..................10-8 Figure 10-3. IOF-240 Starter ..................... 10-9 Figure 10-4. IOF-240 Direct Drive Alternator ................ 10-12 Figure 10-5.
  • Page 226 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Figure 10-48. Engine Low Voltage Harness 50-Pin Connector ..........10-57 Figure 10-49. EMI Gasket and Seal (where arrow is) in Position on ECU ......10-58 Figure 10-50. SSA Signal Conditioner EMI Gasket and Seal in Position....... 10-58 Figure 10-51.
  • Page 227 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-1. Parts Replacement The procedures in this section apply to instances exclusive of overhaul when parts can be repaired or replaced, on condition. The Non-Overhaul Parts Replacement Reference (Table 10-3) in this chapter indicates items that must be replaced and respective procedural references Table 10-2, the Parts Repair Reference Table, indicates the repairable items and respective procedural references.
  • Page 228 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Table 10-3. Non-Overhaul Parts Replacement Reference Replaceable Item Reference Individual engine cylinder (not “Engine Cylinder Maintenance” in Section 10-6. overhaul – cylinder inspection and repair) Hydraulic tappets Steps within “Engine Cylinder Maintenance” in this section. Fuel injectors (See also “Parts “Fuel Injector Removal”...

  • Page 229: Fuel Pump Replacement

    Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-2. Fuel Pump Replacement 10-2.1. Fuel Pump Removal Procedure WARNING If engine electrical power is not disconnected, a faulty ignition circuit could allow the engine to start and the propeller to rotate. Do not stand or place equipment within the arc of the propeller.
  • Page 230 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-2.2. Fuel Pump Installation Procedure WARNING If engine electrical power is not disconnected, a faulty ignition circuit could allow the engine to start and the propeller to rotate. Do not stand or place equipment within the arc of the propeller.
  • Page 231 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-3. Starter Replacement 10-3.1. Starter Removal Procedure WARNING Turn the ignition switch OFF and disconnect engine electrical power before commencing maintenance. Do not stand or place equipment within the arc of the propeller. 1.
  • Page 232 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-3.2. Starter Installation Procedure WARNING Turn the ignition switch OFF and disconnect engine electrical power before commencing maintenance. Do not stand or place equipment within the arc of the propeller. 1. Perform a “Gear Tooth Inspection” on the face gear according to instructions in Section 9.3.1.
  • Page 233 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Lifting Eye Lifting Eye Figure 10-3 repeated for reference IOF-240 Series Engine Maintenance Manual 10-11 31 August 2007 Change 1...
  • Page 234 Replace the alternator needs if it fails to deliver the correct voltage and amperage to the aircraft electrical system. IOF-240-B engines are equipped with either a direct drive rear mounted alternator or a front-mounted, belt driven alternator. Follow the procedure that matches your engine configuration.
  • Page 235 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 9. Remove the spacer (11). 10. Using a blind oil seal puller, remove and discard the oil seal (9). 11. Remove and discard the O-ring (10). 12. Return the alternator core for credit. 10-4.2.
  • Page 236 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 5. Verify the alternator pilot enters the accessory case pilot bore squarely. Do not force the alternator pilot to fit into the pilot bore. 6. Secure the alternator with washers (2) and new lock nuts (3); torque the nuts (3) per Appendix B.
  • Page 237 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement ALTERNATOR BRACKET WASHER WASHER WASHER SPACER SPLIT SHEAVE PIVOT BOLT ALTERNATOR ADJUSTING BRACKET DRIVE SHEAVE BOLT WASHER LOCKWASHER ALTERNATOR ALTERNATOR DRIVE BELT SCREW Figure 10-5. Front View of Belt-Driven Alternator MOUNTING BRACKET WASHERS BOLT LOCK WASHER...
  • Page 238 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-5. Lubrication System Repair 10-5.1. Oil Pump or Tach Drive Repair and Replacement Procedure WARNING If engine electrical power is not disconnected, a faulty ignition circuit could allow the engine to start and the propeller to rotate.
  • Page 239 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-5.2. Oil Sump and Oil Suction Tube Repair and Replacement Procedure WARNING If engine electrical power is not disconnected, a faulty ignition circuit could allow the engine to start and the propeller to rotate.
  • Page 240 Non-Overhaul Removal and Replacement 10-5.3. Oil Cooler Removal and Replacement The IOF-240-B may be equipped with either an oil cooler adapter or a combination oil cooler/oil filter adapter. Follow the appropriate removal and installation instructions based on the engine configuration.
  • Page 241 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-5.3.2. Oil Cooler Adapter Installation Procedure 1. Install the oil cooler adapter with a new gasket (1) on the left crankcase half at through-bolt 32L with plain washers (7), new lock washers (8), plain nuts (9), washers (10), and nuts (11).
  • Page 242 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-5.3.3. Oil Cooler/Filter Adapter Removal Procedure 1. Drain the engine oil according to instructions in Chapter 9, “Engine Oil Servicing.” 2. Refer to Figure 10-9; cut, remove and discard lock wire (12). 3.
  • Page 243 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-5.4. Oil Cooler/Filter Adapter Installation Procedure 1. Install the oil cooler/filter adapter with a new gasket (1) on the left crankcase half at through-bolt 32L with plain washers (7), new lock washers (8), plain nuts (9), washers (10), and nuts (11).
  • Page 244 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-5.5. Oil Temperature Control Valve Inspection and Replacement Procedure 1. Disconnect electrical power to the engine and verify Ignition Switch is turned OFF. WARNING If engine electrical power is not disconnected, a faulty ignition circuit could allow the engine to start and the propeller to rotate.
  • Page 245 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-5.6. Lubrication Component Service Limits The overhaul limits for lubrication components are shown in Table 10-5. Item numbers in the first column correspond to the item numbers in Figure 10-11. Table 10-5. Lubrication System Fits & Limits Item No.
  • Page 246 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-6. Engine Cylinder Maintenance These procedures apply only to instances where an individual engine cylinder is to be replaced or serviced as a maintenance item and not for engine overhaul. Refer to Chapter 15, Overhaul Inspection and Repair in OH-22 for instructions on replacing and/or repairing multiple engine cylinders.
  • Page 247 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Figure 10-12. IOF-240 Cylinders Packing Outer Spring Rocker Cover Baffle Cylinder Inner Retainer Plain Washer Spring Helical Coil Rotocoil Lock Washer Flanged Nut Exhaust Guide Valve Retainer Key Screw Flanged Nut Intake Guide Fitting Gasket Hydraulic Tappet...
  • Page 248 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 14. Remove the rocker arms (20) and shafts (24) from the cylinder studs. 15. Inspect the valve rocker shafts (24), thrust washers (23), and retainers (25). 16. Withdraw all of the push rods (40) from their respective housings (35). 17.
  • Page 249 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 26. Refer to Chapters 7 though 9 of the Overhaul Manual (OH-22) for instructions on cylinder and valve train disassembly, cleaning, inspection and repair. a. Clean the piston (53) as directed in the section “Piston Cleaning” in this section. CAUTION: Do not use automotive-type piston scrapers to clean piston ring lands.
  • Page 250 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-6.2. Piston Cleaning Procedure 1. Soak the cylinder and piston in mineral spirits. 2. If soft or hard carbon deposits do not yield to solvent and deposits remain, install a tight fitting skirt protector and dry blast the piston heads with soft grit or employ the vapor grit method (to clean the piston top).
  • Page 251 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-6.3. Engine Cylinder Dimensional Inspection NOTE: Refer to 10-6.3.1, Cylinder Service Limits for all dimensional limits: Procedure 1. Inspect cylinder bore dimensions according to the Tables and Figures in “Cylinder Service Limits”. Grind any honed cylinder bore that does not conform to the standard size dimensions to the next oversize dimension up to 0.15 inches oversize maximum.
  • Page 252 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-6.3.1. Cylinder Service Limits Refer to the Service Limits in Table 10-6 and corresponding Figure 10-14 and Figure 10- 15. Clean and dry the parts thoroughly according to the “Cleaning” instructions in section 9-1.
  • Page 253 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Table 10-6. Engine Cylinder Fits & Limits Item Description Service Limits (inches) Figure Maximum 10-14 Piston, graphite coated (bottom of skirt) in cylinder diameter Piston, non graphite coated (bottom of skirt) in cylinder diameter 0.0120L Top piston ring in groove side clearance 0.0040L...
  • Page 255 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Figure 10-15. IOF-240 Cylinder Dimensions Table 10-7. IOF-240 Series Cylinder Diameter Dimensions “D” Diameter “D” Diameter “X” Diameter “X” Diameter “Y” Diameter New Size Service Limits Service Limits MIN. MAX. MIN. MAX. MIN.
  • Page 256 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Figure 10-16. Intake Valve Seat Dimensions Figure 10-17. Exhaust Valve Seat Dimensions 10-34 IOF-240 Series Engine Maintenance Manual 29 November 2006...
  • Page 257 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Figure 10-18. Intake Valve Face Dimensions 10-6.4. Engine Cylinder Installation Replace worn or out of tolerance components based on the following criteria: • Only allow parts that meet the service limits to remain in service. •...
  • Page 258 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Procedure 1. Disconnect engine electrical power and turn the Ignition Switch to the OFF position. 2. Refer to Figure 10-12; install a new cylinder base packing (47) lubricated with clean 50-weight aviation engine oil. (Verify the cylinder base packing is free of cracks and deformities).
  • Page 259 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10. Remove the ring compressor and push the cylinder assembly against the crankcase cylinder deck with the stud holes aligned. 11. While supporting the cylinder, install, but do not torque, the cylinder flange nuts (45 and 46).
  • Page 260 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 21. Install the retainer (Figure 10-12), (25), tab washer (26) and nut (27). Torque the nut (27) per Appendix B. Bend the tab on the tab washers (26) up against the flat of the nut (27) with a drift.
  • Page 261 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement WARNING Failure to torque through bolt nuts on both sides of the engine may result in a loss of main bearing crush, main bearing shift, crankshaft fracture, and engine failure. Sequence indicated is for single cylinder torque ONLY. If more than one cylinder, refer to the torque sequence indicated in the Overhaul Manual (OH-22).
  • Page 262 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement CAUTION: Do not scratch, mar, or damage the crankshaft or crankcase while removing the crankshaft nose oil seal. 6. Remove the screws (Figure 10-22) from the crankcase nose oil seal retainer plate on the front of the crankcase.
  • Page 263 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Figure 10-23. Crankshaft Nose Oil Seal Parts 5. Place the spring around the crankshaft in the helix area. 6. Hook the two spring ends to one another. 7. Apply Shell Alvania No. 2 Grease to the lip of the new seal and the propeller flange. 8.
  • Page 264 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-8. Crankcase Repair Cracks occur on the cast aluminum crankcases for various reasons (e.g., improper crankcase assembly or maintenance). WARNING Do not allow a cracked crankcase that exhibits the damage described below to remain in service. Engine failure is imminent if the conditions persist.
  • Page 265 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Figure 10-24. Crankcase Critical (Non-Shaded) and Non-Critical (Shaded) Areas 10-8.2. Crankcase Leak Correction Replace leaking crankcase gaskets. 10-8.3. Crankcase Breather Replacement Procedure 1. Remove leaking or damaged crankcase breather tubes using a slide hammer with hook fixture.
  • Page 266 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-10. Engine Low Voltage Harness Lead Wire Repair and Sensor Replacement The engine low voltage harness is made up a several types of lead wires and sensors which include Exhaust Gas Temperature (EGT) Sensors, the Cylinder Head Temperature (CHT) Sensors and the Manifold Air Temperature (MAT) Sensors.
  • Page 267 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-10.1. Engine Low Voltage Harness Connector Repair CAUTION: Field repair of the engine low voltage harness connectors are prohibited. These connectors are assembled with special tools and are potted with RTV and sealed with high temperature adhesives.
  • Page 268 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-10.2. EGT Sensor and Lead Wire Replacement Equipment Required: • Crimp tool • EGT Sensor/Wire Splice Kit • Utility or razor knife • Scissors • A variable intensity heat gun with a small tip Prerequisites: Before proceeding, review Sections 10-1, “Parts Replacement”...
  • Page 269 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 6. Mark the braided outer shield of the lead wire 1-5/8” from the cut end. 7. Carefully split the jacket lengthwise, with a utility knife, beginning at the 1-5/8-inch mark and continuing to the cut end as shown in Figure 10-26. Use care to avoid cutting or nicking the insulation beneath the jacket.
  • Page 270 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 11. Fold the split portion of the jacket back and use small shears to trim the jacket at the mark to the outside diameter of the lead wire stalk. 12. Strip the outer insulation to expose two insulated wires, one red and one yellow. Carefully inspect each wire for nicks or cuts.
  • Page 271 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement reveal other damage. If there is no continuity between the referenced pins, verify connector pin references are correct and repeat the measurement. Repairing a single segment if the circuit remains open will not resolve a wiring malfunction. 19.
  • Page 272 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Figure 10-34. Chromel wires with pins WARNING Hot air guns are capable of producing levels of heat sufficient to ignite combustible materials found in the aircraft engine nacelle. Thoroughly clean the work area of oil or grease residue.
  • Page 273 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Figure 10-36. Completed EGT Sensor Lead Wire Splice 32. Inspect the continuity of the sensor lead wires. If the inspection reveals poor continuity readings and/or if any wire appears damaged, repair wire as described in this section.
  • Page 274 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 6. Strip two and a half inches of the outer insulation from the cut end of the sensor lead wire. Use care to prevent cutting or nicking the braided shielding beneath the jacket. CAUTION: When stripping the shield, avoid nicking or cutting the insulation of the two conductors within the lead.
  • Page 275 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Figure 10-39. Smooth Braided Shield 11. With the shield prepared, untwist and straighten the two sensor leads until the wires are parallel. One wire has a colored stripe, called the “trace wire.” Figure 10-40.
  • Page 276 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 16. When replacing CHT sensors or fuel injection coils, label and tag the sensor (or coil) wires for the appropriate cylinder. WARNING Failure to install the CHT sensors or fuel injection coils on the correct cylinder will result in abnormal engine operation.
  • Page 277 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Figure 10-45. Completed Splice 22. Inspect the continuity of the sensor lead wires. If the inspection reveals poor continuity readings and/or if any wire appears damaged, isolate the faulty wiring and repeat the procedure. 23.
  • Page 278 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-11. FADEC Component Removal and Installation 10-11.1. ECU or SSA Connector Installation NOTE: If damage is evident to the EMI gaskets or environmental seals on the 50-pin ECU connectors or the 25-pin SSA connectors, replace the damaged gaskets or seals.
  • Page 279 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Header Shell Header Shell 25 Pin 25 Pin Connectors Connectors Figure 10-47. Typical SSA Conditioner 25-pin Connector 5. Apply Alodine to the connector header shell contact area in accordance with the Alodine manufacturer’s instructions. Allow the Alodine to dry. 6.
  • Page 280 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10. Check the resistance between the connector(s) header and the body of each of the Fuel Pressure and Manifold Air Pressure (MAP) Sensors. The resistance must be less than 0.5 ohms. 11. Apply a new seal to the connector header, adhesive side contacting the header. Trim any seal overhang flush with header shell.
  • Page 281 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 17. Safety wire the connector fasteners according to Appendix C. 18. Install a 120 lb. cable tie around the connector and associated safety tab to secure the tab as shown in Figure 10-51 and Figure 10-52. Trim and discard the excess from the cable tie length after tightening.
  • Page 282 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 5. Measure continuity between newly installed ground strap and engine with DVM. Resistance should not exceed 0.5 ohms. 6. Perform a “FADEC Level I Diagnostics” in Chapter 8, Troubleshooting. 10-11.3. Electronic Control Unit (ECU) Removal WARNING Do not attempt to open the ECU.
  • Page 283 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 8. Remove and discard the EMI gasket and environmental seal. 9. Place a protective cover over the mating end of the engine low voltage harness 50-pin connector. 10. Disconnect the grounding straps from the ECU. 11.
  • Page 284 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Ground Ground Points Points Figure 10-53. Grounding Points for the ECU CAUTION: Each ECU requires two independent ground straps mounted to the airframe with at least four inches separation between airframe mounting points. Choose airframe grounding points that will allow the shortest possible strap length.
  • Page 285 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-11.5. Signal Conditioner Removal CAUTION: Prior to handling the signal conditioner, the handler and the SSA signal conditioner are both to be grounded together to airframe ground prior to contacting the 25-pin connector headers. Keep the connector covers in place until the SSA signal conditioner is installed and ready to connect with the 25-pin engine low voltage harness.
  • Page 286 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 4. Cut, remove, and discard the cable ties from each 25-pin connector. 5. Remove the safety wire from the 25-pin connector securing screws. NOTE: The 25 pin connector fasteners are captive in the engine low voltage harness connector backshell and cannot be removed.
  • Page 287 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 8. Secure the signal conditioner with hold-down washers, new lock washers, and nuts. Torque the two nuts per Appendix B. CAUTION: If the resistance measured exceeds 0.5 ohms, the FADEC System has a ground problem. Correct the ground problem and recheck the resistance between the SSA sensor body and airframe electrical ground bus.
  • Page 288 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement To signal To signal To signal conditioner conditioner conditioner Figure 10-55. FADEC Timing Tool 6. Use a TDC locator to find TDC on Cyl #1. Mark the crankcase and propeller hub with a grease pencil to indicate the position. Remove the TDC locator. NOTE: Observe the FADEC Timing Tool LEDs;...
  • Page 289 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-11.8. Fuel Injector Solenoid Removal CAUTION: Avoid introducing contaminants into the fuel injectors. Work with clean hands, tools, and shop towels. Place protective caps on the fuel injectors anytime the fuel line is not connected. Fuel injector solenoid coils are designated for specific cylinders with labels on the Engine Low Voltage Harness near the coil.
  • Page 290 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-11.9. Fuel Injector Removal CAUTION: Avoid introducing contaminants into the fuel injectors. Work with clean hands, tools, and shop towels. Place protective caps on the fuel injectors anytime the fuel line is not connected. Never insert an object into either end of a fuel injector.
  • Page 291 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement NOTE: A Borroughs PN 6185 Fuel Injector Removal and Installation Tool may be used to remove the fuel injector. 7. Thread the injector body into the cylinder head. Use a deep well socket to torque the fuel injector according to Appendix B.
  • Page 292 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-11.12. Manifold Air Pressure Sensor Removal Two Manifold Air Pressure (MAP) sensors install near the throttle body. The MAP sensors thread into tapped bosses and attach to the engine low voltage harness using circular connectors.
  • Page 293 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement When properly mated and locked, the bayonet orientation pins are observable in the locking ring pin observation port as shown in Figure 10-59. Lock Lock Observation Observation Port Port Figure 10-59. Harness Connector and Sensor Orientation Keys 7.
  • Page 294 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 5. Use a DVM to measure the resistance between the connector body and airframe electrical ground bus; resistance must be less than 0.5 ohms. WARNING If the resistance exceeds 0.5 ohms, there is a ground problem. Correct the ground problem and recheck the resistance.
  • Page 295 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-11.16. Manifold Air Temperature (MAT) Sensor Removal Two Manifold Air Temperature (MAT) Sensors are mounted in the intake manifold, as shown in Figure 10-60. These thermistor-type sensors are installed using compression fittings which thread into tapped bosses on the throttle body or the intake manifold. The sensors are an integral part of the engine low voltage harness.
  • Page 296 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 4. Insert the MAT Sensor into the compression fitting. Thread the nut onto the fitting until finger tight. Adjust the probe depth so the mark made in step 2 is visible at the outboard edge of the compression nut.
  • Page 297 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-11.19. Exhaust Gas Temperature Sensor Installation Exhaust gas temperature (EGT) sensors are identified by a label on the Engine Low Voltage Harness for specific cylinders; the sensors are “hardwired” to the Engine Low Voltage Harness.
  • Page 298 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 7. If necessary, bend the sensor to avoid contact with surrounding components. All bends must be made in a smooth arc not to exceed 75° (a minimum of ½-inch radius). 8. Route, clamp, support, and protect the wires in the engine low voltage harness in a manner to prevent chafing, fretting, and wear of the lead wires.
  • Page 299 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-11.20. Cylinder Head Temperature (CHT) Sensor Removal Procedure 1. Locate the faulty CHT Sensor. Sensors leads are designated for specific locations and identified with a tag on the harness. 2. Remove the cable ties securing the CHT sensor lead to allow access to the connector. Discard removed cable ties.
  • Page 300 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-11.22. Five Lamp HSA Removal Procedure 1. Disconnect electrical power to the engine. 2. Remove instrument panel components, as required, to gain access to the rear of the HSA according to the airframe manufacturer’s instructions. 3.
  • Page 301 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 3. Connect the P9 and J10 connectors to the HSA. 4. Slide the HSA into its instrument panel mounting location. 5. While supporting the HSA, re-install the four HSA mounting screws. 6. Use cable ties to secure the cabin harness as required. 7.
  • Page 302 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 10-11.28. Throttle Position Switch Replacement Procedure 1. Refer to Figure 10-64; remove the screw and cushion clamp securing the throttle position switch wiring on the throttle body. Remove the two screws securing the throttle position switch to the throttle body.
  • Page 303 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 5. With the flaps of the scissor connectors as the pivot point, hold each scissor connectors and twist the insulators toward one another. Separate the three pairs of scissor connectors and discard the faulty throttle position switch. Figure 10-68.
  • Page 304 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement 7. Inspect the scissor connectors for serviceability. If the connectors are damaged: a. Cut the scissor connector from the wiring harness just behind the terminal. Figure 10-70. Remove Damaged Connector b. Strip 1/2” of shielding from the end of the wire. c.
  • Page 305 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement Figure 10-73. Assemble Scissor Connectors 10. Slide the heat shrink tubing over the assembled connectors, distributing the heat shrink tubing overlap evenly over the repaired connections. Figure 10-74. Position Heat Shrink Tubing 11.
  • Page 306 Teledyne Continental Motors, Inc. Non-Overhaul Removal and Replacement This Page Intentionally Left Blank 10-84 IOF-240 Series Engine Maintenance Manual Change 1 31 August 2007...
  • Page 307 Teledyne Continental Motors, Inc. Glossary Appendix A. GLOSSARY CONTENTS Appendix A. Glossary....................... A-1 A-1. Acronyms..........................A-2 A-2. Glossary ..........................A-5 IOF-240 Series Engine Maintenance and Overhaul Manual 29 November 2006...
  • Page 308 Glossary Teledyne Continental Motors, Inc. A-1. Acronyms The following acronyms are used throughout this publication. Acronym Definition A & P Airframe & Powerplant Airworthiness Directive Airplane Flight Manual Authorized Oversize Auxiliary Power Unit Authorized Undersize Brake Horsepower BP/BE Best Power/Best Economy BPMS Boost Pump Mode Switch BSOC...

  • Page 309: Appendix A - Glossary

    Teledyne Continental Motors, Inc. Glossary Acronym Definition Horsepower Health Status Annunciator In accordance with Instructions for Continued Airworthiness Manifold Air Pressure Manifold Air Temperature Methyl Ethyl Ketone Material Handling Specifications Main Journal Master Power Control Mandatory Service Bulletin SSA Position of Cylinder 1 Top Dead Center SSA Indication of Engine Speed Original Equipment Manufacturer NATO...
  • Page 310 Glossary Teledyne Continental Motors, Inc. Acronym Definition STANAG Standardization Agreement (STANAG) Speed Sensor Assembly Supplemental Type Certificate Time Between Overhauls Type Certificate Teledyne Continental Motors Top Dead Center Turbine Inlet Temperature Throttle Position Switch Technical Standard Order TSMOH Time Since Major Overhaul Wide Open Throttle IOF-240 Series Engine Maintenance and Overhaul Manual 29 November 2006...
  • Page 311 Teledyne Continental Motors, Inc. Glossary A-2. Glossary Term Definition Airworthiness FAA Tag 8130-3 that identifies a part or group of parts that has been deemed Approval Tag airworthy by an authorized FAA representative. Best Power/Best Cabin-mounted switch that allows for certain levels of pilot control of the Economy Switch calibration function.
  • Page 312 Glossary Teledyne Continental Motors, Inc. Term Definition Health Status A cockpit-mounted indicator panel used by the FADEC System to convey system Annunciator condition information to the pilot. Hydraulic Lock Condition where fluid accumulates in the induction system or the cylinder assembly.
  • Page 313 Teledyne Continental Motors, Inc. Glossary Term Definition Secondary Power Redundant electrical power source for the FADEC System. It may be an engine- Source driven device, such as an alternator or it may be a battery. Secondary Power The SPS battery charging circuit breaker. Source Charge Breaker Secondary Power...
  • Page 314 Glossary Teledyne Continental Motors, Inc. This Page Intentionally Left Blank IOF-240 Series Engine Maintenance and Overhaul Manual 29 November 2006...
  • Page 315 Teledyne Continental Motors, Inc. Torque Specifications Appendix B. TORQUE SPECIFICATIONS CONTENTS Appendix B. Torque Specifications ..................B-1 B-1. General Information......................B-2 B-1.1. Torque Tips...............................B-2 B-2. Cylinder Torque Procedure....................B-3 B-3. Torque Wrench and Extension Calculations............... B-4 LIST OF TABLES Table B-1. General Torque Specifications.................. B-6 Table B-2.
  • Page 316 Torque Specifications Teledyne Continental Motors, Inc. B-1. General Information Tables provided in this appendix list torque values for hardware on TCM’s aircraft engines. Refer to appropriate manufacturer’s accessory overhaul manuals for specified torque on accessories. Table B-1 is for bolts, nuts, screws, driving studs, and pipe plugs; Table B-2 is for fittings, Table B-3 is for hose fittings, and Table B-4 lists specific torque values.
  • Page 317 Teledyne Continental Motors, Inc. Torque Specifications WARNING The use of sealants or lubricants other than those specified by TCM on mating threads and between mating surfaces can cause incorrect torque application and subsequent engine damage or failure. B-2. Cylinder Torque Procedure Proper cylinder installation requires the bolts be torqued in multiple stages.
  • Page 318 Torque Specifications Teledyne Continental Motors, Inc. 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. Figure B-1. Torque Wrench Straight extensions, including wobble extensions up to 15 degrees, which extend the square drive length, do not alter the amount of force applied to the square drive enough to cause concern.

  • Page 319: Appendix B - Torque Specifications

    Teledyne Continental Motors, Inc. Torque Specifications Figure B-3. Extension increases applied torque Examples in Figure B-3 and Figure B-4 indicate the torque at the fastener may be increased or decreased by an extension. The two examples in Figure B-3 increase the force applied to the fastener but the position of the extension in Figure B-4 reduces the effective length of the handle.
  • Page 320 Torque Specifications Teledyne Continental Motors, Inc. Table B-1. General Torque Specifications Bolts, Nuts, Screws Size Torque Dec. In/Lb. Ft/Lb. #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...
  • Page 321 Teledyne Continental Motors, Inc. Torque Specifications Table B-2. Assembly Torque Specifications for Fittings Size Hose Assembly Tube O.D. Torque In / Lb .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...
  • Page 322 Torque Specifications Teledyne Continental Motors, Inc. Table B-4. Component Specific Torque Specifications Torque Value SIZE FASTENER IN./LB. FT/LB. MODELS AFFECTED Crankcase .25 - 28 Nut-Crankcase Flange 100-125 8.3-10.4 A, C, & E Series, O-200, O-300, O- 470(AR) IO-240, IOF-240 .31 - 24 Nut-Crankcase flange 240-280 20.0-23.3...
  • Page 323 Teledyne Continental Motors, Inc. Torque Specifications Table B-4. Component Specific Torque Specifications Torque Value SIZE FASTENER IN./LB. FT/LB. MODELS AFFECTED .25-28 Ejector - Fuel Pump Vapor 90-100 7.5-8.3 All fuel injected models (AR) Separator Cover .25-48 Nut-Aneroid stem jam 25-30 2.1-2.5 All fuel injected models, as required .31-24...
  • Page 324 Torque Specifications Teledyne Continental Motors, Inc. Table B-4. Component Specific Torque Specifications Torque Value SIZE FASTENER IN./LB. FT/LB. MODELS AFFECTED Torque to low limit. If cotter pin will not enter, increase torque gradually up to high limit only. If cotter pin will not enter in this range, replace nut and repeat. IN NO CASE SHALL NUTS BE TIGHTENED BELOW THE MINIMUM TORQUE LIMIT OR OVER THE MAXIMUM TORQUE LIMIT.
  • Page 325 Teledyne Continental Motors, Inc. Torque Specifications Table B-5. Specific Torque Values for Non-lubricated Hardware Torque Location and Hardware Model Thread Qty. In-lbs Ft-lbs Oil pressure relief valve Housing 1.12-18 240-260 20.0-21.7 Oil temperature control ---- 1.00-14 440-460 36.7-38.3 valve Fuel nozzle to cylinder Nozzle 0.125-27 55-65...
  • Page 326 Torque Specifications Teledyne Continental Motors, Inc. This Page Intentionally Left Blank B-12 IOF-240 Series Engine Maintenance Manual 29 November 2006...
  • Page 327 Teledyne Continental Motors, Inc. Standard Practices Appendix C. STANDARD PRACTICES CONTENTS Appendix C. Standard Practices ..................... C-1 C-1. Handling Parts........................C-3 C-2. Replacement Parts....................... C-4 C-2.1. Background...............................C-4 C-2.2. Acceptable Replacement Parts........................C-4 C-2.3. Know Your Supplier ..........................C-4 C-2.4. 100% Parts Replacement Requirements ....................C-5 C-2.5.
  • Page 328 Standard Practices Teledyne Continental Motors, Inc. LIST OF FIGURES Figure C-1. Right-hand-thread safety wire installation .............. C-7 Figure C-2. Safety wire Patterns for Right-Hand Threads ............C-8 Figure C-3. Tab Washer Installation................... C-9 Figure C-4. Helical Coil Extraction Tool ................. C-11 Figure C-5.

  • Page 329: C-1. Handling Parts

    Teledyne Continental Motors, Inc. Standard Practices PRECAUTIONS, WARNINGS, AND TIPS C-1. Handling Parts • Disconnect electrical power to the engine and verify the Ignition and Master Switches are turned OFF to prevent accidental starting. • Inspect replacement parts for deterioration or wear. Do not install parts that appear worn or deteriorated.

  • Page 330: C-2. Replacement Parts

    Standard Practices Teledyne Continental Motors, Inc. C-2. Replacement Parts C-2.1. Background An increasing amount of replacement parts (including standard parts), materials, appliances, and instruments are represented as being of aircraft quality when actually the quality and origin of these units is unknown. Users of such units are usually not aware of the potential hazards involved with replacement parts that are not eligible for use on certified aircraft.

  • Page 331: Appendix C - Standard Practices

    Teledyne Continental Motors, Inc. Standard Practices Therefore, in accordance with FARs, certification of materials, parts, and appliances for aircraft return to service is the responsibility of the person or agency who signs the approval. The owner/operator is responsible for the continued airworthiness of the aircraft.

  • Page 332: C-2.5. Mandatory Overhaul Replacement Parts

    Standard Practices Teledyne Continental Motors, Inc. C-2.5. Mandatory Overhaul Replacement Parts In addition to the previously listed items, the following parts must be discarded and replaced with new parts during engine overhaul. • • Hydraulic valve lifters (tappets) Rocker shafts •...

  • Page 333: C-4. Safety Wiring Hardware

    Teledyne Continental Motors, Inc. 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).

  • Page 334: Appendix C - Standard Practices

    Standard Practices Teledyne Continental Motors, Inc. piece of hardware to ensure that 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. While keeping the protruding strand of safety wire taut, twist the strands (based on the wire gauge specified below) until the twisted part is just short of a hole in the next unit.

  • Page 335: C-5. Tab Washer Installation

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

  • Page 336: C-6. Helical Coil Insert Replacement

    Standard Practices Teledyne Continental Motors, Inc. 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 337: C-6.1. Helical Coil Removal

    Teledyne Continental Motors, Inc. Standard Practices C-6.1. Helical Coil Removal Procedure 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.

  • Page 338: C-6.2. Helical Coil Insertion

    Standard Practices Teledyne Continental Motors, Inc. C-6.2. Helical Coil Insertion Procedure 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 339: C-7. Stud Replacement

    Teledyne Continental Motors, Inc. 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 340 Standard Practices Teledyne Continental Motors, Inc. WARNING Helical coils can only be installed where authorized. 4. A helical coil insert can be used on a cylinder rocker shaft retaining stud provided the minimum wall thickness of more than half of the helicoil diameter remains after tapping for the helical coil insert.

  • Page 341: C-7.1. Stud Removal

    Teledyne Continental Motors, Inc. Standard Practices ® C-7.3. Size-on-Size Rosan Stud Removal To prevent damage to the engine cylinder, take precautions when removing a size-on-size ® Rosan stud. Procedure 1. Carefully cut the damaged stud flush with the cylinder head. Do not come in contact with or mark the cylinder head.

  • Page 342: C-7.4. Step-Type Rosan ® Stud Removal

    Standard Practices Teledyne Continental Motors, Inc. ® C-7.4. Step-Type Rosan Stud Removal ® There are two methods for removing step-type Rosan studs. Each of these methods is described below. The first uses a special tool; the second provides machining instructions to cut the stud, drill a pilot hole and remove the stud with an bolt extractor.

  • Page 343: C-7.5. Rosan ® Studs Installation

    Teledyne Continental Motors, Inc. Standard Practices ® C-7.5. Rosan Studs Installation ® Any type of Rosan stud (size-on-size type or step type) may be installed using the appropriate wrench. Install the stud to the dimensions specified in Figure C-10. CAUTION: Location of the flange is important in preventing the lock ring drive tool from making contact with surface “A”...
  • Page 344 Standard Practices Teledyne Continental Motors, Inc. 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. Procedure 1. Install the nut on the bolt. 2. Verify the nut where the cotter pin is to be inserted has been torqued to the lower limit of the torque specification in Appendix B of this manual.
  • Page 345 Teledyne Continental Motors, Inc. Standard Practices ® C-9. Applying Gasket Maker 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 346 Standard Practices Teledyne Continental Motors, Inc. C-10. Gasket Installation WARNING The use of any form of silicone RTV or other non-TCM approved sealant during reassembly of the engine may cause a loss of through-bolt torque that will result in loss of main bearing crush and fretting of the crankcase parting surfaces.
  • Page 347 Teledyne Continental Motors, Inc. Standard Practices C-11. 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 348 Standard Practices Teledyne Continental Motors, Inc. C-12. Harness Routing Procedure 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. Route the manifold pressure, manifold temperature, fuel pressure, and speed sensor channels separately to ensure signal integrity.

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