Continental Refrigerator IO-240-A Installation And Operation Manual Download Page 131

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IO-240 Series Engine Installation & Operation Manual

C-7

31 October 2011

Standard Practices

C-5. Tab Washer Installation

Tab washers are used in various locations in Continental Motors engines. Do not re-use
tab washers. Always install new tab washers.

1. Insert the locator tab (bent part of the tab washer) in the predrilled hole.

2. Lubricate and torque hardware torqued to Appendix B specifications.

3. Using a soft drift, bend the lock tab on the other side of the tab washer firmly against

the bolt or nut flats as shown in Figure C-3. Ensure the lock tabs are bent flat up
against the hardware without protrusion as shown in top and side views to properly
lock the hardware and prevent the lock tabs from breaking off.

Figure C-3. Tab Washer Installation

Top View

Side View

Locator Tab

Lock Tab

Lock Tabs

Top View

Side View

Locator Tab

Lock Tab

Lock Tabs

Summary of Contents for IO-240-A

Page 1: ...Publication OI 6 2011 CONTINENTAL MOTORS INC OCT 2011 IO 240 A B CONTINENTAL AIRCRAFT ENGINE INSTALLATION AND OPERATION MANUAL FAA APPROVED ...

Page 2: ... thru 1 10 0 2 1 thru 2 32 0 3 1 thru 3 30 0 4 1 thru 4 28 0 A 1 thru A 4 0 B 1 thru B 10 0 C 1 thru C 20 0 Published and printed in the U S A by Continental Motors Inc Available exclusively from the publisher P O Box 90 Mobile AL 36601 Copyright 2011 Continental Motors Inc All rights reserved This material may not be reprinted republished broadcast or otherwise altered without the publisher s wri...

Page 3: ...cement N A M77 19 Intake and Exhaust Rocker Arm Identification and Application Engine Assembly N A M81 8R1 Fuel Pump Screen Restriction Fuel Pump Inspection and Parts Replacement N A M81 25 Exhaust Flange to Cylinder Installation Procedures Engine Installation N A M86 9 Crankcase Modification Engine Overhaul N A M87 15 Alternator Ground Strap Alternator Replacement N A M88 9 Lightning Strikes Unsc...

Page 4: ...Warranties N A N A SID97 3E Procedures and Specifications for Adjustment of TCM Continuous Flow Fuel Injection Systems Engine Operational Check and Engine Specifications 3 4 SID97 4C Cylinder Bore and Piston Fit Specifications Overhaul Service Limits N A SB97 6B Mandatory Replacement Parts Engine Inspection Assembly Appendix C CSB97 10A Piston Pin Plug Wear Service Limits N A SIL97 14 Replacement ...

Page 5: ...gine Specification 3 4 SIL04 12A TCM Authorized Engine Adjustments Component Replacement and Repositioning Engine Specification N A SID05 1 Design Operation and Maintenance of TCM Camshafts and Hydraulic Lifters Inspection Criteria N A SB05 2 Overspeed Limitations Unscheduled Maintenance 4 SIL05 3 Engine Specification Numbers Engine Specification 2 SIL05 4A IO 240 Series PN 656850 Inline Fuel Filt...

Page 6: ...xt in the manual with a citation to the service document i e see SB9X 1 For paragraphs or entire sections draw an X through the affected information in the manual and reference the service document containing the correction SB08 13 Induction System Hose and Clamp Installation Induction System Inspection Assembly Appendix C SB09 14 Camshaft Corrosion Treatmen Engine Inspection N A SIL640 Service Do...

Page 7: ...ions Title Bulletin Number Release Date Affected Sections Title Bulletin Number Release Date Affected Sections Title Bulletin Number Release Date Affected Sections Title Bulletin Number Release Date Affected Sections Title Bulletin Number Release Date Affected Sections Title Bulletin Number Release Date Affected Sections Title Bulletin Number Release Date Affected Sections Title Bulletin Number Re...

Page 8: ... Continental Motors does not provide product manufacturing specifications to aftermarket parts manufacturers and accepts no liability for the suitability durability longevity or safety of such parts installed on Continental Motors engines Installation of aftermarket parts on a Continental Motors engine must be performed using Instructions for Continued Airworthiness prepared by the manufacturer an...

Page 9: ...nition 2 2 2 1 2 Cylinder Number Designations 2 2 2 2 Detailed Engine Description 2 3 2 2 1 Crankcase 2 3 2 2 2 Engine Drive Train 2 4 2 2 2 1 Crankshaft 2 4 2 2 2 2 Connecting Rods 2 5 2 2 2 3 Camshaft 2 6 2 2 3 Accessory Case 2 6 2 2 4 Cylinders 2 7 2 2 4 1 Pistons 2 9 2 2 4 2 Hydraulic Valve Tappets 2 9 2 2 5 Lubrication System 2 10 2 2 5 1 Oil Pump 2 11 2 2 5 2 Oil Sump 2 12 2 2 5 3 Oil Pressu...

Page 10: ...7 3 2 3 2 Fuel Purge and Leak Check 3 8 3 2 4 Installation Inspection 3 9 3 2 5 Preflight and Run up 3 9 3 3 Engine Installation Drawings 3 11 3 3 1 IO 240 A Installation Drawings 3 11 3 3 2 IO 240 B Installation Drawings 3 15 3 3 3 IO 240 Common Installation Drawings 3 22 Chapter 4 Engine Operation 4 1 Introduction 4 1 4 2 Flight Prerequisites 4 1 4 2 1 Oil Change Interval 4 2 4 2 2 Engine Fuel R...

Page 11: ...ot Weather 4 27 4 5 2 3 Ground Operation in Hot Weather 4 27 4 5 2 4 Take off and Initial Climb Out in Hot Weather 4 27 4 5 3 Ground Operation at High Density Altitude 4 28 4 6 Troubleshooting 4 28 Appendix A Glossary A 1 Acronyms A 1 A 2 Glossary A 2 Appendix B Torque Specifications B 1 General Information B 1 B 1 1 Torque Tips B 1 B 2 Cylinder Torque Procedure B 2 B 3 Torque Wrench and Extension...

Page 12: ...er Application C 17 C 11 Gasket Installation C 18 C 12 Hose and Tubing Installation C 19 C 13 Harness Routing C 20 LIST OF TABLES Table 1 1 Related Publications 1 4 Table 2 1 IO 240 A Specifications and Operating Limits 2 21 Table 2 2 IO 240 B Specifications and Operating Limits 2 23 Table 2 3 Accessory Drive Ratios 2 25 Table 4 1 IO 240 Operating Limits 4 4 Table B 1 General Torque Specification ...

Page 13: ...ors Ignition Distribution 2 15 Figure 2 19 Slick Ignition Distribution 2 15 Figure 2 20 IO 240 Standard Fuel Injection System 2 16 Figure 2 21 Standard Fuel Pump 2 17 Figure 2 22 Altitude Compensating Fuel Pump 2 17 Figure 2 23 Fuel Injector 2 18 Figure 2 24 Engine Cooling 2 19 Figure 2 25 IO 240 A Induction System 2 20 Figure 2 26 IO 240 B Crossflow Induction System 2 20 Figure 2 27 IO 240 A Fuel...

Page 14: ...matic 3 29 Figure 3 25 Champion Slick Magneto Ignition Schematic 3 29 Figure 3 26 Airframe Ignition Switch Connections to Magneto 3 30 Figure B 1 Torque Wrench B 3 Figure B 2 Drive extensions B 3 Figure B 3 Extension increases applied torque B 4 Figure B 4 Extension decreases applied torque B 4 Figure C 1 Right hand thread safety wire installation C 5 Figure C 2 Safety wire Patterns for Right Hand...

Page 15: ...dvisories defined as follows WARNING A warning emphasizes information which if disregarded could result in severe injury to personnel or equipment failure CAUTION Emphasizes certain information or instructions which if disregarded may result in damage to the engine or accessories NOTE Provides special interest information which may facilitate performance of a procedure or operation of equipment Wa...

Page 16: ...tified engine model configuration Continental Motors ICAs must not be used for aftermarket parts Exploded assembly illustrations accompany instructions throughout the manual Parts in illustrations Figure 1 1 are identified with numerical callouts indexes Corresponding parts listings follow the illustrations for reference The first time instructions refer to an illustration the figure number is ide...

Page 17: ...inued safe operation of an aircraft persons or property on the ground unless some specific action inspection repair replacement etc is taken by the owner or operator Documents in this category are candidates for incorporation into an FAA Airworthiness Directive May contain updates to ICAs to address a safety issue Category 3 Service Bulletin SB Information which the product manufacturer believes m...

Page 18: ...wnload at web site1 1 Our web site http continentalmotors aero provides 24 hour access to engine technical data via the Internet If you are an internet ser vice subscriber you can access our web site to confirm and review the latest revision of this manual If you have not subscribed to inter net service and are using printed manuals contact using the Contact Information on page 8 to confirm you ha...

Page 19: ...the ICAs prepared by Continental Motors and accepted by the FAA 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 Such Service Documents represent a change to the pub...

Page 20: ...l manual Figure 1 3 If change pages are issued for the manual the change will be identified with an effective date under the heading Effective Changes for This Manual The list of effective pages itemizes the pages in each section by change number Original pages are designated by a 0 in the List of Effective Pages Change column Change Bar Change Number Change Date Change Bar Change Number Change Da...

Page 21: ...nded changes or questions to the attention of Publications at the address listed in Section 1 3 Contact Information or send comments via email to CM techpubs continental aero Notify our Customer Service Department immediately using our toll free number if you discover incorrect information which adversely affects safety Effective Manual Changes and Change Dates Itemized List of Effective Pages Eff...

Page 22: ... service If customers have an inquiry or require technical assistance they should contact their local Continental Motors distributor or field representative To contact a factory representative refer to the contact information below Continental Motors Inc P O Box 90 Mobile AL 36601 Customer Service Toll free within the Continental United States 1 888 826 5465 International 1 251 438 8299 Internet h...

Page 23: ...d with continuous flow fuel injection and a either an updraft or a downdraft induction system depending on the engine model IO 240 series engines are designed with a wet sump positive displacement oil pump installed in the accessory case When properly maintained under normal operating conditions the desired oil pressure is maintained by a pressure relief valve located in the accessory case Engine ...

Page 24: ...ine is the accessory end Viewed from the rear of the engine the left side cylinders are designated by even num bers 2 4 with Cylinder 2 being closest to the rear The right side cylinders have odd number sequential designation 1 3 with Cylinder 1 being closest to the rear Firing order of the engine is 1 3 2 4 Figure 2 2 Cylinder Number Designation I O 240 B 1 Specification Number Model Identifier C...

Page 25: ...left and right crankcase are offset to permit each crankpin to transmit the rotational force to the piston through the connecting rod The crankcase interior is vented by a breather assembly comprised of a tube and baffle assembly with a side extension for a hose attachment The breather assembly is pressed into a boss on the top side of the right crankcase half forward of Cylinder 3 Figure 2 3 IO 2...

Page 26: ...ne driven fuel pump and the optional vacuum pump drive are driven by a gear on the forward end of the camshaft Figure 2 4 Engine Drive Train 2 2 2 1 Crankshaft The crankshaft Figure 2 5 is an aircraft quality steel forging with three machined main journals supported by precision bearing inserts in each of the three bearing saddles machined in the crankcase Four machined rod journals provide attach...

Page 27: ...ece bearing and attach to the crankpin or rod journal with special bolts and nuts The portion of the rod between the rod and the crankpin and piston pin ends is called the I beam A split steel backed bronze bushing is pressed into the piston pin end and machined for a precision pin to bushing fit Figure 2 6 Connecting Rod CRANKSHAFT FLANGE FRONT MAIN JOURNAL ROD JOURNAL ROD JOURNAL ROD JOURNAL REA...

Page 28: ...hich surrounds the front side of the casting Mounting pads for the magnetos alternator cover starter tachometer drive oil filter adapter oil pressure relief valve and an oil suction screen boss are provided The accessory case casting has two holes above and three studs to attach the starter A mounting pad is provided for a permanent oil screen housing In lieu of the oil screen housing an oil filte...

Page 29: ... nitrided cylinder barrel for wear resistance Helical coil thread inserts are installed in upper and lower spark plugs holes A rotocoil assembly retains two concentric springs surrounding the exhaust valve and is locked to the stem by tapered semi circular keys which engage grooves around the valve stems An outer retainer holds two concentric springs which surround the intake valve and is locked t...

Page 30: ...AINER KEYS ROTOCOIL EXHAUST VALVE GUIDE OUTER SPRING INNER SPRING SPRING SEAT INTAKE VALVE GUIDE INTAKE VALVE SEAT INSERT INTAKE VALVE CYLINDER BARREL EXHAUST VALVE COOLING FINS CYLINDER HEAD CYLINDER BARREL COOLING FINS CYLINDER BASE FLANGE CYLINDER SKIRT ROCKER COVER RETAINER EXHAUST VALVE SEAT INSERT THRUST WASHER ONE ON EACH SIDE OF EACH ROCKER ARM ...

Page 31: ...ht differences are limited to ounce between opposing cylinders bays Piston pins are full floating with permanently pressed in aluminum end plugs Figure 2 10 Piston Features 2 2 4 2 Hydraulic Valve Tappets The hydraulic valve tappet lifter provides an interface between the camshaft lobe and the remaining valve train Lifters ride on the eccentric cam lobes opening and closing the intake and exhaust ...

Page 32: ...ressure relief valve an oil sump and oil sensing ports Various optional oil cooler adapters allow connection of an optional remote mounted oil cooler Figure 2 11 IO 240 A Lubrication A A OIL SUCTION TUBE OIL PRESSURE RELIEF VALVE CRANKSHAFT BEARINGS CAMSHAFT BOSS INTAKE EXHAUST PUSHROD HOUSING PUSHROD HYDRAULIC LIFTERS OIL SUMP OIL PUMP GEARS OIL FILTER SCREEN OIL COOLER ADAPTER OIL SUCTION TUBE O...

Page 33: ...shings pressed into the accessory case The oil pump gear shaft incorporates provisions to drive a mechanical tachometer The oil pump housing and oil pump gear chambers are machined in the interior of the accessory case The oil pump drive gear shaft bore is machined in line with the camshaft the driven gear shaft rests in the bore directly above the drive shaft OIL SUCTION TUBE OIL PRESSURE RELIEF ...

Page 34: ...he lower right side of the accessory case for installation of a non adjustable oil pressure relief valve Its passages are connected to the oil pump outlet passage This valve opens when the oil pump pressure exceeds the specified operating limit and directs oil back to the oil sump 2 2 5 4 Oil Cooler Adapter The IO 240 engine features an oil cooler adapter Figure 2 11 or oil cooler filter adapter l...

Page 35: ... Filter Adapter B B OIL BY PASS FLOW PLUG OIL BY PASS VALVE PLUG OIL TEMP PORT OIL FLOW BACK TO ENGINE OIL PRESSURE PORT OIL FLOW OUT TO EXTERNAL OIL COOLER OUT OIL BY PASS FLOW PLUG OIL BY PASS VALVE PLUG OIL TEMP PORT OIL FLOW BACK TO ENGINE OIL PRESSURE PORT OIL FLOW OUT TO EXTERNAL OIL COOLER OUT OUT IN PR T E M P OUT IN PR T E M P OUT IN PR T E M P OUT IN OUT IN PR T E M P OUT IN PR T E M P O...

Page 36: ...e Mount With Retard Breaker 1209 Short Flange Mount 1225 Deep Flange Mount Impulse Coupled 1227 Short Flange Mount Impulse Coupled 1251 Pressurized Version of 1201 1255 Pressurized Version of 1205 1258 Pressurized Version of 1208 1259 Pressurized Version of 1209 D 3000 Serles 3000 Impulse Coupled 3200 With Retard Breaker Magneto Configuration S Single Type Magneto one drive one output distributor ...

Page 37: ...al Motors Ignition Distribution Figure 2 19 Slick Ignition Distribution 7 7 7 7 1 1 5 1 25 5 0 1 72 5 1 25 5 5 7 0 1 72 72 7 0 1 72 6 7 72 5 7 0 1 72 6 7 7 0 1 72 3 7 2 5 4 8 1 6 3 7 2 5 4 8 1 6 3 72 54 8 1 6 3 72 54 8 1 6 7 7 7 7 1 1 5 1 25 5 0 1 72 5 1 25 5 5 7 0 1 72 72 7 0 1 72 6 7 72 5 7 0 1 72 6 7 7 0 1 72 ...

Page 38: ...ve Figure 2 20 IO 240 Standard Fuel Injection System 2 2 7 1 Fuel Pump An engine driven positive displacement fuel pump Figure 2 21 delivers fuel to the fuel injectors Fuel enters the fuel pump at the well of the swirl chamber where the fuel is centrifuged and the liquid is separated from fuel vapor The liquid fuel is directed to the fuel pump blades The fuel pump blades force the fuel to the fuel...

Page 39: ...ospheric variations Figure 2 22 The IO 240 B fuel system with altitude compensating fuel pump incorporates a fuel filter between the fuel pump and fuel manifold valve From the fuel filter fuel flows to the fuel manifold valve and subsequently to the injector nozzles Figure 2 22 Altitude Compensating Fuel Pump PATH TO RELIEF VALVE FUEL INLET STOP PIN VAPOR RETURN DRY BAY DRAIN FUEL SUPPLY TO ENGINE...

Page 40: ...ud is sealed to the nozzle body by o rings The nozzle shrouds are referenced to upper deck pressure to provide a positive air pressure differential to insure proper fuel atomization at all operating parameters Nozzles are calibrated in several ranges and tuned to each cylinder position for optimum balance of engine performance and fuel economy Each nozzle is identified with the cylinder position n...

Page 41: ... the Alternator Service Instructions 2 2 10 Engine Cooling The engine cylinders are cooled by transferring heat from the cylinder barrel and cylinder head cooling fins to the surrounding airflow The airframe engine cowling baffles and baffle seals direct cooling air which is ram air induced by the aircraft s forward speed evenly around the cylinders This airflow is regulated by the size of the coo...

Page 42: ...n System The IO 240 B downdraft induction system Figure 2 26 consists of the air throttle and manifold body mounted on top of the engine Intake tubes carry induction air from the manifold to the individual cylinder intake ports Crossflow design cylinders improve airflow efficiency through the cylinder head Air flows from the aircraft air inlet alternate air door to the engine cylinders through the...

Page 43: ... engine accessory load Standard day conditions are 29 92 in Hg and 59 F Horsepower will vary approximately 1 for each 10 F 5 6 C change in compressor inlet air temperature Correction must also be made for the effect of exhaust back pressure and accessory drive losses Contact Continental Motors engineering for correction factors for specific applications Fuel System Specifications Fuel Minimum Grad...

Page 44: ... Usable Oil 10 Nose Down 3 0 quarts 2 8L Oil Grade Specification SAE J 1899 normal ops SAE J 1966 break in CAUTION Oil must be aviation oil conforming to SAE J 1899 or SAE J 1966 specifications Brake Specific Oil Consumption Maximum BSOC 0 006 lb X engine rated power X power at which measured 100 X duration of test in hours 1 quart 1 875 pounds Engine Physical Specifications Weight dry basic engin...

Page 45: ...ard day conditions are 29 92 in Hg and 59 F Horsepower will vary approximately 1 for each 10 F 5 6 C change in compressor inlet air temperature Correction must also be made for the effect of exhaust back pressure and accessory drive losses Contact Continental Motors engineering for correction factors for specific applications Fuel System Specifications Fuel Control System Multi port Continuous Flo...

Page 46: ...ose Up 3 0 quarts 2 8L Usable Oil 10 Nose Down 3 0 quarts 2 8L Oil Grade Specification SAE J 1899 normal ops SAE J 1966 break in CAUTION Oil must be aviation oil conforming to SAE J 1899 or SAE J 1966 specifications Brake Specific Oil Consumption Maximum BSOC 0 006 lb X engine rated power X power at which measured 100 X duration of test in hours 1 quart 1 875 pounds Engine Physical Specifications ...

Page 47: ...ry from installed performance The charts are neither intended nor suitable for installed performance specifications or flight planning Consult the Airplane Flight Manual or Pilot s Operating Handbook for installed aircraft performance specification Table 2 3 Accessory Drive Ratios Accessory Direction of Rotation1 1 CW Clockwise Rotation CCW Counterclockwise rotation viewed facing the drive OPT Opt...

Page 48: ...2 26 IO 240 Series Engine Installation Operation Manual 31 October 2011 Engine Description 2 3 2 1 IO 240 A Performance Charts Figure 2 27 IO 240 A Fuel Flow vs Brake Horsepower ...

Page 49: ...IO 240 Series Engine Installation Operation Manual 2 27 31 October 2011 Engine Description Figure 2 28 IO 240 A Sea Level Performance ...

Page 50: ...2 28 IO 240 Series Engine Installation Operation Manual 31 October 2011 Engine Description 2 3 2 2 IO 240 B Performance Charts Figure 2 29 IO 240 B Fuel Flow vs Brake Horsepower ...

Page 51: ...IO 240 Series Engine Installation Operation Manual 2 29 31 October 2011 Engine Description Figure 2 30 IO 240 B Sea Level Performance ...

Page 52: ...2 30 IO 240 Series Engine Installation Operation Manual 31 October 2011 Engine Description Intentionally Left Blank ...

Page 53: ... 032 8 Cable ties 9 Bladder type pressure pot at least 1 gallon capacity 10 Type 1 flammable fuel container 11 Clean fuel hoses 12 AN union fittings 13 Rubber grommets 14 MS 122AD Spray procured from Miller Stephenson 15 Spark Plug Manufacturer s recommended spark plug thread lubricant 16 Loctite Hydraulic Sealant 17 Anti seize Lubricant 18 Loctite Pipe Sealant 19 Other supplies and consumables re...

Page 54: ...gine will be stored for any length of time refer to the Engine Preservation and Storage instructions in Chapter 9 of the Maintenance and Overhaul Manual M 6 3 1 2 2 Crating an Engine for Shipping 1 Lower the engine onto the container base 2 Attach the engine using shock mounts and bolts 3 Cover the engine with a plastic bag 4 Install and attach the container cover to the base 3 1 2 3 Acceptance In...

Page 55: ...o not allow the front rear sides or bottom of the engine to strike any obstructions as the extreme weight may damage the engine or its components 1 Attach a hoist to the engine lifting eyes located at the top of the crankcase backbone 2 Take up slack on the hoist prior to loosening the engine mount bolts remove the bolts from the shipping shock mounts 3 Lift the engine and install it on a transpor...

Page 56: ...and allow at least one quart of fuel to flow through the strainer and fuel supply line into a Type 1 fuel container through a paper filter 4 Inspect the paper filter for contamination if the fuel supply is free of contamination proceed with engine installation If contaminants are found in the fuel supply isolate and correct the source of contamination prior to connecting the aircraft fuel supply t...

Page 57: ...el pump inlet fitting Disconnect the fuel pump outlet hose from the outlet fitting Allow the preservative fluid to drain from the fuel pump and hose reconnect the fuel hose to the fuel pump outlet fitting and torque the fitting to Appendix B specifications Re install the shipping cap NOTE Optional accessories such as hydraulic pumps vacuum pumps etc may be installed in the accessory drive pads loc...

Page 58: ...al M 6 6 Turn the Ignition Switch to the OFF position WARNING Do not install the ignition harness B nuts on the spark plugs until the propeller installation and the ignition system operational checkout is complete Failure to comply can result in bodily injury when the propeller is rotated during installation 7 Connect the starter and alternator wiring according to airframe manufacturer s instructi...

Page 59: ...ust be accomplished prior to engine start up after engine installation or overhaul re assembly Two methods are provided in Section 3 2 3 1 1 and Section 3 2 3 1 2 Engine Preoiling Method 1 is preferred 3 2 3 1 1 Engine Preoiling Method 1 1 Install and torque the spark plugs and ignition lead wires according to the Spark Plug Maintenance instructions in Section 6 3 9 2 and Ignition Harness Maintena...

Page 60: ... the engine lubrication system Failure to purge the air from the oil cooler and hoses prior to engine start will damage the engine 2 Turn the fuel selector valve to the OFF position 3 Position the mixture control to the IDLE CUTOFF position and ensure the magneto switch es are in the OFF position WARNING Do not continuously operate the starter for more than 30 seconds 4 Engage the starter for no l...

Page 61: ...t the fuel manifold valve fuel supply hose to the inlet fitting on the manifold valve and torque the fuel hose B nut to Appendix B specifications NOTE Place approved containers at the induction system drain locations to collect fuel as it is drained overboard 10 Turn the aircraft Master Power Switch to the ON position 11 With the Mixture control in FULL RICH and the Throttle OPEN turn the aircraft...

Page 62: ... Operating Limits in Section 2 3 during Flight Check CAUTION Check the oil level in the sump and service if necessary to the capacity specified in Section 2 3 Engine Specifications and Operating Limits with oil meeting the SAE specification described in Engine Oil Specifications in Section 3 2 1 of the Maintenance and Overhaul Manual M 6 Pressure check the fuel system for leaks before starting the...

Page 63: ...ween the IO 240 A and subsequent engine models require separate engine installation drawings Pay particular attention to the model depicted when referencing drawings for engine installation requirements 3 3 1 IO 240 A Installation Drawings Figure 3 1 IO 240 A Top View 10 156 10 50 10 50 9 31 LIFTING EYE Ø 0 625 FUEL VENT DRAIN 0 43765 20 UNF 2A MAGNETO STARTER TERMINAL 0 56 18 UNC 21 LIFTING EYE Ø...

Page 64: ...T THERMOCOUPLE 0 375 24 UNF 2A FUEL INLET 0 56 18 UNF 2A 6 25 23 45 29 82 14 55 7 18 0 96 19 78 C L EXHAUST PORT 4X 2 47 3 81 6 61 8 25 ALTERNATOR ALTERNATOR 3 00 OIL COOLER ADAPTER CYLINDER HEAD TEMPERATURE CHT THERMOCOUPLE 0 375 24 UNF 2A FUEL INLET 0 56 18 UNF 2A 6 25 23 45 29 82 14 55 7 18 0 96 19 78 C L C L EXHAUST PORT 4X 2 47 3 81 6 61 8 25 ALTERNATOR ALTERNATOR 3 00 ...

Page 65: ...40 A Front View 31 41 16 27 8 25 8 30 12 12 IDLE PRESSURE ADJUSTMENT CW TO INCREASE FUEL PUMP CYLINDER DRAIN 0 4375 20 UNF 2A 4 Places FUEL DRAIN 0 4375 20 UNF 2A 31 41 16 27 8 25 8 30 12 12 IDLE PRESSURE ADJUSTMENT CW TO INCREASE FUEL PUMP CYLINDER DRAIN 0 4375 20 UNF 2A 4 Places FUEL DRAIN 0 4375 20 UNF 2A ...

Page 66: ...ELIEF VALVE OIL SCREEN ASSY TACHOMETER DRIVE ADAPTER A854 TYPE 1 AIR OIL SEPARATOR RETURN 0 250 18 NPTF OIL SUMP ALTERNATOR OIL DRAIN PLUG 0 88 HEX 0 625 18 31 41 3 50 3 50 3 50 3 50 5 25 5 25 11 56 SPARK PLUG OIL PRESSURE RELIEF VALVE OIL SCREEN ASSY TACHOMETER DRIVE ADAPTER A854 TYPE 1 AIR OIL SEPARATOR RETURN 0 250 18 NPTF OIL SUMP ALTERNATOR OIL DRAIN PLUG 0 88 HEX 0 625 18 ...

Page 67: ...L 3 328 42 12 93 9 281 235 74 C L CYL 1 2 968 75 39 4 76 120 90 1 38 35 05 C L CYL 4 361 95 14 25 11 406 289 71 C L CYL 2 5 093 2 25 57 15 Optional Altitude Compensating Fuel Pump 35 13 21 14 16 15 22 2 1 2 AND 20000 PAD VAC PUMP DRIVE ROTATION CW DRIVE RATIO 1 1 2X R0 12 0 19 3 05 4 83 2 248 2 250 57 01 57 15 B B F8 2 0 50 0 31 7 87 2 10 4 14 105 161 53 34 X X F7 2 91 19 3 59 30 C L CYL 3 328 42 ...

Page 68: ...3 16 IO 240 Series Engine Installation Operation Manual 31 October 2011 Engine Installation Figure 3 6 IO 240 B Left Side View ...

Page 69: ...IO 240 Series Engine Installation Operation Manual 3 17 31 October 2011 Engine Installation Figure 3 7 IO 240 B Front View ...

Page 70: ...3 18 IO 240 Series Engine Installation Operation Manual 31 October 2011 Engine Installation Figure 3 8 IO 240 B Rear View ...

Page 71: ...IO 240 Series Engine Installation Operation Manual 3 19 31 October 2011 Engine Installation Figure 3 9 IO 240 B w optional Oil Cooler Filter Adapter Top View ...

Page 72: ...3 20 IO 240 Series Engine Installation Operation Manual 31 October 2011 Engine Installation Figure 3 10 IO 240 B w optional Oil Cooler Filter Adapter Left Side View ...

Page 73: ...IO 240 Series Engine Installation Operation Manual 3 21 31 October 2011 Engine Installation Figure 3 11 IO 240 B w optional Oil Cooler Filter Adapter Rear View ...

Page 74: ...llation 3 3 3 IO 240 Common Installation Drawings Figure 3 12 Propeller Flange Ø Ø 0 508 0 521 6 HOLES Ø 4 000 4 880 4 870 30 ARP 502 MODIFIED PROP FLANGE Ø 0 500 0 501 2 HOLES 30 30 Ø Ø 0 508 0 521 6 HOLES Ø 4 000 4 880 4 870 30 ARP 502 MODIFIED PROP FLANGE Ø 0 500 0 501 2 HOLES 30 30 ...

Page 75: ...ange Dimensions Figure 3 14 Standard Fuel Pump Installation 2X R 0 31 Ø 2 50 B C 15 0 3125 24 UNF 3A STUD 0 78 EXTENSION HEIGHT Typical 4 Places 0 06 Ø 1 50 R 0 97 EXHAUST MOUNTING FLANGE 2X R 0 31 Ø 2 50 B C 15 0 3125 24 UNF 3A STUD 0 78 EXTENSION HEIGHT Typical 4 Places 0 06 Ø 1 50 R 0 97 EXHAUST MOUNTING FLANGE ...

Page 76: ...LOW PRESSURE RELIEF VALVE CW INCREASE FUEL INLET VAPOR RETURN VAPOR RETURN LOCATED ON OPPOSITE SIDE ON MOST FUEL PUMPS FUEL INLET IDLE CUTOFF FULL RICH LOW PRESSURE RELIEF VALVE CW INCREASE METERED POWER CW INCREASE DRAIN FUEL OUTLET UNMETERED PRESSURE LOW PRESSURE RELIEF VALVE CW INCREASE FUEL INLET VAPOR RETURN Low Pressure Relief Valve CW Increase Mixture Control Aneroid Adjustment CCW Increase...

Page 77: ...THE FORMED SERRATIONS ON THE SHAFT APPLY CLEAN 50 WEIGHT AVIATION ENGINE OIL TO THE SHAFT THREADS AND LOCK NUT PRIOR TO TORQUE HOLD LEVER AWAY FROM LEVER PIN WHEN TORQUING NUT TORQUE NUT 100 120 IN LBS TO OIL FILTER AND COOLER FOR Ø 0 50 TUBE WITH 37 FLARED FITTING 0 750 16 UNF 2A THDS IN OUT 26 OIL PRESSURE 0 125 27 NPTF OIL TEMPERATURE 0 4375 20 UNJF 3B ALTERNATE OIL PRESSURE 0 125 27 NPTF C L 1...

Page 78: ... 125 27 NPTF OIL PRESSURE SENSOR 0 125 27 NPTF OIL PRESSURE SWITCH 0 125 27 NPTF 1 57 FROM OIL COOLER 37 FLARED FITTING 0 750 16 UNF 2A THDS TO OIL COOLER 37 FLARED FITTING 0 750 16 UNF 2A THDS C L CRANKSHAFT 1 88 0 94 1 77 45 1 14 0 11 0 48 0 55 1 29 OIL TEMPERATURE SENSOR 0 125 27 NPTF OIL PRESSURE SENSOR 0 125 27 NPTF OIL PRESSURE SWITCH 0 125 27 NPTF 1 57 FROM OIL COOLER 37 FLARED FITTING 0 75...

Page 79: ... 31 2 505 2 495 1 255 1 245 Ø 2 169 2 165 1 255 1 245 2 505 2 495 Ø 0 28 0 31 4 HOLES 4X R 31 2 505 2 495 1 255 1 245 Ø 2 169 2 165 1 255 1 245 2 505 2 495 BATTERY TERMINAL 0 25 20 UNC 2A FIELD TERMINAL 10 24 UNC 2A GROUND TERMINAL 10 24 UNC 2A STATOR TERMINAL 10 24 UNC 2A BATTERY TERMINAL 0 25 20 UNC 2A FIELD TERMINAL 10 24 UNC 2A GROUND TERMINAL 10 24 UNC 2A STATOR TERMINAL 10 24 UNC 2A ...

Page 80: ...INE MOUNT ASSEMBLY 4 ASSEMBLIES REQUIRED BUSHINGS ARE SUPPLIED WITH ENGINE 1 REQUIRED SEAT 2 REQUIRED BUSHING LORD J3608 1 2 REQUIRED CUP 2 REQUIRED CRANKCASE 0 19 REAR CRANKCASE FINISH 0 70 HOLE FOR O 0 375 BOLT SPACER 1 REQUIRED 3 00 ENGINE MOUNT ASSEMBLY 4 ASSEMBLIES REQUIRED BUSHINGS ARE SUPPLIED WITH ENGINE 2X 0 10 0 19 CRANKCASE ACCESSORY END 2XO 1 34 2X 0 03 X 45 2XO 1 12 ENGINE MOUNT LEG 2...

Page 81: ... Magneto Ignition Schematic Figure 3 25 Champion Slick Magneto Ignition Schematic 7 7 7 7 1 1 5 1 25 5 0 1 72 5 1 25 5 5 7 0 1 72 72 7 0 1 72 6 7 72 5 7 0 1 72 6 7 7 0 1 72 3 7 2 5 4 8 1 6 3 7 2 5 4 8 1 6 3 72 54 8 1 6 3 72 54 8 1 6 7 7 7 7 1 1 5 1 25 5 0 1 72 5 1 25 5 5 7 0 1 72 72 7 0 1 72 6 7 72 5 7 0 1 72 6 7 7 0 1 72 ...

Page 82: ...TCH SHIELD CONN P LEAD TORQUE 13 15 IN LBS 1 P LEAD TORQUE 13 15 IN LBS 1 1 1 GND Slick Magneto 10 32 TO IGNITION SWITCH OPTIONAL IGNITION SWITCH SHIELD CONN P LEAD TORQUE 13 15 IN LBS 1 1 1 P LEAD TORQUE 13 15 IN LBS 1 1 1 1 GND 1 10 32 TACH SENSOR TERMINAL OPTIONAL IGNITION SWITCH SHIELD CONN 10 32 TO IGNITION SWITCH 1 1 10 32 TACH SENSOR TERMINAL OPTIONAL IGNITION SWITCH SHIELD CONN 10 32 TO IG...

Page 83: ...mely response is critical 4 2 Flight Prerequisites If the engine is newly installed and or has been repaired overhauled perform the sequential tasks listed in the Engine Operational Check instructions in Section 6 3 6 of the Maintenance and Overhaul Manual M 6 prior to releasing the engine for normal operation WARNING The Engine Operational Check in Section 6 3 6 of the Maintenance and Overhaul Ma...

Page 84: ...tallation in the airframe prior to release for normal service Section 2 3 Engine Specifications and Operating Limits contains the engine specifications and operating limits for each engine model Perform an Engine Operational Check and a normal preflight ground run up in accordance with the Airplane Flight Manual AFM or Pilot s Operating Handbook POH before releasing the engine for a Flight Check E...

Page 85: ...verify the engine is operating within the parameters specified in Section 2 3 4 Reduce the engine speed to climb power according to the AFM POH instructions Maintain a shallow climb attitude to achieve optimum airspeed and cooling airflow 5 At cruise altitude a Maintain level flight cruise at 75 power with best power or richer mixture for the first hour of operation NOTE Best power mixture setting...

Page 86: ...tle Speed 2800 25 RPM 2800 25 RPM Idle Speed RPM 1000 25 RPM 900 1000 25 RPM propeller dependent Rated Manifold Air Pressure 29 5 in Hg 29 5 in Hg Engine Intake Air Temperature Ambient Ambient Engine Intake Air Pressure Ambient Ambient Fuel Grade Octane 100 LL or 100 100 LL or 100 Maximum Oil Temperature Limit 240 F 116 C 240 F 116 C Oil Pressure Max Oil Cold 100 psig 100 psig Minimum Oil Pressure...

Page 87: ... the following engine instrument panel indications a engine RPM b fuel flow c oil pressure and temperature d cylinder head temperature and e exhaust gas temperature 4 to verify the engine is operating within the parameters specified in Section 2 3 4 If the engine fails to reach the rated full throttle RPM during ground operations ascend to cruise altitude 2000 above field elevation and verify the ...

Page 88: ... test altitude Repeat and record the leaning authority test NOTE Adjust the fuel mixture control for Peak EGT in a slow deliberate movement while monitoring the EGT indicator Leaning from FULL RICH EGT to PEAK EGT requires no less than 30 seconds Abruptly chopping the fuel mixture control will yield an inaccurate PEAK EGT indication Troubleshoot Fuel System according to instructions in Chapter 8 o...

Page 89: ...odily injury or death Supplemental instructions for normal operation in this section are Pre operational Requirements Engine Start Ground Engine Run up Taxi Preparation Take off Climbing Ascent Cruising Descent Landing Approach Engine Shutdown 4 3 1 Pre operational Requirements 1 Check the oil level and verify the quantity is within specified limits 2 Verify oil fill cap and dipstick are secure 3 ...

Page 90: ...isted in Table 4 2 Flight Prerequisites have been completed in addition to those required by the aircraft POH aircraft manufacturer or Supplemental Type Certificate STC holder Note the following If the engine is being started in extreme cold preheating may be required Refer to Section 4 5 1 Engine Operation in Extreme Cold If the engine is started in hot weather refer to Section 4 5 2 Engine Opera...

Page 91: ...ation is clear before engaging the starter 8 Ignition Switch START RESULT Engine starts and runs smoothly at idle indicated oil pressure is greater than 10 psi If the engine fails to start refer to the troubleshooting instructions in Section 8 of the Maintenance and Overhaul Manual M 6 NOTE Check oil pressure frequently Oil pressure indication must be noted within 30 seconds in normal weather If n...

Page 92: ...jection components especially the fuel pump if equipped may cause fuel vaporization making engine start difficult Supplement the AFM POH normal starting instructions with the following steps 1 Fuel Selector Valve ON 2 Throttle CLOSED 3 Mixture Control IDLE CUT OFF 4 Boost Pump ON 15 20 seconds 5 Boost Pump OFF 6 Allow fuel to drain from intake prior to engine start follow AFM POH starting instruct...

Page 93: ... plugs and smooth operation before returning to single magneto operation Limit ground operation to time necessary to complete engine warm up and pre flight checkout 7 Throttle 1700 RPM a Magneto Checkout 1 Ignition Switch R RESULT Noticeable RPM not to exceed 150 RPM drop and slight engine roughness record Left Magneto channel drop results Maximum allowable RPM drop spread between magneto channels...

Page 94: ...75 F 24 C and the oil pressure is within the 30 60 psi range Operating the engine above idle before reaching minimum oil temperature may cause a loss of oil pressure and engine damage NOTE For taxi operation during high ambient temperature or from fields at higher altitudes the mixture control may require leaning for smooth engine operation A FULL RICH mixture must be used for takeoff 1 Cowling Fl...

Page 95: ...adverse conditions such as high power settings low airspeed extreme ambient temperatures etc Take remedial steps to reduce such temperatures as soon as possible If excessive temperatures are noted and cannot be explained or if abnormal cowl flap and or mixture settings are required to maintain temperatures inspect to determine cause Possible causes are broken or missing baffles inoperative cowl fl...

Page 96: ...ne peak EGT at high power will result in burned valves detonation and engine failure 1 Throttle Greater than 75 rated power 2 Mixture Control FULL RICH 3 Cowl Flaps Set to maintain CHT Oil Temp NOTE Maintain mixture and throttle settings until climb is complete Upon completion of climb power settings may be reduced to desired settings 4 Immediately after takeoff monitor engine gauges not to exceed...

Page 97: ...ture beyond the Best Power setting Excessive mixture leaning will increase engine temperatures and may damage the engine NOTE When increasing power enrich mixture then advance the throttle to increase RPM When reducing power retard throttle then adjust the mixture control Changes in altitude or air temperature will require adjustments in manifold pressure and fuel flow 3 Adjust the mixture control...

Page 98: ...r engine RPM during descent to ensure maximum rated engine RPM is not exceeded If engine RPM approaches maximum rated RPM reduce the angle of descent to increase drag and maintain engine operation within rated specifications If the engine exceeds rated engine RPM for more than one minute refer to Engine Overspeed Inspections in Section 6 4 3 of the Maintenance and Overhaul Manual M 6 3 Cylinder He...

Page 99: ... spark plug fouling NOTE If the engine runs roughly after single magneto operation increase engine speed to 2200 RPM in the BOTH position and lean the mixture control until the RPM peaks for ten seconds before returning to the full rich position to clear the spark plugs and restore smooth operation before returning to single magneto operation The difference between magnetos individual operation sh...

Page 100: ...ntrol of the aircraft at all times Do not stall the airplane attempting to extend the gliding distance 4 4 1 Engine Fire During Start WARNING Maintain control of the aircraft at all times Do not stall the airplane attempting to extend the gliding distance Supplement the AFM POH instructions if possible with the following if flames are observed in the induction or exhaust system during engine start...

Page 101: ...ocedures 1 Follow AFM POH instructions 2 Engine nacelle area Check for damage smoke fire RESULT If any of the checked are noted follow AFM instructions 3 Propeller Blade Check for damage smoke fire 4 If no visible damage smoke or fire is observed perform the following else to step 5 NOTE Do not immediately go to FULL RICH as roughness may be caused by an overly rich mixture a Mixture Adjust to pro...

Page 102: ...reduced oil pressure If oil pressure remains normal a high temperature indication may be caused by a faulty gauge or thermocouple 1 Cowl Flaps OPEN 2 Airspeed Increase 3 Reduce Power if steps 1 and 2 do not lower temperature 4 LAND AS SOON AS PRACTICAL 4 4 7 Low Oil Pressure WARNING If oil pressure drops below 30 psi an engine failure is imminent Follow AFM POH emergency procedures If the oil pres...

Page 103: ...battery may result in damage to the starter relay or possible engine kick back resulting in a broken starter adapter clutch spring False starting failure to continue running after starting often results in condensation on spark plug electrodes This moisture can freeze and must be eliminated either by preheating the engine or removing and cleaning the spark plugs Engine preheating and an auxiliary ...

Page 104: ...inders air intake and oil cooler Because excessively hot air can damage non metallic components such as seals hoses and drive belts do not attempt to hasten the preheat process The preferred method of preheating is to place the aircraft in a heated hangar for a minimum of 4 hours prior to flight Optional preheating methods are A high volume combustion heater with ducts directed to the engine oil s...

Page 105: ...PM before reaching the minimum oil temperature may result in engine malfunction engine failure injury or death 6 Run the engine up to 1700 RPM in 100 RPM increments to prevent oil pressure from exceeding 100 psi CAUTION Continually monitor oil pressure during run up 7 When oil temperature has reached 75 F 24 C and oil pressure does not exceed 60 psi at 2500 RPM the engine has been warmed sufficien...

Page 106: ...il pressure closely If necessary retard the throttle to maintain oil pressure below 100 psi If oil pressure is less than 30 psi or cannot be maintained below 100 psi shut the engine down and repeat the preheat process Do not close the cowl flaps to facilitate engine warm up b Monitor the oil temperature until it reaches at least 75 F 24 C CAUTION Do not operate the engine at speeds above 1700 RPM ...

Page 107: ... the cowl flaps in an attempt to hasten engine warm up 3 Operate the engine at 1000 RPM until some oil temperature is indicated 4 Monitor the oil pressure closely If necessary retard the throttle to maintain oil pressure below 100 psi If oil pressure is less than 30 psi or cannot be maintained below 100 psi shut the engine down and follow the preheat instructions to prevent engine damage Do not cl...

Page 108: ...nstable engine operation can be expected Three hot weather operation situations requiring special instructions are Cooling an Engine in Hot Weather Section 4 5 2 1 Engine Restart in Hot Weather Section 4 5 2 2 Take off and Initial Climb Out in Hot Weather Section 4 5 2 4 Ensure the engine is serviced with the correct viscosity oil specified in Section 3 2 1 Engine Oil Specifications in the Mainten...

Page 109: ... 1 Monitor oil and cylinder temperatures closely during taxiing and engine run up 2 Operate with cowl flaps full open 3 Do not operate the engine at high RPM except for necessary operational checks 4 If take off is not to be made immediately following engine run up face the aircraft into the wind with the engine idling at 900 1000 RPM 4 5 2 4 Take off and Initial Climb Out in Hot Weather 1 Mixture...

Page 110: ...ing takeoff If higher than desired temperatures are experienced during the climb phase establish a lower angle of attack or higher climb speed consistent with safe operating practices to provide increased engine cooling Monitor oil and cylinder temperatures closely during taxiing and engine run up Operate with cowl flaps full open Do not operate the engine at high RPM except for necessary operatio...

Page 111: ...ion BTC Before Top Dead Center CFM Cubic Feet per Minute CHT Cylinder Head Temperature CSB Critical Service Bulletin DVM Digital Volt ohm Meter EGT Exhaust Gas Temperature EMI Electromagnetic Interference FAA Federal Aviation Administration FAR Federal Aviation Regulations FBO Fixed Base Operator HP Horsepower IAW In accordance with ICA Instructions for Continued Airworthiness MAP Manifold Air Pre...

Page 112: ... gases escaping past valve faces In other instances it indicates drawing of the temper of steel parts to a soft blue condition as a result of overheating during an absence of lubrication on moving surfaces such as gear teeth subject to high loading Burr Sharp or rough projection of metal Chafing Condition caused by a rubbing action between adjacent or contacting parts under light pressure which re...

Page 113: ...andatory Service Bulletin Service document relating to known or suspected hazards to safety that have been incorporated in whole or in part into an Airworthiness Directive AD issued by the FAA or have been issued at the direction of the FAA by the manufacturer requiring compliance with an already issued AD or an equivalent issued by another country s airworthiness authority Nick Sharp sided gouge ...

Page 114: ...cturer to be of value to an owner operator in the use of a product by enhancing safety maintenance or economy Service Information Letter Service information communiqué that may be of use to the owner operator or maintained of the aircraft Spalling Distress to a loaded surface where chips of the hardened surface are broken out Static Seal Cylinder seal that consists of the piston rings to the cylin...

Page 115: ...talling nuts and bolts verify the fastening hardware is lubricated according to instructions Inspect all fasteners for proper plating and thread form Failure to verify a fastener s serviceability or to correctly lubricate the fastener prior to installation will result in the fastener not being properly pre loaded Subsequent failure of the fastener may occur B 1 1 Torque Tips WARNING The use of sea...

Page 116: ...ase nuts to the specified value for the cylinder base stud nuts Through bolt nuts must be torqued on both sides of the engine even if only one cylinder is being installed WARNING Failure to torque through bolt nuts on both sides of the engine can result in a loss of main bearing crush with main bearing shift and subsequent engine failure NOTE Through bolt nuts P N 634505 and 649496 have been super...

Page 117: ...t a 90 degree angle in relation to the square drive adapter In any other orientation the extension alters the force applied to the fastener Figure B 2 Drive extensions Apply the formula below to determine the appropriate torque wrench setting when using an extension S T x A Where S desired torque setting or reading T torque applied at square drive adapter A length of handle in inches B length of e...

Page 118: ...dial on the wrench in Figure B 3 to 30 45 12 6 x 12 The same torque wrench used with the extension in Figure B 4 must be set to 90 45 12 6 x 12 to apply 45 inch pounds of torque to the same nut and bolt Figure B 4 Extension decreases applied torque Extension Length B Torque Wrench Square Drive Distance A Fastener Torque Distance Set Torque x A Fastener Torque A B Extension Length B Torque Wrench S...

Page 119: ...0 24 21 25 1 7 2 0 250 20 75 85 6 3 7 1 250 28 90 100 7 5 8 3 3125 18 155 175 12 9 14 6 3125 24 180 220 15 0 18 3 375 16 220 260 18 3 21 7 375 24 275 325 22 9 27 1 44 20 400 450 33 3 37 5 50 20 550 600 45 8 50 0 Driving Studs 250 20 50 70 4 2 5 8 3125 18 100 150 8 3 12 5 375 16 200 275 16 7 22 9 44 14 300 425 25 0 35 4 Pipe Plugs 062 27 30 40 2 5 3 3 125 27 60 80 5 0 6 7 250 18 130 150 10 8 12 5 3...

Page 120: ...inum 625 200 350 88 14 10 Steel 625 300 400 Table B 3 Hose Fitting B Nut Torque Specification Hose Size Hose End Fitting Material Torque In lbs 2 31 24 Brass Aluminum Fitting 50 80 2 31 24 Steel Fitting 75 120 3 38 24 Brass Aluminum Fitting 70 105 3 38 24 Steel Fitting 95 140 4 4375 20 Brass Aluminum Fitting 100 140 4 4375 20 Steel Fitting 135 190 5 500 20 Brass Aluminum Fitting 130 180 5 500 20 S...

Page 121: ...20 Nut Cylinder to Crankcase Studs including 7th stud 490 510 40 8 42 5 All Models AR 44 20 Nut Through Bolt at Cadmium Plated Washer 440 460 36 7 38 3 All Models AR 44 20 Nut Through Bolt at Cylinder Flange 590 610 49 2 50 8 All Models AR 44 20 Nut Through Bolt at Front Mount Belt Driven Alternator 490 510 40 8 42 5 All Models AR 50 20 Nut Crankcase Nose Tie Bolts 640 660 53 5 55 0 All Models AR ...

Page 122: ...n Line 40 45 3 3 3 7 All Fuel Injected Model AR 38 24 Nut Fuel Injection Line 55 60 4 5 5 0 All Fuel Injected Model AR 62 18 Plug Screen Assembly Metering Unit w New Gasket 120 130 10 0 10 8 All Fuel Injected Model AR Miscellaneous Lubrication System Fasteners 25 20 Bolt Oil Pump Cover to Crankcase 75 85 6 3 7 1 All Models AR 62 18 Plug Oil Cooler w crush washer 190 210 15 8 17 5 All Models AR 62 ...

Page 123: ...hometer Sensor 88 18 Adapter Tach Reduction Gear 120 180 10 0 15 0 All Models AR 1 Heat crankshaft gear to 300º F install gear on crankshaft immediately for shrink fit Ensure the gear seats tightly against the end of the crankshaft by tapping lightly with a brass hammer 2 Torque to low limit If cotter pin will not align with holes increase torque gradually up to high limit only If cotter pin holes...

Page 124: ...late 25 35 2 08 2 91 S 20 200 Magnetos Various Nut Ignition Harness Cable Outlet Plate 25 35 2 08 2 91 S 1200 Magnetos Various Screw Ignition Harness Cable Outlet Plate 18 25 1 5 2 08 Slick Magnetos 0 125 27 Fuel Injector Nozzle to Cylinder1 1 Apply Part No 646943 Anti Seize Lubricant 55 65 4 6 5 4 All 0 31 32 B Nut Fuel Injection Line to Fuel Injector Nozzle 40 45 3 3 3 8 All 0 375 24 B Nut Fuel ...

Page 125: ...units for investigation and possible repair To ensure proper re installation of usable parts tag or mark all parts and hardware as they are removed or disassembled Use protective caps plugs and covers to ensure openings are unexposed Install dust caps over the tube ends of open lines and NOT IN the tube ends Be sure to remove the dust caps and covers after the maintenance or repair work is complet...

Page 126: ...ts are represented as being of aircraft quality when actually the quality and origin of these units is unknown Users of such units are usually not aware of the potential hazards involved with replacement parts that are not eligible for use on certified aircraft Frequently such units are deceptively advertised or presented as unused like new or remanufactured implying the quality of such units is e...

Page 127: ...o service is the responsibility of the person or agency who signs the approval The owner operator is responsible for the continued airworthiness of the aircraft To ensure continued safety in aircraft operation it is essential that great care be used when inspecting testing and determining the acceptability of all parts and materials Particular caution should be exercised when the identity of mater...

Page 128: ...t needle ball and roller Bushings rocker arm connecting rod counter weight and crankshaft counterweight blade Camshaft gear bolts Cold Start primer diverter valves Connecting rod bolts and nuts Connecting rod forging number 626119 P N s 646320 and 646321 with beam width less than 0 625 inches Reference CSB96 13 Counterweight pins retaining plates and snap rings Crankshaft alternator face gear bolt...

Page 129: ...fied limits to align holes 1 Verify the hardware bolts or nuts to be safety wired has been correctly torqued to Appendix B specifications 2 Insert half of the required length of new safety wire through the first piece of hardware and do the following a For right hand threaded hardware install the safety wire so the strand will pull and lock clockwise b For left hand threaded hardware install the s...

Page 130: ...safety wire strand with pliers until it is taut but not overstressed 6 Insert the uppermost strand through the hole in the second piece of hardware 7 Bend and wrap the twisted wire braid around the second piece of hardware pulling the wire taut as described in the previous steps which will counter lock the hardware joined by the safety wire Repeat the previous steps for any subsequent hardware to ...

Page 131: ...e 2 Lubricate and torque hardware torqued to Appendix B specifications 3 Using a soft drift bend the lock tab on the other side of the tab washer firmly against the bolt or nut flats as shown in Figure C 3 Ensure the lock tabs are bent flat up against the hardware without protrusion as shown in top and side views to properly lock the hardware and prevent the lock tabs from breaking off Figure C 3 ...

Page 132: ...part of the wire between male and female threads the diameter of the insert is equal to the nominal screw size The special finishing taps size the threaded hole to allow the pitch diameter of the female thread of the installed insert to conform to Class 3 fit with standard bolt threads or Class 4 tight fit with standard size studs The difference in fit is due to a difference in pitch diameters of ...

Page 133: ... Use the proper size extracting tool Figure C 4 for the nominal thread size 2 Tap the extracting tool into the helical coil insert until the sharp edges of the tool dig firmly into the helical coil insert 3 Turn the tool to the left and back out the helical coil until it is free Figure C 4 Helical Coil Extraction Tool ...

Page 134: ...in Figure C 5 5 The outer end of the insert must lie within the first full thread of the hole 6 Break off the driving tang of a notched helical coil by bending it back and forth across the hole with long needle nose pliers or with a special tang break off tool 7 Once the helical coil insert is installed the remaining wall thickness edge distance to the helical coil must not be less than one half t...

Page 135: ...ll a hole matching the diameter of a splined stud extractor tool through the center of the stud Insert the splined stud extractor through the drilled center of the stud and unscrew the stud 3 Examine the course thread end of the damaged stud before discarding it to determine the correct stud size for oversize replacement stud C 7 1 1 Size on Size Rosan Stud Removal To prevent damage to the engine ...

Page 136: ...al torque to remove the stud 3 Lift out the remaining portions of the lock ring 4 Carefully use a sharp punch to break away the remaining portion of the stud from the cylinder head Figure C 6 Rosan Stud Removal Tool Figure C 7 Rosan stud removal tool installed on stud Table C 1 Rosan Stud Primary Secondary Bore Specifications Cylinder Exhaust Port Stud Primary Removal Drill Secondary Removal Drill...

Page 137: ...on C 7 2 1 1 Standard studs have no marking Refer to the table below to determine the proper stud size required or to identify oversize studs Figure C 8 Stud Sizes 2 Clean the casting tapped hole with solvent and blow dry any debris or liquid out of the hole using compressed air WARNING Helical coils can only be installed where authorized 3 Examine the threads in the tapped hole If the threads are...

Page 138: ...the torque values listed in Appendix B 7 Drive the stud in until it reaches the desired length specified in Appendix D C 7 2 1 Rosan Stud Installation Any type of Rosan stud size on size type or step type may be installed using the appropriate wrench Install the stud to the dimensions specified in Figure C 10 CAUTION Location of the flange is important in preventing the lock ring drive tool from m...

Page 139: ...nsert the cotter pin through a hole with the head seated firmly in the slot of the nut CAUTION Do not use side cutting type pliers to bend back the cotter pin ends These pliers cause nicks which can weaken the cotter pin to the extent that it can become detached 5 Spread the exposed ends of the cotter pin Bend the ends over the flat on the nut and the end of the bolt 6 Seat the ends firmly against...

Page 140: ... installation C 9 1 Fuel System Purge 1 Remove the cap from the fuel inlet fitting of the fuel system component hose pump manifold valve fuel control unit inline filter or test equipment 2 Connect the aircraft or engine fuel supply to the inlet fitting and tighten to prevent leakage 3 Connect a clean section of fuel hose to the component fuel outlet s and direct the end of the hose through a paper...

Page 141: ...ankcase parting surfaces will occur The result will be cylinder separation main bearing movement oil starvation and catastrophic engine failure USE ONLY CLEAN 50 WEIGHT AVIATION ENGINE OIL ON SURFACES LISTED 1 Verify the surface where the sealant will be applied is clean and free of nicks burrs oil and grit 2 For the engine nose seal apply Part No 653692 General Purpose Primer Part No 653692 to pr...

Page 142: ...lure USE ONLY CLEAN 50 WEIGHT AVIATION ENGINE OIL ON SURFACES LISTED Gaskets and components must be properly positioned with the hardware torqued and safety wired as required during assembly to prevent oil loss Install only new gaskets Prior to installation inspect each gasket for brittleness cracks wrinkles damage or deformities Do not use a gasket with obvious defects even if new replace with a ...

Page 143: ...e a wrench on both mating connections to avoid applying excessive torque to the fittings Securely tighten fittings and torque to the specified value in Appendix B Torque the hose or tubing end fitting while maintaining sufficient force on adjacent fittings to prevent twisting and shear loads 2 Support the last fitting in the assembly on components that contain multiple fittings coupled in one loca...

Page 144: ...lure may damage the wiring harness 3 Do not secure wiring harnesses to fuel lines 4 Use cushion clamps with stand off spacers where necessary to secure the harness to existing baffle supports and brackets where practical 5 Secure harnesses to minimize the possibility of chafing vibration and excessive heat exposure 6 The largest allowable unsecured segment of wiring harnesses is eight 8 inches 20 ...

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Summary of Contents for IO-240-A

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