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Teledyne Continental Motors CONTINENTAL L/TSIO-360-RB Maintenance Manual

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L/TSIO-360-RB
CONTINENTAL
®
AIRCRAFT ENGINE
MAINTENANCE
MANUAL
TECHNICAL PORTIONS APPROVED BY THE FAA
FORM X30645
CHANGE 2
© 2008 TELEDYNE CONTINENTAL MOTORS INCORPORATED
APRIL 2008

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  • Page 1 L/TSIO-360-RB CONTINENTAL ® AIRCRAFT ENGINE MAINTENANCE MANUAL TECHNICAL PORTIONS APPROVED BY THE FAA FORM X30645 CHANGE 2 © 2008 TELEDYNE CONTINENTAL MOTORS INCORPORATED APRIL 2008...
  • Page 2 Available exclusively from the publisher: P.O. Box 90, Mobile, AL 36601 Copyright © 2008 by Teledyne Continental Motors. All rights reserved. This material may not be reprinted, republished, broadcast, or otherwise altered without the publisher’s written permission. This manual is provided without express, statutory, or implied warranties. The publisher will not be held liable for any damages caused by or alleged to be caused by use, misuse, abuse or misinterpretation of the contents.
  • Page 9 CHAPTER 1 1-1. Introduction ........................1-3 1-2. Scope ..........................1-3 1-3. Definition of Terms ......................1-3 1-4. Manual Revisions ......................1-3 1-5. Revision/Change Distribution ..................1-4 1-6. Related Publications.......................1-4 1-7. Service Documents ......................1-5 1-8. Service Reports and Inquiries ..................1-5 1-9. Suggestions and Corrections ..................1-6 1-10. TCM Contact Information ....................1-6 1-11.
  • Page 10 INTENTIONALLY LEFT BLANK Change 2...
  • Page 11 (ICAs) prepared by Teledyne Continental Motors and approved by the Federal Aviation Administration (FAA). Teledyne Continental Motors releases publication changes in the form of either change pages or complete publication revisions, depending upon the extent of change. Service documents may supplement or replace technical information contained in one publication or an entire series of publications.
  • Page 12 1-5. REVISION/CHANGE DISTRIBUTION Document updates are available via TCMLINK upon notification of FAA document approval. TCM notifies engine owners of technical publication changes free of charge. TCM notifies current TCMLINK service subscribers as publications are updated. Current TCMLINK service subscribers receive a complete publication library on CD delivered quarterly. Current printed publication subscribers receive printed changes and revisions as they are released.
  • Page 13 1-7. 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, TCM service documents are published and available on TCMLINK.
  • Page 14 1-10. TCM CONTACT INFORMATION Teledyne Continental Motors is available to answer technical questions and encourages suggestions regarding products, parts, or service. If customers have an inquiry or require technical assistance, they should contact their local TCM distributor or TCM field representative.
  • Page 15 1-11. ENGINE MODEL DESCRIPTION TS I O - 360 -RB 1 TS I O - 360 -RB 1 Shipping Designation Shipping Designation Specification Number Specification Number Model Identifier Model Identifier Cubic Inch Displacement Cubic Inch Displacement Horizontally Opposed Cylinders Horizontally Opposed Cylinders Fuel Injected Fuel Injected Turbo-Supercharged...
  • Page 16 Figure 1-1. L/TSIO-360-RB Top and Front View Change 2...
  • Page 17 Figure 1-2. L/TSIO-360-RB Side and Aft View Change 2...
  • Page 18 1-13. GENERAL Operating limits and specifications listed in this section apply to the L/TSIO-360-RB aircraft engine model. Consult the L/TSIO-360-RB Operation and Installation Manual, Form X30644 for additional operating specifications. For L/TSIO-360-RB time between overhaul (TBO), see Section XX or the latest TCM Time between Overhaul Service Bulletin.
  • Page 19 TSIO-360 Accessory Drive Ratios Drive rations for LTSIO-360-RB engines are the same as TSIO-360 except the direction of rotation is reversed. CAUTION…A removable oil transfer plug conducts oil pressure from the propeller governor through the crankshaft to the propeller hub. When a test club or fixed propeller is used for testing purposes, the propeller governor cover must have an internal grooved surface to allow the circulating oil to lubricate the front main bearings.
  • Page 20 INTENTIONALLY LEFT BLANK 1-12 Change 2...
  • Page 21 CHAPTER 2 TOOLS AND EQUIPMENT Section Page General Information....................2-2 Possible Special Tool Procurement Sources............2-3 Special Tools ......................2-4...
  • Page 22 GENERAL INFORMATION The mechanic should be equipped with a complete set of the necessary tools that include the following: 1. Wrenches - 1/4" through 1 1/4" 2. Common and Philips Head Screwdrivers 3. Pliers - Common Diagonal Cutters, Needle Nose, Duck Bill, Snap Ring 4.
  • Page 25 ITEM TOOL Section 545-116 Dial Bore Gages available from Federal Tool Supply Co. Inc. 20-6 CFL10 Cylinder Hone available from Snap On Tools 20-6 No. 1675 Valve Seat Grinder Set "Sioux Brand" available from Aircraft Tool Supply 20-6 AEX 375 Valve Seat Grinder Pilot .437 Dia. available from Aircraft Tool Supply K28 Intake Valve Seat Grinding Stone (Roughening 45°) available from Aircraft Tool Supply K98 Intake Valve Seat Grinding Stone (Finishing 45°) available from Aircraft Tool Supply...
  • Page 26 ITEM TOOL Section Borrough's 445, 18mm Spark Plug Tap or equivalent for straightening out damaged 20-6 threads 2769A13 Rosan® Stud Remover available from McMASTER-CARR Supply Co. 20-6 Rosan® is a registered trademark of Fairchild Aerospace Fastener Division 8074 Rosan® Lock Ring Installer available from Kent - Moore 8118 Rocker Arm Bushing Remover/Installer available from Kent - Moore 3610 Reamer Rocker Arm Bushing available from Kent - Moore 20-6...
  • Page 27 CHAPTER 3 SEALANTS AND LUBRICANTS Sealants / Lubricants ........................3-2...
  • Page 28 SEALANTS AND LUBRICANTS Aviation Engine Oil Ashless Dispersant Recommended Grade Above 40°F ambient air, sea level SAE 50 or Multi Viscosity Below 40°F ambient air, sea level SAE 30 or Multi Viscosity Manufacturer Brand Name BP Oil Corporation BP Aero Oil Castrol Castrol Aero AD Oil Castrol Limited (Australia)
  • Page 29 Preservative Oil TYPE SUGGESTED SOURCES APPLICATION MIL-C-6529 Type II (Aeroshell Fluid 2F or equivalent), For Temporary storage (up to 90 days) MIL-P-46002 Grade 1 oil, (NOX RUST VCI-105 For Indefinite storage or equivalent) May be purchased through: Rock Island Lubricant & Chemical P.O.
  • Page 30 Lubricants TYPE SUGGESTED SOURCES APPLICATION Approved Ashless Dispersant Oil See Aviation Engine Oil Ashless Cylinder studs and through bolts, Dispersant Table crankcase studs, connecting rod bolts nuts engine accessory studs unless otherwise specified CHAMPION® - Spark Plug Champion Products Spark plugs Thread Lubricant No.
  • Page 31 Sealants TYPE SUGGESTED SOURCES APPLICATION K & W Copper Coat For Distributor information call: K & W Products Customer Phone: 1-800-423-9446 Loctite Teflon PS/T Pipe Sealant For Distributor information: Pipe threads, pressure relief Loctite Customer Service @ valve housing threads, tach drive Phone: 1-800-243-4874 threads, oil temperature control valve, studs that are exposed to...
  • Page 32 Miscellaneous TYPE SUGGESTED SOURCES APPLICATION TCM P/N 626531-1 May be purchased through High temp. paint for cosmetic and your local TCM Distributor corrosion protection Enamel - Gold (1qt) TCM P/N 626531-2 Enamel - Gold (1 gal) May be purchased through Where applicable for lockwiring TCM P/N 535001S Lockwire -.032 in dia.
  • Page 33 CHAPTER 4 AIRWORTHINESS LIMITATIONS This Airworthiness Limitations section has been 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 34 INTENTIONALLY LEFT BLANK...
  • Page 35 CHAPTER 5 TIME LIMITS/OPERATIONAL INSPECTION/ENGINE TROUBLESHOOTING SECTION PAGE General ....................5-2 Overhaul Periods ................... 5-2 Operational Inspection................5-3 Test Operating Limits ................5-4 Time Interval Inspections............... 5-5 Scheduled Maintenance................ 5-6 Unscheduled Maintenance..............5-11 General Information................5-14 Engine Troubleshooting Chart............. 5-14...
  • Page 36 GENERAL The scheduled inspection and maintenance described in this section must be complied with in addition to all aircraft manufacturer and accessory manufacturer inspection and maintenance requirements. This manual does not contain inspection or maintenance requirements for supplemental type certificated components or systems. Such information must be obtained from the supplemental type certificate holder.
  • Page 37 OPERATIONAL CHECK LIST Check and record the following system data : Starter ......................_________ *Record RPM Drop for each magneto at 1700 (150 RPM 50 RPM ) ...._________ MAXIMUM AND SPREAD MAXIMUM *Propeller Operation at 1700............_________ *Or as specified in aircraft manufacturer's instructions. Increase engine to full power and record: Manifold Pressure................
  • Page 38 TEST OPERATING LIMITS ITEM ENGINE MODEL ENGINE MODEL TSIO-360-RB LTSIO-360-RB * Full Throttle Speed- RPM 2600 2600 Manifold Pressure In. hg. Absolute 38.0 38.0 Idle Speed - RPM 700±25 700±25 Fuel Grade (Octane) 100LL/100 100LL/100 Fuel Flow at 140 - 150 140-150 Full Throttle (Lbs.
  • Page 39 TIME INTERVAL INSPECTIONS Inspection procedures and maintenance information are provided in the individual system chapters. Engine mounted accessories not supplied by TCM may require servicing at specific intervals; some of these are alternators, pneumatic pumps, air / oil separators and stand-by generators.
  • Page 40 SCHEDULED MAINTENANCE 50-HOUR INSPECTION NOTE: Research and comply with the Service Publications and Airworthiness Directives. 1. Thoroughly inspect the engine for any signs of leakage. Clean engine exterior by spraying or brushing with a flame resistant solvent used for general cleaning of engine parts.
  • Page 41 CAUTION ... Failure to properly install the induction air filter will result in unfiltered air being ingested into the engine which will accelerate engine wear and reduce engine service life. 5. Inspect induction air box for security and deterioration in accordance with the aircraft manufacturer's instructions.
  • Page 42 100-HOUR INSPECTION NOTE: Research and comply with the Service Publications and Airworthiness Directives. In addition to the items listed in 50 Hour the following inspections and maintenance must be performed. 1. Drain engine oil. Reinstall oil drain plug with new gasket, torque to 190 - 210 in. lbs. and safety.
  • Page 43 WARNING Insure fuel selector is in the off position prior to removing the fuel metering unit inlet screen. 13. Inspect fuel nozzles, upper deck and fuel injection nozzle reference lines, hoses, manifolds and fittings for proper routing, support and signs of fuel stains. Inspect manifold valve for security of installation, proper venting and signs of fuel stains.
  • Page 44 26. Visually inspect magneto pressurization filter for contamination. If filter element is white, it may be continued in service. If filter element has turned to yellow or red, element is contaminated and must be replaced. If there is visible moisture present in the filter canister the magnetos must be removed from the engine, disassembled and inspected for possible internal contamination and corrosion.
  • Page 45 UNSCHEDULED MAINTENANCE Unscheduled maintenance events include but are not limited to: PROPELLER STRIKES A propeller strike is: (1) any incident, whether or not the engine is operating, that requires repair to the propeller other than minor dressing of the blades or (2) any incident while the engine is operating in which the propeller makes contact with any object that results in a loss of engine RPM.
  • Page 46 b. Following loss of power during ground operation. c. Following momentary engine shutdown. d. During single engine operation for training purposes on twin engine aircraft. 3. Over priming and attempting engine start with the aircraft parked on an incline that negates the effective operation of the drain system.
  • Page 47 c) Remove and inspect inside of rocker covers for debris. Inspect valve stem (keeper grooves) and valve keepers for condition, security and proper installation. Inspect valve springs, rocker arms, spring retainers, rotocoils, pushrods, etc. d) Perform a borescope inspection on all cylinders. e) If no discrepancies are noted, re-service engine, perform operational inspection and correct any discrepancies noted prior to returning the engine to service.
  • Page 48 GENERAL INFORMATION The troubleshooting chart which follows discusses symptoms which can be diagnosed and interprets the probable causes and the appropriate corrective actions to be taken. Troubleshooting for individual systems will be found in that particular section of Chapters 11 through 22.
  • Page 49 TROUBLE PROBABLE CAUSE CORRECTION Engine Will Not Run At Fuel injection system See Section 13-4, "Fuel Injection Idling Speed improperly adjusted System Troubleshooting." Air leak in intake manifold Torque loose connection or replace damaged part. See Section 14-5, "Induction System Maintenance." Rough Idling Fuel injection system See Section 13-4, "Fuel Injection...
  • Page 50 TROUBLE PROBABLE CAUSE CORRECTION Engine Runs Rough At Loose mounting bolts or Torque mounting bolts. Replace High Speed damaged mount pads mount pads. See Section 21-5, "Crankcase Maintenance 'Engine Mounts.' " Plugged fuel nozzle jet Clean. See Section 13-5, "Fuel System Maintenance 'Fuel Nozzles.' "...
  • Page 57 GENERAL Technicians involved with engine preparation and installation into the airframe must possess a detailed knowledge of safe procedures used in engine servicing and the operation of ground support equipment. The engine must have a detailed visual inspection prior to installation in the airframe. UNPACKING Packaging Category "A"...
  • Page 58 Remove the shipping plugs installed in the upper spark plug holes and inspect the cylinder bore with a borescope for rust or contamination. Contact your Teledyne Continental Motors Distributor if any abnormal condition is noted.
  • Page 59 ENGINE INSTALLATION INSTRUCTIONS (See Figures 6-1) CAUTION . . . The engine must be hoisted using the lifting eye brackets only. WARNING The aircraft fuel tanks and lines must be purged to remove all contamination prior to installation of the main fuel inlet line to the fuel pump. Failure to comply can cause erratic fuel injection system operation and damage to its components.
  • Page 60 FIGURE 6-1. INSTALLATION DRAWING...
  • Page 61 FIGURE 6-1. INSTALLATION DRAWING (cont'd)
  • Page 62 FIGURE 6-1. INSTALLATION DRAWING (cont'd)
  • Page 65 discrepancies exist. After the operational inspection a test flight is required to insure that the engine and aircraft meet all of the manufacturer's performance and operational specifications prior to releasing the aircraft for normal service. WARNING Although the engine fuel system was adjusted at engine test, the fuel system must be checked and adjusted in accordance with Chapter 23 "Fuel System Adjustment,"...
  • Page 66 INTENTIONALLY LEFT BLANK 6-12...
  • Page 67 CHAPTER 7 SERVICING FLUIDS SECTION PAGE Servicing, Oil......................7-2 Approved Engine Lubricating Oils................7-3 Fuel ......................... 7-3 Oil Filter Element Inspection .................. 7-4 Spectrographic Oil Analysis ................... 7-4 FIGURE PAGE Oil Servicing Points ....................7-2...
  • Page 68 SERVICING OIL CAUTION . . . Some funnel-type quart oil containers incorporate a styrofoam or aluminum seal. Remove this seal from the container and discard it before adding oil to the engine. If the seal falls into the engine, engine damage and possible failure can result. The oil system must be serviced to capacity with the oil grades specified.
  • Page 69 7-2. APPROVED ASHLESS DISPERSANT OILS 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 Delta Petroleum Company Delta Avoil Oil Exxon Company, USA Exxon Elite Exxon Company, USA Exxon Aviation Oil EE...
  • Page 70 7-4. OIL FILTER ELEMENT INSPECTION TCM recommends oil filter element inspection at each oil and filter change interval if oil analysis is being used. Filter element inspection may identify internal engine wear undetectable through oil analysis. New, rebuilt, or overhauled engines or engines that have had cylinders replaced will generally exhibit noticeable amounts of normal wear material at the first and second oil and filter change.
  • Page 71 SPECTROGRAPHIC OIL ANALYSIS (continued) A proper spectrographic oil analysis program should begin with the first engine oil change. Establishing a wear trend data base for an engine will require analysis of at least three oil samples. As the engine accumulates operating time and additional oil samples are analyzed, a definitive wear trend can be identified.
  • Page 72 INTENTIONALLY LEFT BLANK...
  • Page 73 CHAPTER 8 ENGINE PRESERVATION AND STORAGE Section Page General ........................8-2 Engine Preservation ....................8-2 Temporary Storage....................8-2 Indefinite Storage ....................8-3 Indefinite Storage Inspection Procedures .............. 8-4 Returning An Engine To Service................8-4...
  • Page 74 GENERAL There is no practical procedure that will insure corrosion prevention on installed aircraft engines. Susceptibility to corrosion is influenced by geographical location, season and usage. The owner/operator is responsible to recognize the conditions that are conducive to corrosion and take appropriate precautions. ENGINE PRESERVATION Corrosive attack can occur in engines that are flown only occasionally regardless of geographical location.
  • Page 75 6. Seal all engine openings exposed to the atmosphere using suitable plugs and covers. 7. Tag each propeller in a conspicuous place with the following notation on the tag: DO NOT TURN PROPELLER - ENGINE PRESERVED - PRESERVATION DATE NOTE. . . If the engine is not returned to flyable status on or before the 90-day expiration, it must be preserved in accordance with "Indefinite Storage"...
  • Page 76 INDEFINITE STORAGE INSPECTION PROCEDURES 1. Aircraft prepared for indefinite storage must have the cylinder dehydrator plugs visually inspected every 15 days. The plugs must be changed as soon as they indicate other than a dark blue color. If the dehydrator plugs have changed color in one-half or more of the cylinders, all desiccant material on the engine must be replaced.
  • Page 77 CHAPTER 9 STANDARD PRACTICES SECTION PAGE General ......................9-2 Lockwire Procedure ................... 9-3 Tab Washer Procedure ..................9-5 Cotter Pin Procedure..................9-5 Application Of Adhesives ................... 9-6 Installation Of Gaskets ..................9-6 FIGURE PAGE General Lockwire Procedure................9-3 General Lockwire Patterns................9-4 Tab Washer Installation Procedure..............
  • Page 78 GENERAL To facilitate and insure proper reinstallation, tag or mark all parts and hardware as they are removed or disassembled. Tag any unserviceable parts or units for investigation and possible repair. Take extreme care to prevent foreign matter, lockwire, nuts, washers, dirt, etc., from entering the engine on or off the aircraft.
  • Page 79 LOCKWIRE PROCEDURE Lockwiring is the securing together of two or more parts with lockwire which shall be installed in such a manner that any tendency for a part to loosen will be counteracted by additional tightening of the wire. Wire shall be pulled taut while being twisted and caution must be exercised during the twisting operation to keep the wire tight without over stressing.
  • Page 80 LOCKWIRE PROCEDURE (cont'd) Various examples of lockwiring are shown in Figure 9-2, "General Lockwire Patterns." 1. All items to be lockwired must be properly torqued. Applying torque that is above or below specified limits to obtain alignment of the holes is not permitted. 2.
  • Page 81 TAB WASHER PROCEDURE Tab washers are installed by fitting a tab in a tab slot and bending the remaining tabs firmly against the bolt or nut flat. Tab washers are used in various locations in TCM engines and must not be reused after removal. The tabs that are provided to be bent up against the head flats must be seated firmly, with no scarring of the tabs.
  • Page 82 FIGURE 9-4. GENERAL COTTER PIN INSTALLATION APPLICATION OF ADHESIVES Adhesives and sealants will be used as specified in this manual. WARNING The improper use of sealants and adhesives will cause engine malfunction or failure. Gasket Maker P/N 646942 must be applied in a thin even coat. Gasket Maker surfaces must be clean and free of oil and grit.
  • Page 83 CHAPTER 10 ENGINE MAINTENANCE 10-1 GENERAL During engine 50 and 100 hour inspections, if engine components must be remove and replaced, refer to the applicable disassembly/reassembly instructions found in the TSIO- 360 Series Overhaul Manual, Form OH-08 as outlined in Maintenance Section of each system.
  • Page 84 INTENTIONALLY LEFT BLANK 10-2...
  • Page 85 CHAPTER 11 EXHAUST SYSTEM SECTION PAGE 11-1 Exhaust System Description................11-2 11-2 Turbocharger Detailed Description..............11-4 11-3 Exhaust By-pass Valve (Wastegate) Detailed Description......11-5 11-4 Variable Absolute Pressure Controller (VAPC) Detailed Description ..11-6 11-5 Turbocharger Lubrication System ..............11-7 11-6 Exhaust System Inspection ................
  • Page 86 11-1 EXHAUST SYSTEM DESCRIPTION The L/TSIO-360-RB exhaust system contains the following engine components: rear mounted turbocharger, hydraulic wastegate, lubrication plumbing, exhaust collector assembly, and turbocharger tailpipe assembly. During normal engine operation, exhaust gases exiting the cylinder combustion chambers, flow through the exhaust collector to the turbocharger turbine housing inlets. The exhaust gas flow provides turbine wheel rotation and exits through the turbine housing discharge port and tailpipe assembly.
  • Page 87 FIGURE 11-1. INDUCTION AND EXHAUST SYSTEM 11-3...
  • Page 88 11-2 TURBOCHARGER DETAILED DESCRIPTION. The turbocharger consists of a radial inward flow turbine and turbine housing, a centrifugal flow impeller (compressor) and compressor housing, each bolted to a center housing. The center housing incorporates bearings that support the turbine/compressor shaft. The shaft and bearings are lubricated with pressurized engine oil that enters the center housing through an oil inlet check valve and fitting.
  • Page 89 FIGURE 11-3. TURBOCHARGER SECTIONAL VIEW 11-3 EXHAUST BY-PASS VALVE (WASTEGATE) DETAILED DESCRIPTION. The Exhaust By-pass Valve or wastegate used on the L/TSIO-360-RB engine is an oil actuated, butterfly type valve. The exhaust by-pass valve butterfly valve is connected to the actuator by mechanical linkage.
  • Page 90 11-4 VARIABLE ABSOLUTE PRESSURE CONTROLLER (VAPC) DETAILED DESCRIPTION. The variable absolute pressure controller is designed to maintain deck pressures to provide sea level horsepower at varying altitudes. By means of a sensing port in the pneumatic section of the controller, the outside of the aneroid bellows is subjected to deck pressure. The aneroid bellows is linked to a poppet valve, spring loaded normally closed.
  • Page 93 11-7 EXHAUST SYSTEM TROUBLESHOOTING This troubleshooting chart is provided as a guide. Review all probable causes given, check other listings of troubles with similar symptoms. Items are presented in sequence of the approximate ease of checking, not necessarily in order of probability. TROUBLE PROBABLE CAUSE CORRECTION...
  • Page 94 TROUBLE PROBABLE CAUSE CORRECTION Loss Aircraft's Critical Aftercooler plugged or damaged Repair or replace as required. Altitude (cont’d) Turbocharger Seals Worn or damaged seals Refer Turbocharger Leaking Manufacturer's Instructions Engine Oil Level Frequently Leaking Turbocharger check Replace check valves. Refer to Low After Servicing Prior to valves and seals Turbocharger...
  • Page 97 CHAPTER 12 IGNITION SYSTEM SECTION PAGE 12-1 Slick Ignition System Description ................. 12-2 12-2 Ignition System Component Detailed Description ..........12-2 12-3 Ignition System Inspection 50/100/500 Hour ............12-2 12-4 Ignition Troubleshooting ..................12-4 12-5 Ignition System Maintenance ................12-5 FIGURE PAGE 12-1...
  • Page 98 12-1 SLICK IGNITION SYSTEM DESCRIPTION The L/TSIO-360 engines utilize two Slick (Unison) 6224 Series pressurized magnetos. The left magneto fires the 1-3-5-lower and the 2-4-6 upper spark plugs, while the right magneto fires the 1-3-5 upper and 2-4-6-lower spark plugs. The Slick 6224 Series pressurized magnetos, manufactured by Slick Electro Incorporated, 530 Blackhawk Park Avenue, Rockford, Illinois 61101, are designed to provide ignition for six cylinder light aircraft engines.
  • Page 99 12-3 IGNITION SYSTEM INSPECTION (continued) 100 HOUR INSPECTION - Perform all requirements of 50 hour inspection and the following: WARNING Magneto-to-engine timing maintenance does not insure magneto, harness and spark plug performance. Failure to properly maintain the magneto, harness and spark plugs will lead to internal engine damage and failure.
  • Page 100 12-3 IGNITION SYSTEM INSPECTION (continued) NOTE . . . Minor changes in magneto timing can be expected during normal engine service. The time and effort required to check and adjust the magnetos to specifications is slight and the operator will be rewarded with longer contact point life, smoother engine operation and less corrective maintenance between routine inspections.
  • Page 103 Spark Plugs - Remove the spark plugs for cleaning or replacement in accordance with applicable portions of Ignition System Disassembly/Reassembly instructions in the TSIO- 360-MB &-SB Overhaul Manual, Form. After spark plugs are removed, clean and gap the spark plugs in accordance with the spark plug manufacturer's instructions and test. Replace any spark plug that does not meet the manufacturer's specifications.
  • Page 104 CYLINDER ROTATION CYLINDER CYLINDER NUMBER NUMBER FROM 1 TOP 6 BOTTOM 1 BOTTOM 6 TOP 2 TOP 5 BOTTOM 2 BOTTOM 5 TOP 3 TOP 4 BOTTOM 3 BOTTOM 4 TOP 4 TOP 3 BOTTOM 4 BOTTOM 3 TOP 5 TOP 2 BOTTOM 5 BOTTOM 2 TOP...
  • Page 105 12-5 IGNITION SYSTEM MAINTENANCE (Continued) NOTE . . . If the engine is equipped with a right angle drive starter adapter and does not freely turn in the opposite direction of normal rotation the starter motor must be removed from the starter adapter. Some right angle starter drive adapters incorporate an over-riding spring clutch design that restricts engine rotation in the opposite direction of normal rotation.
  • Page 106 5. Slowly rotate the crankshaft in the opposite direction of normal rotation until the piston lightly touches the dead center locator. Observe reading on the disk under the pointer. NOTE: DIAL INDICATOR POSITIONS SHWON ARE EXAMPLES ONLY. POSITIONS ON THE PROTRACTOR/TIMING INDICATOR DISC WILL DIFFER FROM ENGINE TO ENGINE.
  • Page 107 8. Remove the top dead center locator from the number 1 cylinder and find the compression stroke on the number 1 cylinder by placing a finger over the spark plug hole as the crankshaft is rotated. Continue rotating crankshaft on the compression stroke until the 0°...
  • Page 108 POSI TI VE DEAD CENTER LOCATOR REMOVED. EXAMPLE: FULL ADVANCE FI RI NG POSI TI ON 2 0 BEFORE TOP DEAD CENTER. # 1 CYLI NDER NORMAL DI RECTI ON OF ROTATI ON. NOTE: THE PROTRACTOR/ TI MI NG I NDI CATOR SHOWN I S USED WI TH THE PROPELLER AND SPI NNER I NSTALLED.
  • Page 109 C. Insure that the crankshaft is positioned in accordance with Section 12-6 "Placing Crankshaft In Timing Position." D. Insure that the magneto drive coupling bushings and retainers are properly installed. Place a new gasket on the magneto flange and install magneto carefully so that the drive coupling lugs mate with the slots of the drive bushings.
  • Page 110 To prevent sticking of sleeves and to minimize twisting of ferrule coat insulating sleeves, use MS122N/C02 Spray, Miller-Stephenson Chemical Co., Inc., 16 Sugar Hollow Road, Danbury, Connecticut 06810. See Figure 12-9, "Coating Insulating Sleeve." NOTE . . . Hold ferrules while torquing or loosening spark plug coupling nuts to protect against twisting conduit or cable.
  • Page 111 UPPER UPPER SPARK PLUGS SPARK PLUGS ENGINE FIRING ORDER 1 6 3 2 5 4 MAGNETO FIRING ORDER 1 2 3 4 5 6 LEFT MAG RIGHT MAG LOWER LOWER SPARK PLUGS SPARK PLUGS FIGURE 12-10. IGNITION WIRING DIAGRAM 12-15...
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  • Page 113 CHAPTER 13 FUEL SYSTEM SECTION PAGE 13-1 Engine Fuel System Description ..............13-2 13-2 Fuel Injection System Component Detailed Description ......13-2 13-3 Fuel Injection System Inspection 50/100 Hour..........13-4 13-4 Fuel Injection System Troubleshooting............13-6 13-5 Fuel System Maintenance ................13-7 FIGURE PAGE 13-1...
  • Page 114 13-1 ENGINE FUEL SYSTEM DESCRIPTION Fuel System L/TSIO-360-RB The fuel injection system, composed of a TCM fuel pump, manifold valve, nozzles and a ®Precision Airmotive fuel servo. Fuel flows from the fuel pump to the fuel servo unit. The fuel then flows from the fuel servo unit to the fuel manifold valve where it is distributed to the six fuel injector nozzles.
  • Page 115 FIGURE 13-2. GENERAL FUEL MANIFOLD VALVE DESCRIPTION Fuel manifold Valve (See Figure 13-2) The fuel manifold valve body contains a fuel inlet, diaphragm chamber and outlet ports for fuel lines to the individual nozzles. The diaphragm is enclosed by a vented cover which retains the diaphragm loading spring.
  • Page 116 FIGURE 13-3. FUEL NOZZLE DESCRIPTION Fuel nozzle (See Figure 13-3) The fuel discharge nozzle is located in the cylinder head. The nozzle outlet is screwed into the tapped fuel nozzle hole in the cylinder head. The nozzle body has a drilled central passage with a counterbore at each end.
  • Page 117 WARNING Never clean nozzles with wire or other similar object. If nozzle jet is plugged and obstruction cannot be removed by solvent action REPLACE THE NOZZLE. 100 Hour- Perform all requirements under 50 hour inspection. The fuel nozzles must be removed, cleaned and visually inspected every three hundred hours of operation.
  • Page 118 FUEL INJECTION SYSTEM INSPECTION (cont’d). WARNING Failure to comply with the following instructions can result in fuel system linkage and/or related component damage and subsequent loss of engine power. Inspect the operation of each engine related control, including the throttle, mixture, propeller and alternate air controls.
  • Page 123 CHAPTER 14 INDUCTION SYSTEM SECTION PAGE 14-1 Induction System Description................14-3 14-2 Overboost Valve Detailed Description ............. 14-3 14-3 Induction System Inspection 50/100 Hour ............14-4 14-4 Induction System Troubleshooting..............14-4 14-5 Induction System Maintenance ................ 14-5 FIGURE PAGE 14-2 Overboost Valve....................
  • Page 124 14-1 INDUCTION SYSTEM DESCRIPTION See Figure 11-1, “Induction and Exhaust System Schematic,” for induction system components and induction air flow. The induction system is mounted above the engine. It serves to carry induction air to the individual cylinder intake ports. Engine components through which air flows following the aircraft air inlet filter/alternate air door are: turbocharger compressor, aftercooler, overboost/controller adapter, fuel servo unit throttle area, balanced manifold, induction tubes and cylinder intake ports.
  • Page 127 CHAPTER 15 AIR CONDITIONING SECTION PAGE 15-1 Air Conditioning System Description..............15-2 15-2 Air Conditioning System Component Detailed Detail Description ..................... 15-2 15-3 Compressor Bracket Inspection ............... 15-3 15-4 Air Conditioning Troubleshooting ..............15-3 15-5 Compressor Bracket Maintenance..............15-3 FIGURE PAGE 15-2 Compressor Drive (TSIO-360-RB) ..............
  • Page 128 15-1 AIR CONDITIONING SYSTEM DESCRIPTION Air Conditioning – The TSIO-360-RB engine utilizes a compressor mounting kit for the addition of a customer supplied belt driven compressor and air conditioning system. For a description of the complete air conditioning system refer to the airframe manufacturer’s information.
  • Page 131 CHAPTER 16 ELECTRICAL SYSTEM SECTION PAGE 16-1 Electrical Charging System Description............16-2 16-2 Electrical Charging System Component Detailed Description ..... 16-2 16-3 Charging System Inspection 50/100 Hour............16-2 16-4 Charging System Troubleshooting ..............16-2 16-5 Charging System Maintenance................. 16-2 16-1...
  • Page 132 16-1 ELECTRICAL CHARGING SYSTEM DESCRIPTION The L/TSIO-360-RB engines incorporate provisions on the right front crankcase half for mounting a belt driven alternator. The alternator generates electrical current for powering the aircraft electrical system. For description of the aircraft electrical and charging system see the applicable Airframe manufacturer’s Instructions.
  • Page 135 CHAPTER 17 STARTING SYSTEM SECTION PAGE 17-1 Starter And Starter Adapter Description............17-2 17-2 Starting System Component Detail Description ......... 17-2 17-3 Starter And Starter Adapter Inspection ............17-3 17-4 Starting System Troubleshooting ..............17-4 17-5 Starting System Maintenance ............... 17-4 FIGURE PAGE 17-1...
  • Page 136 17-1 STARTER AND STARTER ADAPTER DESCRIPTION The L/TSIO-360-RB engines utilize a starting system that employs an electric starter motor mounted on a right angle drive adapter. As the starter motor is electrically energized, the adapter worm shaft and gear engage the starter shaftgear by means of a spring and clutch assembly.
  • Page 139 Ref. Description Serviceable Limit Starter shaftgear in bearing....................Diameter 0.0045 Starter shaftgear front (bearing) journal................. Diameter 1.058 Starter shaftgear in needle bearing..................Diameter 0.0031L Scavenge pump gear shaft in cover bushing ................. Diameter 0.0035L Bushing in adapter cover ....................... Diameter 0.003T Adapter cover oil seal bore ....................
  • Page 140 17-5 STARTING SYSTEM MAINTENANCE (cont'd) Ref. Description Serviceable Limit Starter shaftgear in bearing ..................Diameter 0.0045 Starter shaftgear front (bearing) journal..............Diameter 1.059 Starter shaftgear in needle bearing..................0.0031L Starter shaftgear in accessory drive adapter bushing............. 0.002L Bushing in adapter cover ......................0.003T Gearshaft housing oil seal bore ....................
  • Page 141 FIGURE 17-4. STARTER ADAPTER FITS & LIMITS 17-7...
  • Page 142 INTENTIONALLY LEFT BLANK 17-8...
  • Page 143 CHAPTER 18 ACCESSORY CASE SECTION PAGE 18-1 Accessory Case....................18-2 18-2 Accessory Case Detailed Description..............18-2 18-3 Accessory Case Inspection .................. 18-4 18-4 Accessory Case Troubleshooting ................ 18-4 18-5 Accessory Case Maintenance................18-4 FIGURE PAGE 18-1 Accessory Case Description ................18-3 18-1...
  • Page 144 18-1 ACCESSORY CASE The aluminum alloy casting is attached to the rear of the engine crankcase. Crankcase dowels align the accessory case with the crankcase. The accessory case is secured to the crankcase by crankcase studs and various attaching hardware. Accessory mount pads on the rear surface are machined in one plane parallel to the machined parting flange which surrounds the front side of the casting.
  • Page 147 CHAPTER 19 LUBRICATION SYSTEM SECTION PAGE 19-1 Lubrication System Description................19-2 19-2 Lubrication System Component Detailed Description Oil Pump ....................... 19-4 Oil Cooler and Oil Temperature Control Valve ............ 19-6 Oil Sump ....................... 19-7 Oil Suction Tube ....................19-7 19-3 Lubrication System Inspection ................
  • Page 148 19-1 LUBRICATION SYSTEM DESCRIPTION The engine oil supply is contained in the oil sump. Oil is drawn from the sump through the oil suction tube to the intake side of the engine driven, gear type, oil pump. From the outlet side of the pump, oil passes to an oil pressure relief valve installed in the oil gallery in the accessory case.
  • Page 149 FIGURE 19-1 LUBRICATION SYSTEM SCHEMATIC 19-3...
  • Page 150 19-2 LUBRICATION SYSTEM COMPONENT DETAILED DESCRIPTION Oil Pump - The oil pump is a positive displacement pump that consists of two meshed steel gears that revolve inside the oil pump cavity machined in the accessory case. The camshaft drives the oil pump drive gear, which drives the oil pump driven gear. The oil pump driven gear is supported by a shaft pressed into the accessory case and supported by the oil pump cover plate.
  • Page 151 ACCESSORY CASE INTERNAL VIEW TSIO-360 FIGURE 19-2. OIL PUMP DESCRIPTION TSIO-360 19-5...
  • Page 152 ACCESSORY CASE INTERNAL VIEW LTSIO-360 FIGURE 19-3. OIL PUMP DESCRIPTION LTSIO-360 19-6...
  • Page 153 19-2 LUBRICATION SYSTEM COMPONENT DETAILED DESCRIPTION (continued) Oil Cooler And Oil Temperature Control Valve - Oil flowing from the oil filter enters the oil cooler inlet, oil temperature control valve cavity. When the oil is below normal operating temperature, the oil temperature control valve (vernatherm) is open allowing oil to flow through the by-pass portion of the oil cooler adapter.
  • Page 154 19-2LUBRICATION SYSTEM COMPONENT DETAILED DESCRIPTION (continued) Oil Sump - The oil sump is cast aluminum. The sump is attached to the crankcase flange with 14 nuts, washers and lock washers. The oil sump assembly incorporates a tapped drain plug boss. The drain plug boss has provisions for safety wiring of the oil drain plug. Oil Suction Tube - The oil suction tube is threaded into the oil sump and sealed to the accessory case by the accessory case gasket.
  • Page 159 used when overhauling an engine. See the current L/TSIO-360 Series Overhaul Manual Form X30596A for minimum fits and limits. 19-5 LUBRICATION SYSTEM MAINTENANCE (continued) If the accessory case is removed from the engine the following components must be dimensionally inspected. SERVICEABLE REF.
  • Page 160 INTENTIONALLY LEFT BLANK 19-14...
  • Page 163 20-2 CYLINDERS, PISTONS AND VALVE DRIVE TRAIN The cylinders, pistons and valve train are the portion of the engine that develop power. The cylinder combustion chamber provides a controlled area for burning fuel/air mixture and converting that heat energy into mechanical energy. Aviation fuel and air is 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 the spark plug.
  • Page 164 20-3 CYLINDER ASSEMBLY DETAILED DESCRIPTION Cylinder, Valve Guides, Valves, Rotocoils - The externally finned aluminum alloy head castings are heated and valve seat inserts installed before the head is screwed and shrunk onto an externally finned steel alloy barrel to make the permanent head and barrel assembly.
  • Page 165 20-3 CYLINDER ASSEMBLY DETAILED DESCRIPTION (continued). Piston - Pistons are aluminum alloy castings with a steel insert cast into the top ring groove. Pistons have three ring grooves above the pin hole and one ring groove below. Compression rings are installed in the top, and second grooves. The groove below the pin hole contains an oil scraper.
  • Page 166 20-3 CYLINDER ASSEMBLY DETAILED DESCRIPTION (continued). Valve Rocker arms, Shafts, Pushrods And Housings (Valve Train) - Valve rocker arms are steel forgings with hardened pushrod sockets and rocker faces. The rocker arm has a precision bronze bushing that accommodates the rocker shaft. The rocker arm shaft is secured to the rocker boss studs using retainers, lock tabs and nuts.
  • Page 181 CHAPTER 21 CRANKCASE ASSEMBLY SECTION PAGE 21-1 Crankcase Description ..................21-2 21-2 Crankcase Detailed Description................21-2 21-3 Crankcase Inspection 50/100 Hour..............21-3 21-4 Crankcase Troubleshooting ................. 21-5 21-5 Crankcase Maintenance..................21-5 FIGURE PAGE 21-1 Crankcase Description ..................21-2 21-2 Inspection of Crankcase Non Critical Area ............21-3 21-3 Inspection of Crankcase Critical and Non Critical Areas ........
  • Page 182 21-1 CRANKCASE DESCRIPTION The crankcase provides a tight enclosure and oil galleries for lubrication. The crankcase is sufficiently rigid to provide support for the crankshaft, camshaft and bearings. 21-2 CRANKCASE DETAILED DESCRIPTION Two aluminum alloy castings are joined along the vertical center plane to form the complete crankcase.
  • Page 183 FIGURE 21-1. CRANKCASE DESCRIPTION 21-3...
  • Page 184 21-3 CRANKCASE INSPECTION 50 HOUR - Visually inspect accessories for security and all gasket areas for oil leaks. All accessory and cylinder mounting studs must be visually inspected and checked for security. Safety mechanisms such as lockwire and locking tab washers must be inspected for proper installation and security.
  • Page 189 CHAPTER 22 ENGINE DRIVE TRAIN SECTION PAGE 22-1 Engine Drive Train Description................22-2 22-2 Engine Drive Train Component Detailed Description .......... 22-3 22-3 Engine Drive Train Inspection ................22-5 22-4 Engine Drive Train Troubleshooting..............22-5 22-5 Engine Drive Train Maintenance................22-6 FIGURE PAGE 22-1...
  • Page 190 22-1 ENGINE DRIVE TRAIN DESCRIPTION When starting engine, torque is transmitted from the starter (12) through adapter components (13, 14, 15 & 16) to crankshaft gear (1). As worm-wheel (15) is turned, the spring mounted on its hub, is tightened to grip drum of shaftgear (16). After engine is started the spring returns to its normal position releasing the shaftgear and disengaging the starter.
  • Page 197 CHAPTER 23 POST MAINTENANCE ADJUSTMENT AND TEST SECTION PAGE 23-1 Post Maintenance Operational Test..............23-2 23-2 Engine Adjustment And Setup ................23-4 23-3 Test Flight ......................23-12 FIGURE PAGE 23-1 General Oil Pressure Adjustment................. 23-4 23-2 Fuel Pump Adjustment - Idle Speed ..............23-5 23-3 Fuel Servo Adjustments ..................
  • Page 198 23-1 POST MAINTENANCE OPERATIONAL TEST STARTING WARNING Over priming can cause hydrostatic lock and subsequent engine malfunction. CAUTION. . . Insure propeller area is clear before initiating starting sequence. NOTE. . . If engine has had a new cylinder or cylinders and piston rings installed, start the engine in accordance with the airframe manufacturer's Airplane Flight Manual (AFM.) Operate the engine at 750 RPM for one minute, gradually increasing RPM to 1000 RPM in three minutes.
  • Page 199 Reduce engine to idle and record: Manifold Pressure................__________ RPM....................__________ Oil Pressure ..................__________ Oil Temperature................__________ Cylinder Head Temperature ............__________ Magneto System Grounding Check ..........__________ CAUTION. . . The magneto system grounding check must be accomplished at idle RPM only. Damage to the engine may result at engine speeds above idle RPM. WARNING Absence of RPM drop when checking magnetos is an indication of a malfunction in the ignition system resulting in a hot magneto.
  • Page 200 23-2 ENGINE ADJUSTMENT AND SETUP Oil Pressure Adjustment The adjusting screw is turned clockwise to increase oil pressure and counterclockwise to decrease oil pressure. With normal operating oil temperature (180° - 200°F), adjust oil pressure to maintain, 30-80 pounds per square inch at full power RPM. Torque locknut and safety as required.
  • Page 201 23-2 ENGINE ADJUSTMENT AND SETUP (continued) Fuel System Adjustment Verify that the aircraft fuel system is operating properly in accordance with the airframe manufacturer's instructions before performing any engine fuel system setup procedures. Adjust the engine fuel system as follows: NOTE : .
  • Page 202 c. Repeat static runup and readjust pressure as required to obtain fuel pump pressure of 35 to 45 psig. Idle Mixture: Check and adjust idle mixture as follows: Idle Performance a. Operate the engine at 1500 to 1800 rpm until cylinder head temperatures are 250° F to 350°...
  • Page 208 23-3 TEST FLIGHT Ambient air and engine operating temperatures are of major concern during this test flight. Do a normal pre-flight run-up in accordance with the Airplane Flight Manual. Conduct a normal take-off with full power and monitor the fuel flow, RPM, oil pressure, cylinder head temperatures and oil temperatures.

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