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Page 3: Status Page
DESTROY SUPERSEDED PAGES. WARNING If the user of this manual is uncertain whether all current revisions have been incorporated into the manual, contact Teledyne Continental Motors. Do not perform any operation, maintenance, installation or other operation until the manual is confirmed current.
Page 4 Replacement Parts group of parts that have been approved by an WARNING authorized FAA representative. Use only parts meeting the engine type design. 2. FAA Technical Standard Order (TSO) number and identification mark indicating that Replacement Parts the part or appliance was manufactured in Beware of replacement parts, materials and accordance with the requirements of FAR 21 accessories that may be sold as aircraft quality...
Page 5: Notice To All Users
About… Notice to all users comply with the Instructions for Continued Airworthiness result engine This manual does contain operation, malfunction, engine failure, injury or death. maintenance installation information supplemental type certificated components or systems. This manual contains information on The Mechanic engines, components and systems designed, tested maintenance, alteration, Prior to performing,...
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Page 7: Table Of Contents
Table of Contents FRONT SECTION COVER PAGES PAGE Status Page ..................iii Replacement Parts Warning............. iv Notice To All Users ................v Notes, Cautions and Warnings ............v Introduction ..................1-1 AIRWORTHINESS LIMITATIONS Airworthiness Limitations..............AWL SECTION 1 ENGINE OPERATION CHAPTER PAGE Normal Engine Operation ............
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Page 9 INTRODUCTION Chapter Contents Page Introduction.................... 1-2 Scope ...................... 1-2 Definition of Terms ................1-2 Manual Revisions ................... 1-3 Related Publications ................1-3 Service Documents ................. 1-4 Service Reports and Inquiries ..............1-4 Engine Model Code Description ............1-4 Engine Design Features................. 1-4 Glossary ....................
Page 10: Introduction
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Page 11: Introduction
This manual covers the TSI0L-550-C engine. accessories until the manual has been SCOPE confirmed to be current. This publication contains the information This manual is current and correct to the necessary to operate, perform scheduled...
Page 12: Related Publications
4. Fuel Injection Manual, Form X30593A. 5. Starter Service Instructions, Form X30592. 6. Alternator Maintenance and Parts Catalog, Form No. X30631 A. The above publications can be ordered through your Teledyne Continental Motors Distributor or ordered directly, if prepaid, from: Teledyne Continental Motors P.
Page 13: Service Documents
Aircraft Engine service publications should be AD (or an equivalent issued by another made through your distributor or Teledyne country's airworthiness authority). Continental Motors, P. 0. Box 90, Mobile, AL CATEGORY 2: "CRITICAL SERVICE 36601, ATTN: Publications Sales Department. BULLETIN" (CSB)- Service documents (not...
Page 14 Introduction The induction system also includes an airframe A wet oil sump is located at the bottom of the mounted aftercooler with a manifold pressure crankcase and positive displacement oil pump is relief valve (overboost valve) and a sonic located at the lower rear of the crankcase. Oil venturi nozzle to provide air for cabin pressure is maintained by a pressure relief valve pressurization.
Page 15: Glossary
Introduction GLOSSARY BURNING: As applied to valve heads this term NICK: A sharp sided gouge or depression with a indicates roughening or erosion due to high "V" shaped bottom which is generally the result temperature gases escaping past valve faces. In of careless handling of tools and parts.
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Page 17 Section 1 Engine Operation Section Contents Chapter Normal Engine Operation ............1 Emergency Procedures ...............2 Operations Under Abnormal Environmental Conditions ............3 Engine Operating Specifications ..........4...
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Page 19 Chapter 1 Engine Operation Chapter Contents Page Normal Operating Procedures ......... 1-3 Preflight ................1-3 Starting ................1-4 Flooded Engine..............1-4 Hot Starts ................. 1-5 Before Takeoff Check ............1-5 Power Control ..............1-5 Takeoff ................1-6 Climb ................1-6 Cruise................
Page 20: Section 1 Engine Operation
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Page 21: Normal Operating Procedures
Engine Operation 2. Check the throttle, mixture, propeller, and Normal Operating Procedures alternate air controls for freedom of movement and full range of travel. SCOPE This section pertains to operation under normal and 3. Insure that fuel tanks contain the specified grade extreme ambient environmental conditions.
Page 22: Starting
Engine Operation CAUTION… WARNING Release starter switch as soon as engine fires. Never engage the starter while the propeller is still turning. Failure to properly preheat a cold-soaked If the starter has been engaged for 30 seconds and engine could result in oil congealing within the engine has not started, release the starter switch and allow the starter motor to cool for three to five the engine, oil hoses and oil cooler with...
Page 23: Hot Starts
Engine Operation magnetos operated individually should not HOT STARTS differ more than 50 RPM with a maximum drop of 150 RPM for either magneto. Refer to Pilot's Operating Handbook / Airplane Observe engine operation for roughness Flight Manual for specific instructions. during this check.
Page 24: Takeoff
Engine Operation obstacle clearance, increase air speed by reducing TAKEOFF rate of climb, if necessary, to control temperatures. Refer to Pilot's Operating Handbook / Airplane Flight Manual for specific instructions. CRUISE 1. Position mixture to FULL RICH. Where Follow the specific leaning procedure in the airframe installed, cowl flaps must be positioned as manufacturer’s Pilot's...
Page 25: Engine Shutdown
ENGINE SHUTDOWN Refer to Pilot's Operating Handbook / Airplane Flight Manual for specific instructions. 1. If boost pump has been on for landing, turn to OFF. 2. With engine speed at idle rpm, quickly turn both magnetos off then back on. The engine should cease running momentarily indicating both magnetos are properly grounded.
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Page 27: Emergency Procedures
Chapter 2 Emergency Procedures Chapter Contents Page Engine Fire During Start..............2-3 General In-flight Information ............2-3 Abnormal Engine Instrument Indications......... 2-3 High Coolant Temperature............... 2-3 High Oil Temperature............... 2-4 Low Oil Pressure ................2-4 In-Flight Restarting ................2-4 In-Flight Engine Fire................ 2-4...
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Page 29: Engine Fire During Start
Emergency Procedures Observe engine nacelle area for visible damage or EMERGENCY PROCEDURES evidence of smoke or flame. If any of these are ENGINE FIRE DURING START noted, follow airframe manufacturer's instructions. Refer to Pilot's Operating Handbook / Airplane Extreme roughness may be indicative of a propel- Flight Manual for specific instructions.
Page 30: Low Oil Pressure
Emergency Procedures LOW OIL PRESSURE IN-FLIGHT ENGINE FIRE Refer to Pilot's Operating Handbook / Airplane WARNING Flight Manual for specific instructions. 1. Fuel Selector - OFF. If the oil pressure drops from a normal in- 2. Mixture Control - IDLE CUT-OFF. dication of 30 to 60 PSI, land as soon as pos- sible.
Page 31: Operation Under Abnormal Environmental Conditions
Chapter 3 Operation Under Abnormal Environmental Conditions Chapter Contents Page Abnormal Environmental Conditions.............3-3 Cold Weather Operation ................3-3 Preheating ....................3-3 Hot Weather Operation................3-4 Ground Operation at High Altitude Airports.........3-4...
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Page 33 Emergency Procedures 2. The preferred method of preheating is to place ABNORMAL ENVIRONMENTAL the aircraft in a heated hangar for a minimum of CONDITIONS two hours prior to flight. GENERAL 3. Minimum preheat application may warm the engine enough to permit starting but will not de- Three areas of operation require special attention: congeal oil in the sump, lines, cooler or filter.
Page 34 Emergency Procedures e. Insure that aircraft tie-downs are NOTE.… installed and verify that the cabin Prior to operation in hot weather conditions, insure door latch is open. that the engine is serviced with the correct viscosity oil. Do not stand within the arc of the propeller blades while turning the propeller.
Page 35: Engine Operating Specifications
Chapter 4 Engine Operating Specifications Chapter Contents Page Engine Operating Specifications............4-3 Constant Speed Sea Level Performance Curve........4-4 Fuel Flow VS. Brake Horsepower Performance Curve .......4-5 Fuel Flow VS. Metered Pressure Performance Curve......4-6...
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Page 37 Operating Specifications Usable Oil (quarts) Engine Operating Limits 20° nose up ..........7.5 Maximum Continuous BHP (-0, +5%).....350 14.5° nose down .......... 6.5 Manifold Pressure, in. Hg (Kpa) .....39.5 Maximum oil consumption, lb/bhp/hr RPM..............2600 .006 x % Power Maximum Recommended Cruise: Note: 1 quart = 1.9 pounds ........262 hp.
Page 41 Airworthiness Limitations AIRWORTHINESS Other Related Procedures LIMITATIONS Subject to additional information contained in the Airworthiness Directives (AD) This Airworthiness Limitations section has been issued after the date of certification, there FAA approved and specifies maintenance are no other related procedures required required under §§...
Page 42 Airworthiness Limitations INTENTIONALLY LEFT BLANK Airworthiness Limitations...
Page 43 Section 2 Engine Maintenance Section Contents Chapter Scheduled Maintenance and Servicing Fluids......... 1 Engine Preservation and Storage............2 Tools, Equipment, Sealants and Lubricants, ........... 3 Troubleshooting..................4 Standard Practices .................. 5 Engine Maintenance ................6 Exhaust and Turbocharger System............7 Ignition System ..................
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Page 45: Scheduled Maintenance And Servicing Fluids
Chapter 1 Scheduled Maintenance and Servicing Fluids Chapter Contents Page General ......................1-3 Overhaul Periods..................1-3 Operational Inspection.................1-3 Test Operating Limits ...................1-4 Time Interval Inspections ................1-5 25 Hour Inspection ................1-5 50 Hour Inspection ................1-6 100 Hour Inspection ................1-8 200 Hour Inspection ................1-10 300 Hour Inspection ................1-10 500 Hour Inspection ................1-10 Annual Inspection ..................1-10...
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Page 47 Airworthiness Directives as specified in Part 39 of the Federal Aviation Regulations (FAR); Engine Model Overhaul Period reference FAR 91.163. The owner/operator is TSI0L-550-C 2000 HOURS responsible for assuring the engine meets the conformity requirements as specified by the original NOTE…...
Page 48 Scheduled Maintenance Slowly move mixture control to IDLE CUT OFF and record: OPERATIONAL CHECK LIST Mixture RPM Rise ( 25 to 50 RPM ) .__________ Check and record the following system data : Positive Fuel Cutoff ......__________ When propeller stops rotating, place ignition switch, Starter.............
Page 49 Scheduled Maintenance Magneto Drop......... 150 RPM Magneto Spread (Max.)......50 RPM 1. After the first 25 hours of operation on new, rebuilt or overhauled engines, perform a complete Coolant temperature 100-hour inspection. Drain the oil used for engine Out of Coolant Pump (limit)......230º F break-in.
Page 50 Scheduled Maintenance accordance with the aircraft manufacturer's 50-HOUR INSPECTION instructions. With induction air filter installed: (a) Verify the induction air filter retainer is NOTE… properly installed and the attaching hardware Research and comply with any applicable Service is secure in accordance with the aircraft Publications and Airworthiness Directives.
Page 51 Scheduled Maintenance 9. Drain engine oil. During engine oil change, oil 17. At the completion of any maintenance event the must be drained into an appropriate container and engine must be given a complete and thorough disposed of properly. Reinstall oil drain plug with operational run-up.
Page 52 Scheduled Maintenance 8. Clean, inspect, gap, test and rotate all spark plugs. 100-HOUR INSPECTION See chapter 8 of this section for spark plug wear determination and spark plug rotation. NOTE… Research and comply with the Service Publications WARNING and Airworthiness Directives. Worn spark plugs that are continued in In addition to the items listed in 50 Hour the service may cause internal arcing in the...
Page 53 Scheduled Maintenance NOTE… 19. Remove the turbocharger compressor discharge Any environmentally hazardous materials used in duct and inspect the interior for evidence of oil. If cleaning must be caught and disposed of in there is evidence of oil in the duct, further accordance with Environmental Protection Agency inspection of the turbocharger is required to regulations.
Page 54: Annual Inspection
Scheduled Maintenance 200-HOUR INSPECTION ANNUAL INSPECTION Perform all requirements of 25, 50, 100, 200, 300 Change coolant every 200 hours or annually, hour and any calender inspections due. Replace the whichever comes first in accordance with the magneto pressurization filter with a new element and airframe manufacturer’s instructions.
Page 55: Unscheduled Maintenance
Unscheduled Maintenance induction system and/or cylinder assembly or failure to properly drain preservation oil. UNSCHEDULED MAINTENANCE Unscheduled maintenance events include but are not Damage from a hydraulic lock can be extensive. limited to: Engine components such as connecting rods, cylinder assemblies, pistons, piston pins, crankcase and PROPELLER STRIKES crankshaft can be damaged due to overstress.
Page 56: Engine Overspeed Inspection
Unscheduled Maintenance RPM TO 3300 ENGINE OVERSPEED INSPECTION In addition to action required for "" above proceed as Engine operation at engine speeds in excess of rated follows: RPM limitations can cause damage to the engine and 1. Remove all cylinder assemblies including rods can result in subsequent engine failure.
Page 57: Servicing Fluids
Servicing Fluids SERVICING FLUIDS WARNING Engine operation with no oil or severely CAUTION… reduced levels will cause engine Some funnel-type quart containers incorporate a malfunction or failure. styrofoam or aluminum seal. Remove this seal from the container and discard it before adding oil to the engine.
Page 58 Servicing Fluids CAUTION... OIL ANALYSIS Petroleum base aviation engine oil is flammable Spectrographic oil analysis has become popular and must be stored in a well ventilated area away with the owners and operators of general aviation from any heat source. piston powered aircraft.
Page 59 Servicing Fluids sample is taken from the oil as it drains from the SPECTROGRAPHIC OIL ANALYSIS sump, allow approximately 1/3 of the oil drain prior to taking the sample. If the sample is taken A proper spectrographic oil analysis program via the oil filler or other location using a sampling should begin with the first engine oil change.
Page 60 Servicing Fluids tank and bleed until air-free coolant is observed. WARNING d. Inspect for leaks. Removing filler cap with a hot pressurized e. Check coolant level and refill as required. system can result in severe burns. Install filler cap and run engine at 1000 rpm FILLING PROCEDURE for two minutes.
Page 61: Engine Preservation And Storage
Chapter 2 Engine Preservation and Storage Chapter Contents Page General....................... 2-3 Engine Preservation................... 2-3 Temporary Storage ..................2-3 Preparation for Storage................2-4 Indefinite Storage Inspection Procedures ..........2-4 Returning an Engine to Service After Storage .......... 2-4...
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Page 63: General
Preservation c. Throttle position "CLOSED." GENERAL d. Mixture control "IDLE-CUT-OFF." There is no practical procedure that will insure corrosion prevention on installed aircraft engines. e. Set brakes and block aircraft wheels. Susceptibility corrosion influenced Insure that aircraft tie-downs are geographical location, season and usage. The installed and verify that the cabin owner/operator is responsible to recognize the door latch is open.
Page 64: Preparation For Storage
Preservation 5. Re-spray each cylinder. To thoroughly cover PREPARATION FOR STORAGE all surfaces of the cylinder interior move the 1. Remove oil sump drain plug and drain oil. nozzle or spray gun from the top to the Replace drain plug, torque and safety. Remove bottom of the cylinder.
Page 65 Preservation WARNING 5. Service and install spark plugs and ignition leads To prevent possibility of serious bodily injury accordance with manufacturer's or death, before moving the propeller instructions. accomplish the following: 6. Service engine and aircraft in accordance with a. Disconnect all spark plug leads. the manufacturer's instructions.
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Page 67: Tools, Equipment, Sealants And Lubricants
Chapter 3 Tools, Equipment, Sealants, and Lubricants Chapter Contents Page General Information................3-3 Possible Special Tool Procurement Sources........3-4 Special Tools ..................3-5 Sealants and Lubricants............... 3-8...
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Page 69: General Information
TOOLS GENERAL INFORMATION The mechanic should be equipped with a complete set of the necessary tools that include the following: Wrenches - 1/4” through 1 1/4" Common and Philips Head Screwdrivers Pliers - Common, Diagonal Cutters, Needle Nose, Duck Bill, Snap Ring , Safety Wire Ratchets 1/4", 3/8", 1/2"...
Page 70: Possible Special Tool Procurement Sources
TOOLS POSSIBLE SPECIAL TOOL PROCUREMENT SOURCES —NOTICE— All tools in the "Special Tool" list are for reference only, and not for the purpose of promoting or suggesting tools to be purchased from the indicated sources. The following information is given as an aid for special tool procurement purposes.
Page 71 TOOLS SPECIAL TOOLS Specific tools listed or equivalent tools marketed by other manufacturers are necessary for overhaul and maintenance of the aircraft engine. ITEM TOOL SECTION GENERAL ENGINE RECIPROCATING 646953 Master Orifice Tool for cylinder compression test available from Kent - Moore. 7251 Differential Pressure Cylinder Checker available from Kent - Moore.
Page 72 TOOLS ITEM TOOL SECTION Borrough's 5221A Holding Fixture Adapters or equivalent. 20-6 Borrough's 5221 13A Cylinder Holding Fixture or equivalent. Borrough's 8156 Cylinder Heating Stand or equivalent. Borrough's 8086 Valve Seat Insert Remover & Replacer or equivalent. Borrough's 4910 Installer Valve Seat Insert or equivalent. Borrough's 4956 Installer Valve Seat Insert or equivalent.
Page 73 TOOLS ITEM TOOL SECTION Borrough's 8087A Polishing Tools for Crankshaft Bearings or equivalent. 22-5 4965A Crankshaft Blade and Damper Bushing Remover/Replacer available from Kent- Moore. Borrough's 8077A Bushing Remover & Replacer, Counterweight or equivalent. . Borrough's 8111A Connecting Rod Fixture or equivalent. Borrough's 8042C Adapter Kit or equivalent for connecting rod inspection 5008 Reamers for connecting rod bushing available from Kent - Moore D-4000 Federal Dimension Air Gauge for connecting rod bushing inspection available...
Page 74: Sealants And Lubricants
Sealants And Lubricants 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...
Page 75 Sealants And Lubricants Preservative Oil TYPE SUGGESTED SOURCES APPLICATION (Aeroshell Fluid 2F or equivalent) For Temporary storage (up to 90 MIL-C-6529 Type 11 days) MIL-P-46002, Grade 1 oil (NOX RUST VCI-105 or For Indefinite storage equivalent) May be purchased through: Rock Island Lubricant & Chemical Co.
Page 76 Sealants And Lubricants Lubricants TYPE SUGGESTED SOURCES APPLICATION May be purchased through your All fuel injector nozzles (at cylinder 646943 - Anti Seize Lubricant local TCM Distributor or For head) Distributor information: Loctite Loctite Anti-Seize Lubricant 767 Customer Service @ Phone: 1-800-243-4874 Exhaust studs (nut end before torquing)
Page 77 Sealants And Lubricants Sealants TYPE SUGGESTED SOURCES APPLICATION LUBRIPLATE® 930 AA For Distributor information Call Apply to the outside diameter of valve (P/N L0096-035) LUBRIPLATE® guides at installation @ Phone: 1-800-733-4755 May be purchased through Spray exhaust end of turbocharger for TCM P/N 654514 CRC 336 Rust Preventative Compound your local TCM Distributor...
Page 78 Sealants And Lubricants TYPE SUGGESTED SOURCES APPLICATION All pipe thread fittings in fuel #646940 - F/I Sealant May be purchased through injection system (use sparingly on your local TCM Distributor male threads only) Loctite Hydraulic Sealant 569 For Distributor information: Loctite Customer Service, Phone: 1-800-243-4874 Miller Stephenson...
Page 79 Sealants And Lubricants Miscellaneous TYPE SUGGESTED SOURCES APPLICATION TCM P/N 626531-1 May be purchased through High temp. paint for cosmetic and Enamel - Gold (1 qt) your local TCM Distributor corrosion protection TCM P/N 626531-2 Enamel - Gold (1 gal) TCM P/N 535001S May be purchased through Where applicable for lockwiring...
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Page 81: Troubleshooting
Chapter 4 Troubleshooting Chapter Contents Page General Information .................. 4-3 Engine Troubleshooting................4-3 Fuel Injection Troubleshooting ..............4-9 Induction Troubleshooting................. 4-12 Ignition Troubleshooting ................4-12 Starting Troubleshooting ................4-13 Lubrication Troubleshooting ..............4-14 Cylinder Troubleshooting ................4-15 Crankcase Troubleshooting............... 4-16 Cranshaft Troubleshooting ................
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Page 83 Troubleshooting Any attempt by unqualified personnel to adjust, repair GENERAL INFORMATION or replace any parts, may result in engine malfunction The troubleshooting chart which follows discusses or failure. symptoms which can be diagnosed and interprets the WARNING probable causes and the appropriate corrective actions to be taken.
Page 84 Troubleshooting ENGINE TROUBLESHOOTING (continued) TROUBLE PROBABLE CAUSE CORRECTION Rough Idling (continued) Hydraulic tappets fouled Replace fouled tappets. Inspect and clean oil filter at more frequent intervals Burned or warped exhaust valves Inspect, repair or replace cylinder. worn seat, scored valve guides Replace any burned, warped or worn exhaust valves Manifold valve vent obstruction...
Page 85 Troubleshooting ENGINE TROUBLESHOOTING (continued) TROUBLE PROBABLE CAUSE CORRECTION Continuous Missing At Plugged fuel nozzle jet Clean. Replace nozzle if obstruction High Speed (continued) cannot be cleared by solvent action. Never use wire or any other object to clear nozzle jet Burned or warped valve Inspect, repair or replace cylinder.
Page 86 Troubleshooting ENGINE TROUBLESHOOTING (continued) TROUBLE PROBABLE CAUSE CORRECTION Oil Leaks At front of engine, damaged Replace crankshaft oil seal crankshaft oil seal Around plugs, fittings and gaskets Torque or replace due to looseness or damage Low Compression Piston rings excessively worn Inspect, repair or replace cylinder.
Page 87 Troubleshooting ENGINE TROUBLESHOOTING (continued) TROUBLE PROBABLE CAUSE CORRECTION Engine Has Incorrect fuel/air mixture, worn Replace worn elements of linkage. Poor Acceleration (continued) control linkage, or restricted air Service air cleaner in accordance cleaner with airframe manufacturer's instructions Malfunctioning ignition system Check ignition cables and connections in accordance with the ignition manufacturer's instructions...
Page 88 Troubleshooting ENGINE TROUBLESHOOTING (continued) TROUBLE PROBABLE CAUSE CORRECTION Engine Lacks Power, Malfunctioning ignition system Inspect spark plugs for fouled Reduction in Maximum component electrodes, heavy carbon deposits, Manifold Pressure (continued) erosion of electrodes, improperly adjusted electrode gaps, cracked porcelains. Test plugs for regular firing under...
Page 89 Troubleshooting ENGINE TROUBLESHOOTING (continued) TROUBLE PROBABLE CAUSE CORRECTION Low Oil Pressure Indication On Low oil supply. Oil viscosity too Replenish. Drain and refill with Engine Gauge (continued) correct viscocity Malfunctioning oil pump Repair or replace oil pump Weak or broken oil pressure relief Replace spring.
Page 90 Troubleshooting FUEL INJECTION (continued) TROUBLE PROBABLE CAUSE CORRECTION Fluctuating or Erroneous Fuel Flow Vapor in system, excess fuel If not cleared with auxiliary pump, Indications temperature check for clogged ejector jet in vapor separator cover. Clean only with solvent, no wires. Refer to airframe manufacturer's instruction Air in fuel flow gauge line.
Page 91 Troubleshooting FUEL INJECTION (continued) TROUBLE PROBABLE CAUSE CORRECTION Rough Idle (continued) Improper idle mixture Adjust fuel mixture in accordance with section 2, chapter 18, "Fuel System Adjustment” Poor Acceleration Idle mixture incorrect Adjust fuel mixture in accordance with section 2, chapter 18, "Fuel System Adjustment”...
Page 92 Troubleshooting INDUCTION TROUBLE PROBABLE CAUSE CORRECTION Engine Will Not Start Induction system intake obstructed Locate and remove obstruction Engine Will Not Run At Idling Induction system leakage See section 2, chapter 10 Speed Engine Runs Too Rich At Cruise Restrictions in air intake passages Check air passages remove Power |restriction...
Page 93 Troubleshooting IGNITION (continued) TROUBLE PROBABLE CAUSE CORRECTION Rough At Speeds Above Idle High tension leak in ignition Inspect ignition harness in (continued) harness accordance with harness manufacturer's instructions Weak or burned out condenser as Replace points and condenser in evidenced by burned or pitted accordance with magneto breaker points manufacturer's instructions...
Page 94 Troubleshooting LUBRICATION TROUBLE PROBABLE CAUSE CORRECTION Excessive Oil Consumption Oil leakage Replace leaking oil lines, torque loose connections Gasket or seal leakage Replace gasket or oil seals Improper seasonal weight or grade Service engine with proper oil, see section 2, chapter 1 Worn piston rings or valve guides Inspect, repair or replace cylinder.
Page 95 Troubleshooting CYLINDERS TROUBLE PROBABLE CAUSE CORRECTION Rough Idling Hydraulic tappets fouled See section 2, chapter 15, Cylinder Assembly Maintenance "Hydraulic Tappets" Burned or warped exhaust valves, See section 2, chapter 15, Cylinder worn valve seats. Scored valve Assembly Maintenance "Cylinders" guides Valve seats worn and leaking, See section 2, chapter 15, Cylinder...
Page 96 Troubleshooting CRANKCASE TROUBLE PROBABLE CAUSE CORRECTION Oil Loss Loose accessories or deteriorated See section 2, chapter 16, gaskets "Crankcase Maintenance Cracked crankcase See Section 2, chapter 16, "Crankcase Inspection Insuffcient torque Tighten hardware to proper torque in accordance with the applicable Overhaul Manual Loose accessories Loose or stripped studs...
Page 97 Troubleshooting EXHAUST TROUBLE PROBABLE CAUSE CORRECTION Engine Lacks Power, Reduction in Improperly adjusted controller Adjust controller in accordance Maximum Manifold Pressure Or with section 2, chapter 7 Critical Altitude Loose or damaged exhaust system Inspect entire exhaust system to turbocharger for cracks and leaking connections.
Page 98 Troubleshooting EXHAUST (continued) TROUBLE PROBABLE CAUSE CORRECTION Engine Oil Level Frequently Low Leaking check valve Replace check valve After Servicing Prior to Operation Leaking Turbocharger check valves Replace check valves. Refer to and seals Turbocharger Manufacturer's Instructions for turbocharger maintenance Lack of Oil to Turbocharger Damaged check valve Replace check valve...
Page 99: Standard Practices
Chapter 5 Standard Practices Chapter Contents Page General....................... 5-3 Lockwire Procedure................... 5-4 Tab Washer Procedure ................5-6 Cotter Pin Procedure ................. 5-6 Application Of Adhesives................5-7 Installation Of Gaskets................5-7...
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Page 101: General
Chapter 5 GENERAL All lockwire and cotter pins must fit snugly in holes drilled in specific hardware. On castellated nuts, unless otherwise specified, the cotter pin head must fit To facilitate and insure proper reinstallation, tag or into a recess of the nut with the other end bent such mark all parts and hardware as they are removed or that one leg is back over the stud and the other is disassembled.
Page 102: Lockwire Procedure
Chapter 5 LOCKWIRE PROCEDURE and require twisting at a rate of 7 to 10 twists per inch. Smaller lockwire (when specified or required) will require twisting at a rate of 9 to 12 twists per inch. Lock wiring is the securing together of two or more Lockwire must be new at each application.
Page 103 Chapter 5 Various examples of lockwiring are shown in Figure twisted portion should be within one-eighth 5-2, "General Lockwire Patterns." (1/8) inch from the hole in either unit. 1. Check the units to be lockwired to insure 2. Insert the uppermost strand through the hole they have been correctly torqued.
Page 104: Tab Washer Procedure
Chapter 5 FIGURE 5-3 GENERAL TAB WASHER INSTALLATION PROCEDURE Cotter pins are not reusable and must be replaced with TAB WASHER PROCEDURES a new cotter pin after removal. Tab washers are installed by fitting a tab in a tab slot and bending the remaining tabs firmly against the bolt 1.
Page 105: Application Of Adhesives
Chapter 5 FIGURE 5-4. GENERAL COTTER PIN INSTALLATION NOTE… APPLICATION OF ADHESIVES TCM general purpose primer P/N 653160 must be used for surface preparation before applying Gasket Maker at the engine nose seal area. Adhesives and sealants will be used only in specific applications outlined in Chapter 2, "Table Of Sealants INSTALLATION OF GASKETS and Lubricants."...
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Page 107: Engine Maintenance
Chapter 6 Engine Maintenance Corrections and adjustments will be found in the GENERAL individual system chapters of this manual under During engine 50 and 100 hour inspections, if "Maintenance," and section 2, chapter 18, "Post engine components must be removed and replaced, Maintenance Adjustment And Test."...
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Page 109 Chapter 7 Exhaust & Turbocharger System Chapter Contents Page Exhaust System Description..............7-3 Turbocharger Description ..............7-4 Turbocharger Lubrication System ............7-5 Bypass Valve (Wastegate) Description ..........7-6 Sloped Controller Description .............7-7 Controller Adjustment................7-8 Exhaust System Maintenance...............7-8...
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Page 111: Exhaust System Description
Exhaust During normal engine operation, exhaust gasses exit Exhaust System Description the cylinder combustion chambers, and flow through The exhaust system is comprised of the following the exhaust collector to the turbocharger turbine components: housing inlet. The exhaust flow rotates the turbine and exits through the turbine discharge port and the 1.
Page 112: Turbocharger Description
Exhaust Turbocharger Description Engine manifold pressure is maintained within the specified limits by controlling the turbocharger The turbocharger consists of a radial inward flow compressor discharge pressure. turbine and turbine housing, a centrifugal flow Compressor discharge pressure (deck pressure) is impeller (compressor) and compressor housing, each regulated by controlling the flow of exhaust gas bolted to a center housing.
Page 113: Turbocharger Lubrication System
Exhaust FIGURE 7-2. TURBOCHARGER DESCRIPTION Turbocharger Lubrication System Turbocharger lubricating oil is supplied by the engine. An oil supply hose from the rear of the oil Piston ring-like oil seals on the compressor wheel cooler adapter directs engine oil through a hose to shaft prevent the lubricating oil from entering the the turbocharger center housing and bearings.
Page 114 Exhaust Exhaust Bypass Valve (Wastegate) valve actuator. The pressurized oil acting on the Description actuator plunger and against spring pressure, drives the by-pass valve butterfly to the closed position. The exhaust by-pass valve or wastegate is an oil A sloped controller is connected in the oil return actuated, butterfly type valve.
Page 115: Sloped Controller Description
Exhaust constantly monitors deck pressure, and the pressure Sloped Controller Description differential between the deck and manifold pressure due to a partially closed throttle. If either the deck The sloped controller is designed to maintain the pressure or throttle differential pressure rises, the rated compressor discharge (deck) pressure at wide- controller poppet opens, increasing oil flow, open throttle, to reduce the deck pressure at wide-...
Page 116: Controller Adjustment
Exhaust System Disassembly/Reassembly in the range. After reaching normal operating TSI0L-550-C Overhaul Manual, Form OH-15. temperatures run the engine to full power to clear Turbochargers, Wastegate, Controller any congealed oil from the wastegate and oil lines. replacement...
Page 117: Ignition System
Chapter 8 Ignition System Chapter Contents Page General.................... 8-3 Ignition Systems Description............8-3 Spark Plugs ..................8-4 Magneto to Engine Timing.............. 8-6 Magneto Impulse Coupling Test ............8-6 Ignition System Maintenance ............8-12...
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Page 119: General
Ignition eight studs, washers and nuts. The magneto drive General gear assemblies are installed in the front of the This chapter describes the Slick 6320 ignition adapter and meshed in the proper position with the system installed on TSIOL-550-C engines and idler gear.
Page 120: Spark Plugs
Ignition 3. Replace any spark plug that does not fire properly. Insure that each spark plug is free of residue from the cleaning process. Spark Plugs 4. Apply Champion thread lubricant to all spark ® Remove spark plugs for cleaning or replacement in plugs in accordance with the manufacturer’s accordance with...
Page 121 Ignition NORMAL ELECTRODE CONDITION Insulator tip gray, tan or light brown. Few combustion deposits. Electrodes not burned or eroded. Proper type heat range plug for engine and service. Spark plug should be cleaned regapped and tested before reinstallation. NORMAL WORN-OUT CONDITION Electrodes eroded by high-voltage sparking and by corrosive gases formed during combustion to less than 1/2 original thickness.
Page 122: Magneto To Engine Timing
Ignition Magneto to Engine Timing Magneto Impulse Coupling Test WARNING WARNING To prevent possibility of serious bodily Failure to properly ground magnetos will injury death, before moving result in engine ignition and possible injury propeller accomplish the following: to personnel. a.
Page 123 Ignition When performing a magneto timing check, use the 4. Install the Top Dead Center locator into number 1 following tools: cylinder top spark plug hole. • Top dead center locator 5. Slowly rotate the crankshaft in the direction of •...
Page 124 Ignition FIGURE 8-4. TIMING PROCEDURE STEP 2 2. Slowly turn crankshaft in opposite direction of normal rotation until the piston lightly touches the TDC locator. 3. Observe the reading on the disc under the pointer and move the disc exactly one half of the number of degrees observed toward the top center mark.
Page 125 Ignition FIGURE 8-5. TIMING PROCEDURE STEP 3 1. Remove the TDC locator from the cylinder and find the compression stroke on the No. 1 cylinder by placing a finger over the spark plug hole (or by any other adequate method). As you come up on compression, stop the pointer at the TDC location determined in step 3.
Page 126 Ignition 5. To check either the magneto timing or to time the magneto to the engine, move the propeller in the opposite direction of normal rotation past the specified magneto timing setting and then back in the direction of normal rotation until the desired setting before top dead center is under the pointer.
Page 127 Ignition FIGURE 8-7. TIMING PROCEDURE STEP 5 The breaker points should just be starting to open at this setting. Breaker point opening must be checked with a timing light. 8-11...
Page 128: Ignition System Maintenance
Ignition Ignition System Maintenance Magneto Drive Adapter Removal and Replacement Remove magneto drive adapter assemblies for repair or replacement in accordance with the applicable portion of the “Magneto And Accessory Drive” disassembly instructions in the TSIOL-550-C Overhaul Manual, Form OH-15. When performing magneto drive adapter repairs prior to engine TBO, the dimensional limits on page 8-13 may be used.
Page 129 Ignition Service Limits Refer to Figure 8-8 below for the location of the following magneto components: Ref. Service Description Limits Bushing in magneto and accessory drive adapter ......Diameter: 0.0040T Magneto and accessory drive gear in adapter bushing....Diameter: 0.0050L Oil seal in adapter ..............Diameter: 0.0070T Sleeve in magneto and accessory drive gear ......
Page 130 Ignition Magneto Removal and Replacement Ignition Harness Removal and Remove the magnetos for repair or replacement in Replacement accordance with “Ignition System Remove the harness assemblies for repair or Disassembly/Reassembly” in the TSIOL-550-C replacement in accordance with the applicable Overhaul Manual, Form OH-15. “Ignition System Disassembly/Reassembly...
Page 131: Fuel Injection System
Chapter 9 Fuel Injection System Chapter Contents Page General ......................9-2 Fuel System Description................9-2 Fuel Pump ....................9-4 Throttle and Fuel Metering Unit ..............9-6 Fuel Manifold Valve ..................9-7 Fuel Nozzle Assembly ...................9-8 Fuel System Maintenance................9-9 Throttle and Mixture Control Levers............9-9 Fuel Manifold Valve Replacement ............9-11 Fuel Nozzles Removal, Cleaning and Replacement ......9-12 Fuel Pump Replacement................9-14 Fuel Pump Coupling Service Limits............9-14...
Page 132: General
The fuel metering unit/air throttle controls the This chapter describes the fuel injection system amount of intake air admitted into the intake installed on the TSI0L-550-C and provides manifold and meters the proportionate amount of scheduled maintenance information. fuel to the fuel manifold valve.
Page 133 Fuel System AIRCRAFT SUPPLY UNMETERED FUEL PRESSURE FUEL P.S.I. METERED FUEL UPPER DECK METERED PRESSURE PRESSURE FUEL MANIFOLD VALVE VAPOR RETURN FUEL INJECTOR NOZZLES UPPER DECK PRESSURE REFERENCE FUEL PRESSURE P.S.I. FUEL PUMP WITH MIXTURE CONTROL UNMETERED PRESSURE THROTTLE BODY FIGURE 9-1.
Page 134: Fuel Pump
Fuel System full rich position, fuel exits the fuel pump outlet. If Fuel Pump the mixture control is placed in an intermediate Fuel enters the fuel pump at the swirl well of the position, fuel flows through the pump outlet and vapor separator.
Page 135 Fuel System FIGURE 9-2. FUEL PUMP DESCRIPTION...
Page 136: Throttle And Fuel Metering Unit
Fuel System Fuel flow through the fuel metering plug calibrated Throttle and Fuel Metering Unit orifice is controlled by the position of the eccentric The throttle and fuel metering unit controls engine cam connected to the throttle shaft and the adjusted air intake and sets the metered fuel pressure for position of the fuel metering plug.
Page 137: Fuel Manifold Valve
Fuel System Fuel Manifold Valve plunger is down in the body bore, fuel passages to The fuel manifold valve distributes fuel to the fuel the nozzles are closed off. The plunger is drilled injector nozzle in each of the six cylinders for passage of fuel from the diaphragm chamber to its base and to the valve within the plunger.
Page 138: Fuel Nozzle Assembly
Fuel System Fuel Nozzle Assembly The fuel discharge nozzle assembly is located in body to admit air. A sleeve is mounted on the the cylinder head. The nozzle outlet is screwed into nozzle body and extends over the nozzle body. the tapped fuel nozzle hole in the cylinder head.
Page 139 Fuel System If the fuel system is not functioning properly, see Fuel System Maintenance section chapter “Fuel System Compare recorded findings operational Troubleshooting” to determine the cause and the inspection with the following data: procedure for correcting it.” Unmetered or Pump Pressure (PSI) Throttle And Mixture Control Levers 6.0 - 8.0.........@600 RPM To insure proper...
Page 140 Fuel System Worn or corroded cable connections, attaching offers rebuilt fuel injection system hardware, levers or lever bushings must be components as an alternative to field repair of replaced accordance with airframe components. Fuel system component repairs must manufacturer’s instructions and the applicable be performed in accordance with the Fuel Injection disassembly/reassembly instructions in the TSI0L- System Parts and Overhaul Manual, Form...
Page 141 Fuel System Inspect all screw threads to insure that none Fuel Manifold Valve Replacement are damaged. Use the following procedure to remove and replace 13. Orient manifold valve bracket on new the fuel manifold valve: manifold valve using 4 plain washers and 1.
Page 142 Fuel System 2. Loosen and remove the fuel line from the fuel an additional 3/4 to 1 turn. Avoid deforming the injector nozzle assembly. rubber seals. 3. Remove the air reference tube and the rubber 15. Torque the fuel line “B” nut to 40 - 45 inch seal from the sleeve assembly.
Page 143 Fuel System FIGURE 9-8. FUEL NOZZLE ASSEMBLY 9-13...
Page 144 Fuel System and the fuel pump drive coupling to fuel pump Fuel Pump Replacement clearance 0.0030L to 0.0090L must be checked. The fuel pump can be replaced or it can be repaired CAUTION... and calibrated in accordance with the applicable When performing dimensional inspections, the instructions in the Fuel Injection System Parts And following Fits and Limits may be used.
Page 145 Fuel System CAUTION... Fuel Pump Replacement (continued) Never use Teflon tape on fuel injection system 1. Remove any airframe components required to fittings. gain access to the fuel pump in accordance 10. The fittings must be clean and free of damage with the airframe manufacturer’s instructions.
Page 146 Fuel System instructions in the Fuel Injection System Parts And 20. After requirements scheduled Overhaul Manual, Form X30593, latest revision. maintenance have been performed and prior to any engine operation, a complete fuel system leak check must be performed in accordance 9.
Page 147 Fuel System assembly to junction box on throttle and with the aircraft manufacturer or STC holder’s fuel metering unit. information. Fuel Hose Replacement 13. Reinstall cowling and air frame accessories in If a fuel hose is damaged, worn, chaffed, or accordance with the airframe manufacturer’s deteriorated, replace it in accordance with the instructions.
Page 148 Fuel System 5. Remove the air reference tube assembly. 6. If both sides of the air reference system are to be removed, remove the two hose clamps and the hose from the other side of the air reference junction box and repeat steps 5 and 6 above. 7.
Page 149 Fuel System TABLE 1. TORQUE SPECIFICATIONS FOR FITTINGS SIZE FITTING AND MATERIAL TUBE O.D. INCH POUNDS #2 (Brass/Aluminum) .125 15-30 5/16-24 5/16-24 #2 (Steel) .125 15-50 3/8-24 #3 (Brass/Aluminum) .188 40-65 3/8-24 #3 (Steel) .188 50-90 7/16-20 #4 (Brass/Aluminum) .250 60-80 7/16-20 (Steel)
Page 150 INTENTIONALLY LEFT BLANK 9-20...
Page 151: Induction System
Chapter 10 Induction System Chapter Contents Page Induction System Description ..............10-2 Overboost Valve Detailed Description ............10-2 Induction System Inspection ...............10-3 50 Hour ....................10-3 100 Hour ....................10-3 Induction System Maintenance..............10-3 10-1...
Page 152 Induction System Installed on the aftercooler is an overboost valve that INDUCTION SYSTEM DESCRIPTION will relieve excessive deck pressure in the event of See Figure 7-1, " Exhaust And Induction System wastegate/controller malfunction. Air exiting the Schematic," for induction system components and throttle assembly flows into the induction manifold induction air flow.
Page 153 TSI0L-550-C Overhaul Manual, Form OH-15. Induction System disassembly and reassembly procedures. WARNING Modification of or deviation from the original intake manifold design may result in...
Page 154 Induction System INTENTIONALLY LEFT BLANK 10-4...
Page 155 Chapter 11 Liquid Cooling System Chapter Contents Page General...................11-2 Liquid Cooling System ..............11-2 Cooling System Components............11-2 Coolant System Flushing ...............11-3 Maintenance...................11-3 Coolant Pump Replacement............11-3 Coolant System Clamps and Tubing ...........11-3 11-1...
Page 156: Liquid Cooling System
Liquid Cooling System General 2. Airframe mounted heat exchanger (radiator) This chapter provides inspection and maintenance 3. An airframe manufacturer supplied, engine information for the TSIOL-550-C liquid cooling mounted coolant reservoir. system. 4. Coolant manifolds, tubing and clamps. Liquid Cooling System The coolant pump circulates coolant through the CAUTION...
Page 157 Liquid Cooling System Coolant System Flushing 3. Measure gap between cap assembly flange and accessory drive adapter. Do not secure cover at The coolant system must be flushed periodically as this time. specified airframe manufacturer accordance with airframe manufacturer’s 4. Shim consists of a .024 inch solid shim plus nine instructions.
Page 158 Insure that the clamp instructions in the TSI0L-550-C Overhaul assembly latches firmly and apply lockwire to Manual, Form OH-15. clamp as shown in Figure 11-2.
Page 159: Air Conditioning
Chapter 12 Air Conditioning Air Conditioning This chapter is reserved for engines that use air conditioner compressor mounting brackets and components supplied on some engine models by Teledyne Continental Motors. 12-1...
Page 160 INTENTIONALLY LEFT BLANK 12-2...
Page 161 Chapter 13 Electrical Charging System Chapter Contents Page General....................13-2 Electrical Charging System..............13-2 Inspections....................13-3 50 Hour Inspection ................13-3 100 Hour Inspection ................13-3 Alternator Drive Hub Slippage Inspection......... 13-3 Maintenance .................... 13-4 Direct Drive Alternator Removal and Replacement......13-4 Belt Driven Alternator Removal and Replacement ......
Page 162: Electrical Charging System
Electrical Charging System General Electrical Charging System This chapter includes inspection and maintenance The TSIOL-550-C Permold Series engine direct information TCM-supplied electrical drive alternator is mounted on the right front charging system. crankcase half. The alternator generates electrical For a description of the aircraft electrical and current for powering the aircraft electrical system charging system,...
Page 163: Inspections
Electrical Charging System Maintenance Drive hubs that do not conform with the above specifications must be discarded. Alternator For maintenance or repair of TCM alternators, refer Repair/Replacement to TCM Form X30531-3, “Alternator Service Instructions.” The alternators may be removed for 1.
Page 164 Electrical Charging System INTENTIONALLY LEFT BLANK 13-4...
Page 165 Chapter 14 Starting System Chapter Contents Page Starter and Starter Adapter Description ..........14-2 Starter System Component Detail Description........14-2 Starter ....................14-2 Starter Adapter ................. 14-2 Maintenance .................... 14-4 Starter ....................14-4 Starter Adapter ................. 14-4 Starter Motor Replacement............... 14-7 Starter Adapter Replacement............
Page 166: Starter And Starter Adapter
See Figure 14-2. The starter adapter assembly uses a worm drive gear shaft and worm gear to transfer See Figure 14-1. The TSI0L-550-C engine utilizes a torque from the starter motor to the clutch assembly. starting system that employs an electric starter motor The shaft is supported in the housing at the starter mounted on a right angle drive adapter.
Page 167 Starting System FIGURE 14-2. STARTER ADAPTER DESCRIPTION 14-3...
Page 168: Maintenance
Starting System Maintenance CAUTION... When performing dimensional inspection Starter following "Service Limits" may be used. However, The starter motor may be removed for repair or they are only intended as a guide for re-use when maintenance in accordance with applicable portions performing maintenance of the engine prior to major starter starter...
Page 169 Starting System REF. NO. DESCRIPTION SERVICEABLE LIMIT Scavenge pump driver gear on starter gear shaft ....Side clearance: 0.003L Gerotor on shaftgear spline drive..........Major dia.: 0.053 Gerotor on shaftgear spline drive..........Minor dia.: 0.041 Bevel gear on shaftgear spline drive .......... Major dia.: 0.029 Bevel gear on shaftgear spline drive ..........
Page 170 Starting System FIGURE 14-4. SHAFTGEAR DRUM DIMENSIONS DESCRIPTION “A” DIAMETER MIN. MAX. New Shaftgear Drum 1.931 1.932 0.015 Undersize 1.916 1.917 FIGURE 14-5. WORM WHEEL DRUM DIMENSIONS DESCRIPTION “A” DIAMETER “B” DIAMETER MIN. MAX. MIN. MAX. New Wormwheel Drum 1.931 1.932 1.955 1.960...
Page 171: Starter Motor Replacement
3. Remove four sets of attaching parts (two on outside of crankcase between cylinder No. 1 and starter, and two on cover assembly.) remove starter adapter assembly from crankcase. Discard lock washers. The starter adapter must be repaired in accordance with the TSI0L-550-C Overhaul Manual, Form OH- 14-7...
Page 172 Starting System INTENTIONALLY LEFT BLANK 14-8...
Page 173 Chapter 15 Lubrication System Chapter Contents Page Lubrication System Description .............. 15-2 Oil Pump Description................15-4 Remote Oil Cooler Adapter Description ..........15-5 Oil Sump Description ................15-6 Oil Suction Tube Description ..............15-6 Lubrication System Maintenance ............15-7 Oil Filter Adapter Stud Replacement ........... 15-7 Oil Pump ....................
Page 174: Lubrication System
Lubrication System From the governor drive gear lubricating oil is Lubrication System Description directed from the left main gallery through drilled See Figure 15-1. The engine oil supply is contained crankcase passages and oil transfer collar to the in the -oil sump. The oil is drawn from the sump crankshaft.
Page 175 Lubrication System FIGURE 15-1. LUBRICATION SYSTEM SCHEMATIC 15-3...
Page 176: Oil Pump Description
Lubrication System oil is then forced around the outside of the gears and Oil Pump Description directed through a gallery to the oil filter adapter and The positive displacement oil pump consists of two pressure relief valve. Oil that flows past the pressure meshed gears that revolve inside the pump housing relief valve is directed through a passage back to the cavity.
Page 177: Remote Oil Cooler Adapter Description
Lubrication System incorporates a bypass valve which allows oil flow in Remote Oil Cooler Adapter Description the event that the external cooler become clogged. The remote oil cooler adapter is located on the lower The adapter incorporates connection points for oil 2, 4, 6 side lower rear crankcase.
Page 178: Oil Sump Description
Lubrication System Oil Sump Description Oil Suction Tube Description See Figure 15-3. The oil sump is a stamp-pressed See Figure 15-3. The oil suction tube extends from aluminum alloy assembly. The sump is held to the the oil sump to the oil pump inlet providing oil pick- crankcase sump mount flange with 32 bolts, washers up and flow path.
Page 179: Lubrication System Maintenance
Lubrication System Lubrication System Maintenance 5. Apply a line of Loctite 271 (TCM P/N 646941) Oil Filter Adapter Stud Replacement along the large threads (.8125-16 end) of the Removal stud and install it into the adapter finger tight (30 inch pounds torque). Verify correct stud 1.
Page 180: Oil Pump
Malfunctioning oil pumps or oil pump components If the oil sump must be removed for repair or must be removed and discarded. replacement, TSI0L-550-C Overhaul Manual, Form OH-15. Any airframe components The oil pump may be removed in accordance with...
Page 181: Oil Pressure Relief Valve
Lubrication System Oil Pressure Relief Valve 8. Reassemble serviceable or new relief valve If difficulty is experienced achieving the specified housing and adjusting screw. Turn the adjusting oil pressure adjustment: screw approximately halfway. Install new 1. Cut safety wire and remove the oil pressure copper washer and nut.
Page 182 Lubrication System REF. DESCRIPTION SERVICE LIMIT OIL PRESSURE RELIEF VALVE ASSEMBLY Oil pressure relief valve adjusting screw in plunger......Diameter: 0.0070 Oil pressure relief valve seat in housing ..........Depth: 1.060 OIL PRESSURE PUMP ASSEMBLY Oil pump driver gear in pump housing ..........Diameter: 0.0065L Oil pump driver gear shaft in pump housing ........
Page 183 Lubrication System FIGURE 15-7. LUBRICATION SYSTEM SERVICE LIMITS 15-11...
Page 184 Lubrication System INTENTIONALLY LEFT BLANK 15-12...
Page 185 Chapter 16 Cylinders and Pistons Chapter Contents Page Cylinder Cooling ..................16-2 Cylinder, Pistons and Valve Drive Train ..........16-2 Cylinder Assembly Detailed Description.......... 16-3 Pistons....................16-4 Valve Rocker Arm ................16-5 Hydraulic Tappet ................16-6 Cylinder Assembly Maintenance ............. 16-6 Cylinder Compression Test ..............
Page 186: Cylinder Cooling
Cylinders Cylinder Cooling past half of one revolution, the connecting rod and See section 2, chapter 11, “Liquid Cooling System.” piston start moving outward on the exhaust stroke toward the cylinder head. During this movement, the Cylinders, Pistons And Valve Drive Train exhaust valve begins to open allowing the burned The cylinders, pistons and valve train are the portion mixture (exhaust) to escape.
Page 187: Cylinder Assembly Detailed Description
Cylinders stems are solid. A rotocoil assembly retains the two Cylinder Assembly Detailed Description concentric springs surrounding the exhaust valve The aluminum alloy head castings are heated and and is locked to the exhaust valve stem by tapered, valve seat inserts installed before the head is semi-circular keys which engage grooves around the screwed and shrunk onto a steel alloy barrel to make stem.
Page 188: Pistons
Cylinders grooved and slotted oil control ring is installed in the Pistons third groove which has six oil drain holes to the Pistons are aluminum alloy castings with a steel interior. Weight differences are limited to 1/2 ounce insert cast into the top ring groove. The skirts are or 14.175 grams in opposing bays.
Page 189: Valve Rocker Arm
Cylinders (4) in the housing (3). The check valve is opened by Valve Rocker Arm outward motion of the plunger under pressure of the Valve rocker arms are steel forgings with hardened expanding spring whenever a clearance occurs in the pushrod sockets and rocker faces.
Page 190: Cylinder Assembly Maintenance
Cylinders Cylinder Assembly Maintenance Cylinder Compression Test The dynamic seal consists of the piston rings to the The differential pressure test is an accepted method cylinder wall seal. This seal leakage can vary from of determining cylinder condition by measuring air cylinder to cylinder, ring gap position, wear or the pressure loss past the pistons, rings and valves.
Page 191 Cylinders FIGURE 16-6. STATIC SEAL FIGURE 16-7. DYNAMIC SEAL orifice calibrated pressure reading. After the master Master Orifice Tool orifice calibrated pressure reading has been For conformity in testing equipment a Master recorded, close regulator pressure valve and remove Orifice Tool, Part Number 646953, has been Master Orifice Tool from the cylinder adapter.
Page 192 Cylinders FIGURE 16-8. DIFFERENTIAL PRESSURE TESTER CALIBRATION (2) Turn the crankshaft by hand in the direction of WARNING rotation until the piston, in the cylinder being checked, is coming up on its compression stroke. To prevent possibility of serious bodily injury or death, before moving the propeller (3) Install an adapter in the spark plug hole and accomplish the following:...
Page 193 Cylinders CAUTION WARNING When correcting a low reading in this manner, Care must be exercised in opening the rotate the propeller so the piston will not be at top dead center. This is necessary to prevent the valve cylinder pressure valve, since sufficient air from striking the top of the piston in some engines.
Page 194 80 pounds per square inch and Assembly Repair And Replacement" in the determine amount of loss. If the gauge reading is TSI0L-550-C Overhaul Manual, Form OH-15. higher than the previously determined master orifice calibrated reading, proceed to next After cylinder compression test, if all cylinders are cylinder to be tested.
Page 195 Cylinders Compression Test Troubleshooting Use the following troubleshooting chart as a guide. Review the probable causes and other listings of problems that have similar symptoms. The probable causes are listed in order of “easiest to find” which is not necessarily in order of probability of occurrence. Corrective First Check Check For...
Page 196: Single Cylinder Removal
Remove cylinder using cylinder and piston removal instructions in the TSI0L-550-C Overhaul Manual, Form OH-15. NOTE... When the cylinder is removed with the spark plugs installed, inspection can be accomplished by filling...
Page 197: Single Cylinder Reinstallation
Cylinders Single Cylinder Reinstallation Reinstall all valve train components that were removed using new o-rings, seals and gaskets in 1. Reinstall repaired or new cylinder in accordance accordance with in the TS10L-550-C Overhaul with the TSIOL-550-C Overhaul Manual, Form Manual, Form OH-15. Rocker cover screws must be OH-15.
Page 198: Cylinders
Cylinders DESCRIPTION SERVICE LIMITS NO.. CYLINDERS Cylinder bore (lower 4-1/4 inch of barrel)......Diameter: See Figure 16-12 Cylinder bore choke (at 5.75 inch from open end of barrel) ..Taper: See Figure 16-12 Cylinder bore out-of-round ..............: 0.0030 Cylinder bore ............Allowable Oversize: See Figure 16-12 Cylinder bore surface (Nitrided Barrels) Cross hatch.................Angle:...
Page 199 Cylinders DESCRIPTION SERVICE LIMITS NO.. PISTONS, RINGS AND PINS Top ring gap at 1.00 ± .50 depth (in cylinder barrel)....Gap: 0.042 Second ring gap at 1.00 ± .50 depth (in cylinder barrel) ... Gap: 0.050 Third ring gap at 1.00 ± .50 depth (in cylinder barrel) ..... Gap: 0.036 Fourth ring gap at 1.00 ±...
Page 200 Cylinders FIGURE 16-12. MAINTENANCE CYLINDER DIMENSIONS 16-16...
Page 201 Chapter 17 Crankcase Chapter Contents Page Crankcase Description ................17-2 Crankcase Maintenance ................17-3 Crankcase Cracks................17-3 Crankcase ................... 17-4 Studs ....................17-4 Engine Mounts..................17-4 Crankcase Separation ................ 17-5 Crankcase/Starter Needle Bearing Installation ......... 17-5 17-1...
Page 202: Crankcase
Crankcase crankcase half for the governor drive gear shaft. A CRANKCASE DESCRIPTION needle bearing bore is located on the right crankcase The crankcase is the foundation of the engine. It half at the rear main bearing saddle for the starter supports the crankshaft, camshaft, various gears adapter needle bearing.
Page 203 Crankcase previously observed crack has progressed to two (2) CRANKCASE MAINTENANCE or more inches in length, repair or replace the Crankcase Cracks crankcase prior to further flight. If any crack is Critical (white) and non-critical (shaded) areas are observed in a critical (white) area, repair or replace illustrated in Figure 17-3.
Page 204 Weld repairs must not be performed in the accordance with the applicable component system section in the TSI0L-550-C Overhaul Manual, Form critical (white) areas of the crankcase as OH-15. During reassembly, insure that all reinstalled shown in Figure 17-3.
Page 205 Exercise judgment in determining how far systems determination, reinstallation in airframe and test and components should be disassembled. flight in accordance with the TSI0L-550-C Overhaul Manual, Form OH-15. Any maintenance of engine systems and components removed from engine must be performed in...
Page 206 Crankcase FIGURE 17-4. CRANKCASE NEEDLE BEARING INSTALLER FIGURE 17-5. MODIFIED CRANKCASE NEEDLE BEARING TOOL 17-6...
Page 207 Chapter 18 Engine Drive Train Chapter Contents Page Engine Drive Train Description.............. 18-2 Crankshaft Description ................18-4 Connecting Rod Description ..............18-5 Camshaft Description................18-6 Idler Gear Description ................18-6 Engine Drive Train Maintenance............18-7 Crankshaft Nose Oil Seal ..............18-7 Engine Drive Train Component Removal ..........
Page 208 Engine Drive Train upper rear are driven by internal splines of magneto Engine Drive Train Description drive gears. When starting engine, torque is transmitted from the starter (13) through starter adapter components (14 The fuel pump coupling is driven directly from the through 19) to crankshaft gear (1).
Page 209: Engine Drive Train Description
Engine Drive Train FIGURE 18-1. ENGINE DRIVE TRAIN DESCRIPTION 18-3...
Page 210: Crankshaft Description
Engine Drive Train times revolution, counteracting Crankshaft Description counterweight is a 5th order counterweight. The crankshaft is made of aircraft quality steel. The crankshaft has five, machined, main journals which Two sixth order counterweights are installed on the rotate on the bearings in the crankcase. Six, #2 cheek hangers.
Page 211: Connecting Rod Description
The portion of the rod between the crankpin and Connecting Rod Description piston pin ends is called the "I" beam. A split steel The connecting rods are made of aircraft quality backed bronze bushing is pressed into the piston pin steel.
Page 212: Camshaft Description
Engine Drive Train mechanical linkage of the pushrods and rocker arms. Camshaft Description The valves opening and closing is synchronized with The camshaft is made of aircraft quality steel. The piston position due to timing of the camshaft and forging is machined on four (4) main journals, nine crankshaft gears.
Page 213: Engine Drive Train Maintenance
Engine Drive Train 3. Remove any plating in the one inch area shown Engine Drive Train Maintenance in Figure 18-6, "Helix Pattern Application." Crankshaft Nose Oil Seal Remove plating by working a piece of very fine The crankshaft nose oil seal may be replaced emery cloth back and forth around the shaft.
Page 214 Engine Drive Train FIGURE 18-7. CRANKSHAFT OIL SEAL installation in the crankcase. Press the reinforcing Oil Seal Installation spring into the oil seal recess by moving fingers in 1. Use the specified oil seal assembly only. Check both directions from split. Insure spring is in the spring length.
Page 215: Engine Drive Train Component Removal
CAUTlON... engine components, the engine must be removed Dimensional inspection of the crankcase and from the airframe and disassembled in accordance crankcase internal components must be performed in with the TSI0L-550-C Overhaul Manual, Form OH- accordance with TSI0L-550-C Overhaul 15 and the airframe manufacturer's instructions.
Page 216 Engine Drive Train INTENTIONALLY LEFT BLANK 18-10...
Page 217: Post Maintenance Adjustment And Test
Chapter 19 Post Maintenance Adjustment And Test Chapter Contents Page Testing After Maintenance ..............19-2 Servicing With Fluids ................19-2 Post Maintenance Operational Test............19-2 Oil Pressure Adjustment................19-2 Fuel System Adjustment................19-3 Test Flight ....................19-11 19-1...
Page 218 Post Maintenance Testing After Maintenance Check the magneto circuit for proper grounding prior to a normal shut-down. Allow the engine to cool Operational test must performed after 50/100 hour or adequately and make a visual inspection for any annual inspection. irregularities.
Page 219 Post Maintenance TCM recommends the Model 20 ATM - C Porta Fuel System Adjustment Test Unit P/N 630045-20 ATM-C or equivalent to insure the fuel injection system meets all WARNING pressure flow specifications. alternative procedure would be to use The procedures and values provided apply to calibrated gauges.
Page 220 Post Maintenance 7. Insure the fuel manifold valve vent and fuel pump drain lines are properly installed, open and Pre-Setup Procedures free of obstruction. Correct any discrepancies noted. 1. Prior to fuel system adjustments, flush the aircraft fuel system by first removing the engine 8.
Page 221 Post Maintenance Post Maintenance FIGURE 19-2. THROTTLE AND METERING UNIT ADJUSTMENTS Setup Procedures 4. Connect the Unmetered test hose from the Porta Test Unit to the tee fitting and torque. If using the alternative procedure, connect the 0-60 PSI WARNING gauge to the swivel tee using a length of hose which will provide proper clearance from the During removal and installation of fuel lines...
Page 222 gauge pressure fitting to the metered pressure 15. Fuel Flow Vs. Metered Pressure Performance swivel tee using a hose of sufficient length to Curve provide clearance from the aircraft and propeller NOTE... arc. Connect an equal length of hose to the To insure optimum cooling during FULL POWER "suction"...
Page 223 Post Maintenance FIGURE 19-3. FUEL PUMP ADJUSTMENTS NOTE… WARNING Insure that all engine and aircraft systems are Make all adjustments with the engine adjusted and functioning properly before making any adjustment to the fuel system. stopped and the ignition and master switches in the off position! 16.
Page 224 Post Maintenance 19. With engine operating at the specified IDLE unmetered fuel pressure and fuel/air mixture. If RPM and unmetered fuel pressure, slowly move any values are not within specified limits, repeat the mixture control from the FULL RICH the adjustment procedures. position toward IDLE CUT-OFF to check 22.
Page 225 NOTE: All values are approximate. Variations may be noticed due to engine and installation specific influences. Example: TSI0L-550-C, Maximum Rated RPM = 2600 Metered Fuel Pressure Limits = 15.0 - 16.5 If maximum static engine RPM = 2540, (-60 RPM) use Correction Factor .973...
Page 227 Post Maintenance Descent from high altitude should be accomplished at Test Flight low cruise power settings. During descent engine Refer to the aircraft manufacturer’s or Supplemental pressures and temperatures must be carefully Type Certificate (STC) holders POH/AFM for monitored. Avoid long descents with cruise RPM and specific operational information.
Page 228 Post Maintenance INTENTIONALLY LEFT BLANK 19-12...
Page 229 Section 3 Installation Section Contents Chapter Engine Installation .................. 1...
Page 230 INTENTIONALLY LEFT BLANK...
Page 231: Engine Installation
Chapter 1 Engine Installation Chapter Contents Page General....................1-2 Unpacking ....................1-2 Ground Handling ..................1-2 Crating and Shipping ................1-2 Preparation for Service ................1-3 Engine Installation Instructions .............. 1-3 Engine Pre-Oiling ................... 1-8 Flight Testing ..................1-9...
Page 232: General
2. Lift the wooden cover vertically and remove. with a borescope for rust or contamination. Contact your Teledyne Continental Motors Distributor if any 3. Open the moisture proof plastic bag. abnormal condition is noted.
Page 233: Engine Installation Instructions
Installation CAUTION… NOTE… During installation of propeller governor in Drain preservative oil from sump. Engines that have accordance with the airframe manufacturer's a complete set of overhauled or new cylinders and instructions ,insure that the governor gear splines new piston rings installed must be serviced with align properly with the camshaft governor drive clean Engine...
Page 234 Installation FIGURE 1-1. INSTALLATION DRAWING TSI0L-550-C...
Page 235 Installation FIGURE 1-1. INSTALLATION DRAWING TSI0L-550-C (continued)
Page 236 Installation FIGURE 1-1. INSTALLATION DRAWING TSI0L-550-C (continued)
Page 237 Installation FIGURE 1-1. INSTALLATION DRAWING TSI0L-550-C (continued)
Page 238: Engine Pre-Oiling
Installation means the top spark plug of the number one ENGINE PRE-OILING cylinder. It is important that all engine internal moving parts be properly lubricated before initial running of PREFLIGHT AND RUN-UP engine. Pre-oil engine prior to initial engine NOTE… operation according to the following procedure: Engines that have a complete set of overhauled or 1.
Page 239: Flight Testing
Installation WARNING Although the engine fuel system was adjusted FLIGHT TESTING at engine test, the fuel system must be After engine has been installed, has had an checked and adjusted in accordance with operational inspection and has been found to be section chapter "Fuel...
Page 240 Installation INTENTIONALLY LEFT BLANK 1-10...

Continental Motors TSI0L-550-C Operation, Maintenance & Installation Manual

Replacement Parts Intentionally

Chapter 1 Engine Operation

Chapter 2 Emergency Procedures

And Servicing Fluids

And Storage

And Lubricants

Chapter 5 Standard Practices

System

Chapter 8 Ignition System

Chapter 9 Fuel Injection System

Chapter 13 Electrical Charging System

Chapter 14 Starting System

Chapter 15 Lubrication System

Chapter 16 Cylinders and Pistons

Chapter 18 Engine Drive Train

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Chapters

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Summary of Contents for Continental Motors TSI0L-550-C

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