Continental Motors O-200-D User manual

Publication OI-2
©2017 CONTINENTAL MOTORS, INC. JAN 2017
O-200-D
X
CONTINENTAL AIRCRAFT ENGINE
INSTALLATION
AND
OPERATION
MANUAL
FAA APPROVED

A O-200-D & X Series Engine Installation and Operation Manual
3 January 2017
Supersedure Notice
This manual incorporates references to M-0, Standard Practice Maintenance Manual and revises O-200-D & X
series Installation and Operation Manual, Publication Number OI-2 dated 31 August 2011. Upon FAA Approval, and
publication release, this manual supersedes all previous revisions of this manual. Instructions in this manual are for
O-200-D and subsequent engine models only and shall not be used for O-200-A, B or C series engines.
Effective Changes for this Manual
0 ............ 3 January 2017
List of Effective Pages
Document Title: O-200-D & X Series Engine Installation and Operation Manual
Publication Number: OI-2 Initial Publication Date: 3 January 2017
Page Change Page Change Page Change Page Change
Cover............................0
A...................................0
i-viii ............................... 0
1-1 thru 1-12.................0
2-1 thru 2-32.................0
3-1 thru 3-28.................0
4-1 thru 4-22.................0
A-1 thru A-2..................0
B-1 thru B-2..................0
C-1 thru C-2 .................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, 2015, 2017 Continental Motors, Inc. All rights reserved. This material may not be reprinted, republished, broadcast, or
otherwise altered without the publisher's written permission. This manual is provided without express, statutory, or implied warranties. The
publisher will not be held liable for any damages caused by or alleged to be caused by use, misuse, abuse, or misinterpretation of the contents.
Content is subject to change without notice. All other products or company names mentioned in this publication are trade names, trademarks, or
registered trademarks of their respective owners.

O-200-D & X Series Engine Installation and Operation Manual i
3 January 2017
PREFACE
Continental Motors (CM) provides the OI-2 Installation and Operation Manual to owners of CMI
engines in accordance with Title 14, Code of Federal Regulations (CFR) Part 33 §33.5. While this
manual is provided to owners, it is intended for use only by an OEM or STC aircraft customer for
assistance in defining the installation and operational requirements during the initial OEM FAA
(or equivalent) Type Certification Process. Such activity is performed by personnel who meet the
FAA (or equivalent) regulatory requirements, working in direct liaison with CM engineering and
technical personnel. Information and instructions contained in this manual anticipate the user
possesses and applies the knowledge, training, and experience commensurate with the regulatory
requirements. It is not intended and should not be used by a pilot/owner or maintenance
personnel.
Installation and Operation instructions in this manual may be modified or used intact to create the
aircraft AFM or POH manuals. In service, those aircraft manuals are to be used by owners,
operators and maintenance personnel.
WARNING
Ensure you have the latest revision of this manual, any
applicable change pages, FAA Airworthiness Directives and
CMI service documents prior to commencing engine
installation or development of any installation or engine
operating instructions for the aircraft.
It is the responsibility of the facility performing the engine installation design to verify only the
latest approved version of this manual, including change pages, service documents and applicable
FAA ADs are used during the development process. FAA Airworthiness Directives are available
on the FAA web site.
Electronic versions of current Continental Motors publications, change pages, and service
documents are available on the Continental Motors web site.

ii O-200-D & X Series Engine Installation and Operation Manual
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Intentionally Left Blank

O-200-D & X Series Engine Installation and Operation Manual iii
3 January 2017
TABLE OF CONT E NTS
Chapter 1. Introduction
1-1. Scope and Purpose of This Manual ................................................................. 1-1
1-1.1. Instructions for Continued Airworthiness.................................................................... 1-1
1-1.2. Advisories .................................................................................................................... 1-2
1-1.3. Using this Manual ........................................................................................................ 1-2
1-1.4. Compliance .................................................................................................................. 1-4
1-1.5. Order of Precedence..................................................................................................... 1-5
1-2. Publications...................................................................................................... 1-6
1-2.1. Publication Access ....................................................................................................... 1-6
1-2.2. Publication Changes..................................................................................................... 1-6
1-2.3. Updates/Change Distribution....................................................................................... 1-6
1-2.4. Service Documents ...................................................................................................... 1-9
1-2.4.1. Service Documents Incorporated in this Manual ............................................ 1-10
1-2.4.2. Service Documents Released After Publication .............................................. 1-11
1-2.5. Related Publications................................................................................................... 1-13
1-2.5.1. Suggestions and Corrections ........................................................................... 1-13
1-3. Contact Information....................................................................................... 1-14
Chapter 2. Engine Description
2-1. General Engine Description............................................................................. 2-1
2-1.1. Engine Model Number Definition ............................................................................... 2-2
2-1.2. Cylinder Number Designations.................................................................................... 2-2
2-2. Aircraft Interface Requirements ...................................................................... 2-3
2-2.1. Crankcase Breather Ventilation.................................................................................... 2-4
2-2.2. Engine Cooling ............................................................................................................ 2-4
2-2.3. Induction System.......................................................................................................... 2-4
2-2.4. Mass Flow .................................................................................................................... 2-4
2-2.5. Air Filtration ................................................................................................................ 2-4
2-2.6. Alternate Air System.................................................................................................... 2-4
2-2.7. Manifold Air Pressure.................................................................................................. 2-5
2-2.8. Engine Instrumentation ................................................................................................ 2-5
2-2.9. Fuel System.................................................................................................................. 2-5
2-2.9.1. Fuel Supply Hose Routing................................................................................. 2-6
2-2.9.2. Fuel Filter Requirements ................................................................................... 2-6
2-2.9.3. Fuel Temperature............................................................................................... 2-6
2-2.9.4. Aircraft Fuel Boost Pump.................................................................................. 2-6
2-2.9.5. Water Separator ................................................................................................. 2-6
2-2.10. Lubrication System ...................................................................................................... 2-6
2-2.10.1.Oil Temperature and Pressure Connection Locations ....................................... 2-6
2-2.10.2.Oil Flow and Heat Rejection ............................................................................. 2-7
2-2.10.3.Oil Level Gauge................................................................................................. 2-7
2-2.10.4.Oil Filter ............................................................................................................ 2-7
2-2.10.5.Oil Cooler Adapter (Optional)........................................................................... 2-7
2-2.11. Electrical System.......................................................................................................... 2-7
2-2.11.1.Starter................................................................................................................. 2-7

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2-2.11.2.Alternator........................................................................................................... 2-7
2-2.11.3.Magnetos ........................................................................................................... 2-8
2-2.11.4.Spark Plugs........................................................................................................ 2-8
2-2.11.5.Ignition Harness ................................................................................................ 2-8
2-2.12. Exhaust System............................................................................................................ 2-8
2-2.13. Engine Mount Isolators................................................................................................ 2-9
2-2.14. Engine Mounting ......................................................................................................... 2-9
2-2.15. Propeller System .......................................................................................................... 2-9
2-2.15.1.Propeller Drive .................................................................................................. 2-9
2-2.15.2.Propellers........................................................................................................... 2-9
2-3. Detailed Engine Description.......................................................................... 2-10
2-3.1. Crankcase................................................................................................................... 2-10
2-3.2. Engine Drive Train .................................................................................................... 2-11
2-3.2.1. Crankshaft ....................................................................................................... 2-12
2-3.2.2. Connecting Rods ............................................................................................. 2-12
2-3.2.3. Camshaft......................................................................................................... 2-13
2-3.3. Accessory Case .......................................................................................................... 2-14
2-3.4. Cylinders.................................................................................................................... 2-14
2-3.4.1. Pistons ............................................................................................................. 2-16
2-3.4.2. Hydraulic Valve Tappets................................................................................. 2-16
2-3.5. Lubrication System .................................................................................................... 2-17
2-3.5.1. Oil Pump.......................................................................................................... 2-17
2-3.5.2. Oil Sump.......................................................................................................... 2-18
2-3.5.3. Oil Pressure Relief Valve................................................................................ 2-18
2-3.5.4. Oil Cooler Adapter .......................................................................................... 2-19
2-3.6. Ignition System .......................................................................................................... 2-19
2-3.7. Starter Assembly........................................................................................................ 2-21
2-3.8. Alternator ................................................................................................................... 2-21
2-3.9. Engine Cooling .......................................................................................................... 2-21
2-3.10. Fuel System................................................................................................................ 2-22
2-3.11. Induction System ....................................................................................................... 2-22
2-4. Engine Specifications .................................................................................... 2-23
2-4.1. Accessory Drive Ratios ............................................................................................. 2-27
2-4.2. Induction .................................................................................................................... 2-27
2-4.3. Electrical .................................................................................................................... 2-27
2-4.4. Propeller..................................................................................................................... 2-27
2-4.5. Performance Data ...................................................................................................... 2-28
2-4.5.1. O-200-D & X Performance Charts.................................................................. 2-29
2-4.6. Accessory Weights..................................................................................................... 2-32
Chapter 3.Engine Installation
3-1. Engine Installation........................................................................................... 3-1
3-1.1. Common Tools and Consumable Supplies Required .................................................. 3-1
3-1.2. Engine Receipt and Handling ...................................................................................... 3-2
3-1.2.1. Uncrating the Engine......................................................................................... 3-2
3-1.2.2. Crating an Engine for Shipping......................................................................... 3-2
3-1.2.3. Acceptance Inspection....................................................................................... 3-3
3-1.3. Engine Transport.......................................................................................................... 3-3
3-2. Installation Procedures..................................................................................... 3-4

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3 January 2017
3-2.1. Prepare the Aircraft for Engine Installation ................................................................. 3-4
3-2.2. Prepare the Engine for Installation............................................................................... 3-4
3-2.3. Installation Sequence ................................................................................................... 3-5
3-2.3.1. Engine Pre-oiling............................................................................................... 3-7
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.................................................................................................. 3-10
3-3. Engine Installation Drawings......................................................................... 3-11
3-3.1. O-200-D & X Series Engine Common Installation Drawings................................... 3-11
3-3.2. O-200-D Installation Drawings.................................................................................. 3-17
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 Requirements ........................................................................................... 4-2
4-2.3. Flight Check and Break-In........................................................................................... 4-3
4-2.3.1. Engine Break-In................................................................................................. 4-3
4-2.3.2. Flight Check ...................................................................................................... 4-4
4-3. Normal Operation ............................................................................................ 4-5
4-3.1. Pre-operational Requirements...................................................................................... 4-5
4-3.2. Engine Start.................................................................................................................. 4-6
4-3.2.1. Cold Start........................................................................................................... 4-7
4-3.2.2. Flooded Engine.................................................................................................. 4-7
4-3.2.3. Hot Start............................................................................................................. 4-8
4-3.3. Ground Run-up ............................................................................................................ 4-8
4-3.4. Taxi Preparation ......................................................................................................... 4-10
4-3.5. Power Control ............................................................................................................ 4-10
4-3.6. Take-Off ..................................................................................................................... 4-10
4-3.7. Cruise Climb .............................................................................................................. 4-11
4-3.8. Cruise ......................................................................................................................... 4-11
4-3.9. Descent....................................................................................................................... 4-12
4-3.10. Landing ...................................................................................................................... 4-12
4-3.11. Engine Shutdown ....................................................................................................... 4-13
4-4. Emergency Operation .................................................................................... 4-15
4-4.1. Engine Fire during Start............................................................................................. 4-15
4-4.2. Engine Roughness...................................................................................................... 4-15
4-4.3. Engine Overspeed ...................................................................................................... 4-16
4-4.3.1. Category I Overspeed ...................................................................................... 4-16
4-4.3.2. Category II Overspeed..................................................................................... 4-16
4-4.3.3. Category III Overspeed Inspection.................................................................. 4-16
4-4.4. High Cylinder Head Temperature .............................................................................. 4-16
4-4.5. High Oil Temperature ................................................................................................ 4-17
4-4.6. Low Oil Pressure........................................................................................................ 4-17
4-4.7. In-Flight Restart ......................................................................................................... 4-17
4-4.8. Engine Fire In Flight .................................................................................................. 4-18
4-4.9. Propeller Strike........................................................................................................... 4-18

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4-5. Engine Operation in Abnormal Environments .............................................. 4-19
4-5.1. Engine Operation in Extreme Cold............................................................................ 4-19
4-5.1.1. Engine Preheating............................................................................................ 4-19
4-5.2. Engine Operation in Hot Weather.............................................................................. 4-20
4-5.2.1. Cooling an Engine in Hot Weather ................................................................. 4-20
4-5.2.2. Engine Restart in Hot Weather........................................................................ 4-21
4-5.2.3. Ground Operation in Hot Weather .................................................................. 4-21
4-5.2.4. Take-off and Initial Climb Out in Hot Weather .............................................. 4-21
4-5.3. Ground Operation at High Density Altitude.............................................................. 4-22
Appendix A. Glossary
Appendix B.Torque Specifications
Appendix C.Standard Practices
C-1. Handling Parts ................................................................................................. C-1
C-2. Replacement Parts ........................................................................................... C-1
C-2.1. Background.................................................................................................................. C-1
C-2.2. Acceptable Replacement Parts..................................................................................... C-1
C-2.2.1. Know Your Supplier .........................................................................................C-1
C-2.3. 100% Parts Replacement Requirements ...................................................................... C-1
C-2.4. Mandatory Overhaul Replacement Parts ..................................................................... C-1
C-2.5. Authorized Oversize/Undersize Parts.......................................................................... C-1
C-2.6. Engine Data Plate Replacement................................................................................... C-1
C-3. Safety Wiring Hardware .................................................................................. C-1
C-4. Tab Washer Installation ................................................................................... C-1
C-5. Heli-Coil Replacement .................................................................................... C-1
C-6. Stud Replacement ............................................................................................ C-1
C-7. Cotter Pin Installation ...................................................................................... C-1
C-8. Fuel System Service ........................................................................................ C-1
C-9. Gasket Maker® Application............................................................................ C-2
C-10. Gasket Installation ........................................................................................... C-2
C-11. Hose and Tubing Installation........................................................................... C-2
C-12. Harness Routing............................................................................................... C-2

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3 January 2017
LIST OF TABLES
Table 1-1. Related Publications .................................................................................. 1-11
Table 2-1. Recommended Instrument Range Markings ................................................. 2-5
Table 2-2. Oil Gauge Rod Error ..................................................................................... 2-7
Table 2-3. O-200-D Specifications .............................................................................. 2-23
Table 2-4. O-200-X Specifications .............................................................................. 2-25
Table 2-5. Accessory Drive Ratios .............................................................................. 2-27
Table 2-6. O-200-D & X Accessory Weights .............................................................. 2-32
Table 4-1. Overspeed Categories ................................................................................. 4-16

viii O-200-D & X Series Engine Installation and Operation Manual
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LIST OF ILLUSTRATIONS
Figure 1-1. Figure and Index Reference ................................................................... 1-3
Figure 1-2. Change Page Identification .................................................................... 1-5
Figure 1-3. List of Effective Pages ........................................................................... 1-6
Figure 2-1. Engine Features - Typical ...................................................................... 2-1
Figure 2-2. Engine Model Definition ....................................................................... 2-2
Figure 2-3. Cylinder Number Designation ............................................................... 2-2
Figure 2-4. Crankcase Features .............................................................................. 2-10
Figure 2-5. Engine Drive Train .............................................................................. 2-11
Figure 2-6. Crankshaft ............................................................................................ 2-12
Figure 2-7. Connecting Rod ................................................................................... 2-13
Figure 2-8. Camshaft .............................................................................................. 2-13
Figure 2-9. Accessory Case Features ..................................................................... 2-14
Figure 2-10. Cylinder Features ................................................................................. 2-15
Figure 2-11. Piston Features ..................................................................................... 2-16
Figure 2-12. Lubrication Schematic ......................................................................... 2-17
Figure 2-13. Oil Pump .............................................................................................. 2-18
Figure 2-14. Oil Cooler Adapter Footprint .............................................................. 2-19
Figure 2-15. Continental Motors Magneto Part Number Structure .......................... 2-20
Figure 2-16. Champion Ignition Harness Routing (typical) ..................................... 2-20
Figure 2-17. Engine Cooling .................................................................................... 2-21
Figure 2-18. Fuel Flow vs. Brake Horsepower ........................................................ 2-29
Figure 2-19. Full Throttle and Prop Load Curves .................................................... 2-30
Figure 2-20. Sea Level Performance ........................................................................ 2-31
Figure 2-21. Altitude Performance (uninstalled) ...................................................... 2-31
Figure 3-1. Propeller Flange ................................................................................... 3-11
Figure 3-2. Exhaust Flange Dimensions ................................................................ 3-11
Figure 3-3. 60 Amp Alternator Detail .................................................................... 3-12
Figure 3-4. 50 Amp Alternator Detail .................................................................... 3-12
Figure 3-5. Engine Mounts ..................................................................................... 3-13
Figure 3-6. Starter Connection Details ................................................................... 3-14
Figure 3-7. Ignition Distribution - Champion (Slick) Magnetos ............................ 3-15
Figure 3-8. Ignition Distribution - Continental Magnetos ..................................... 3-15
Figure 3-9. Ignition Switch Connections to Magneto ........................................... 3-16
Figure 3-10. O-200-D Engine Installation Drawing - Front and Top View ............. 3-19
Figure 3-11. O-200-D Engine Installation Drawing - Detail Views ........................ 3-21
Figure 3-12. O-200-X Engine Installation Drawing - Left Side and Rear Views .... 3-23
Figure 3-13. O-200-X Engine Installation Drawing - Top and Front Views ........... 3-25
Figure 3-14. O-200-X Engine Installation Drawing - Detail Views ........................ 3-27

O-200-D & X Series Engine Installation and Operation Manual 1-1
3 January 2017
Introduction
Chapter 1. Introduction
1-1. Scope and Purpose of This Manual
This manual is supplied to fulfill the requirements of Title 14, Code of Federal
Regulations § 33.5, “Instruction manual for installing and operating the engine.” For
continued airworthiness instructions, refer to the Instructions for Continued Airworthiness
in publication M-2, O-200-D & X Series Engine Maintenance and Overhaul Manual.
This manual contains engine interface requirements, installation instructions, installation
drawings and operating instructions for O-200-D & X Series Engines, manufactured by
Continental Motors. For information specific to other Continental Motors engine series,
including the O-200-A, B & C model engines, engine accessories, or the airplane, refer to
the appropriate manual. This document is intended for use only by an OEM or STC
customer for assistance in defining the installation and operational requirements during
the initial OEM FAA (or equivalent) Type Certification Process. Such activity is done by
properly qualified people typically with direct liaison with CM technical personnel. It is
not intended and should not be used by a pilot/owner or maintenance personnel.
Chapter 2 contains the engine description, aircraft interface requirements, engine
specifications and uninstalled engine performance charts. Chapter 3 contains instructions
and installation drawings to facilitate installation of the engine in a new aircraft. Chapter 4
provides supplemental information for the airplane flight manual (AFM) or pilot operating
handbook (POH) in regards to specific engine operating procedures.

1-2 O-200-D & X Series Engine Installation and Operation Manual
3 January 2017
Introduction
1-1.1. Advisories
This manual utilizes three types of advisories; defined as follows:
WARNING
A warning emphasizes information which, if disregarded, could
result in severe injury to personnel or equipment failure.
CAUTION: Emphasizes certain information or instructions, which if
disregarded, may result in damage to the engine or accessories.
NOTE: Provides special interest information, which may facilitate
performance of a procedure or operation of equipment.
Warnings and cautions precede the steps to which they apply; notes are placed in the
manner which provides the greatest clarity. Warnings, cautions, and notes do not impose
undue restrictions. Failure to heed advisories will likely result in the undesirable or unsafe
conditions the advisory was intended to prevent. Advisories are inserted to ensure
maximum safety, efficiency, and performance. Abuse, misuse, or neglect of equipment can
cause eventual engine malfunction or failure.
1-1.2. Compliance
The information in this manual must be incorporated into the applicable aircraft design
data and the Airplane Flight Manual/Pilot’s Operating Handbook (AFM/POH) by the
aircraft manufacturer.
Refer to the AFM/POH published by the aircraft manufacturer for operating instructions
and specifications relative to your aircraft. Prior to commencing engine installation,
consult the Continental Motors web site to verify the current status of the manual relating
to the intended procedure.
1-1.3. Using this Manual
Except for the engine installation drawings, illustrations in this manual are for reference
only, depicting the most prominent configuration in the engine series. Consult the
illustrated parts breakdown on the Continental Motors web site for your specific engine
model and each subsystem.
Exploded assembly illustrations accompany instructions throughout the manual. Parts in
illustrations (Figure 1-1) are identified with numerical callouts (indices). Corresponding
parts listings follow the illustrations for reference. The first time instructions refer to an
illustration, the figure number is identified in parentheses, followed by the callout. In
subsequent parts references, only the callout will be specified unless the referenced
illustration changes.

O-200-D & X Series Engine Installation and Operation Manual 1-3
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Introduction
Figure 1-1. Figure and Index Reference

1-4 O-200-D & X Series Engine Installation and Operation Manual
3 January 2017
Introduction
1-2. Publications
This most current approved version of this manual is delivered to the customer at time of
purchase. This manual and all subsequent revisions or changes are published in Adobe
portable document format (PDF) and available for download on the Continental Motors
Internet web site at http://www.continentalmotors.aero. Printed version are also available.
1-2.1. Publication Access
Printed technical publications may be ordered through authorized Continental Motors
distributors or via the Internet at http://www.continentalmotors.aero. Contact an
authorized Continental Motors distributor to discuss publication or service subscription
options and pricing or visit our web site.
1-2.2. Publication Changes
WARNING
Verify and use only the latest revision of all publications. Using
superseded information may jeopardize airworthiness.
The instructions in this manual represent the best and most complete information available
at the time of publication. Product or process improvements may trigger changes to
existing product design specifications or procedures contained in publications. As new
technical information becomes available, Continental Motors will make the information
available to the customer.
Continental Motors releases publication changes in the form of either change pages or
complete publication revisions, depending upon the extent of change.
Continental Motors issues service documents in the form of Service Bulletins on a wide
variety of topics. Some service documents may affect or supplement information in this
manual and should be reviewed prior to performing maintenance. All active service
documents applicable to the O-200-D & X Series Engine have been incorporated in these
instructions as of the date of publication.
1-2.3. Updates/Change Distribution
Document updates are available on our web site upon notification of FAA document
acceptance/approval. Printed publication subscribers receive printed changes and
revisions as they are released.
Document revisions are released if the update changes more than 50% of the contents of a
publication. Revisions replace the previous version of a publication from cover to cover.
Minor corrections are released as change pages to the original publication, identified with
a change number and effective change date in the page footer. Information on the page that
changed from the previous edition is identified by a vertical, six-point black line (Figure
1-2), referred to as a “change bar” in the outside margin of the page.
A change page replaces only the previous edition of the affected page. In the event a
change page forces repagination, a new page will be inserted with a decimal extension
added to the page number. For example, if additional pages are required between pages 1-

O-200-D & X Series Engine Installation and Operation Manual 1-5
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Introduction
6 and 1-7, the inserted page numbers will be 1-6.1, 1-6.2, and so on until sufficient pages
are added to incorporate the new material.
Page A of the manual contains the original publication date and an itemized list of changes
issued for the technical 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” on Page A. 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.
Figure 1-2. Change Page Identification

1-6 O-200-D & X Series Engine Installation and Operation Manual
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Introduction
Figure 1-3. List of Effective Pages

O-200-D & X Series Engine Installation and Operation Manual 1-7
3 January 2017
Introduction
1-2.4. Service Documents
Continental Motors may issue Service Documents in one of six categories ranging from mandatory
(Category 1) to informational (Category 6). Definitions of the categories are listed below:
NOTE: Upon FAA approval, Continental Motors publishes service
documents for immediate availability on our web site. The service
document cover page indicates the engine models affected by the service
document. Service documents may alter or replace manufacturer’s ICAs.
Insert a copy of applicable Service Documents in affected manuals until
the service document instructions are incorporated in the manual, or the
service document is canceled or superseded.
Category 1: Mandatory Service Bulletin (MSB)
Used to identify and correct a known or suspected safety hazard which has 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). May contain updates to Instructions for Continued Airworthiness (ICAs)
to address a safety issue.
Category 2: Critical Service Bulletin (CSB)
This category identifies a condition that threatens continued 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 may improve the inherent safety of an aircraft or
aircraft component; this category includes the most recent updates to ICAs.
Category 4: Service Information Directive (SID)
The manufacturer directs the owner/operator/mechanic in the use of a product to enhance safety,
maintenance or economy. May contain updates to ICAs in the form of maintenance procedures or
specifications.
Category 5: Service Information Letter (SIL)
This category includes all information (not included in categories 1 through 4) that may be useful to the
owner/operator/technician. May contain updates to ICAs for optional component installations, which are not
covered in the Applicable Operator, Maintenance, or Overhaul Manuals.
Category 6: Special Service Instruction (SSI)
This category is used to address an issue limited to specific model and/or serial number engines. We will
distribute SSI notification directly to the affected engine’s owners. SSIs will not be included in the general
service document set but will be made available through our Customer Service Department to owners of the
affected engines only. An SSI may update the applicable engine’s Instructions for Continued Airworthiness.

1-8 O-200-D & X Series Engine Installation and Operation Manual
3 January 2017
Introduction
1-2.4.1. Service Documents Incorporated in this Manual
Applicable technical information in the service documents listed below, relevant to the
engine models covered by this engine manual, have been incorporated in this manual. The
full content of active Continental Motors service documents is available at http://
www.continentalmotors.aero. Refer to Section 1-3, “Contact Information” for Continental
Motors web site details.
Service Document Subject Affected Chapter
SIL93-11B, Service Document Format Service Documents M-0
SIL93-15, General Practices for Installation of Lock Wire, Tab
Washers, and Cotter Pins Standard Practices M-0
SIL95-5, Hose and Tubing Installation Hose and tubing installation M-0
SB96-7D, Torque Limits fastener torque M-0
SB96-11B, Propeller Strikes and Hydraulic Lock Unscheduled Inspection M-0
SB96-12, Continued Airworthiness for TCM Cylinders Scheduled Inspection M-0
SB97-6B, Mandatory Replacement Parts Engine Inspection &
Assembly M-0
SIL98-9E, Time Between Overhaul Periods Engine Specifications,
Scheduled Maintenance M-0
SIL99-1, Engine Preservation for Active and Stored Aircraft
Engine preservation and
returning an engine to
service after storage
M-0
SIL99-2C, Current Listing of Authorized of Sealants, Lubricants
and Adhesives Materials M-0
SIL03-1, Cold Weather Operation – Engine Preheating Preheating procedures M-0
SIL03-2C, Currently Active Approved Spark Plug Application Spark plugs M-0
SIL04-12A, Authorized Engine Adjustments, Component
Replacement and Repositioning Engine Specification M-0
SB05-2, Overspeed Limitations Unscheduled Maintenance M-0
SIL05-3, Engine Specification Numbers Engine Specification 2
SB14-8, Exhaust Flange to Cylinder Installations Exhaust installation 3, M-0
SIL15-9, Remote Mounted Oil Coolers Engine servicing/pre-oiling 3, M-0
SIL640, Service Document Format Service Documents 1
SB653, Hot Magneto Test Inspection & Operation 3, 4

O-200-D & X Series Engine Installation and Operation Manual 1-9
3 January 2017
Introduction
1-2.4.2. Service Documents Released After Publication
Continental Motors strives to provide clear, concise, and accurate information and
instructions based on best known engineering data at the time of publication. Ongoing
process improvements may change a specification or procedure after a manual is released.
Service documents, defined in Section 1-2.4, expedite customer notification and serve as
the prevailing instruction over conflicting information until the new information is
incorporated in the manual text. As service documents are received, note the service
document number, release date, title, and applicable section affected by the service
document in the blank cells below and insert a copy of the service document behind the
last page of this section. Make pen & ink corrections, where appropriate, to the original
text 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.
Service Bulletins Release After This Manual
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1-10 O-200-D & X Series Engine Installation and Operation Manual
3 January 2017
Introduction
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Title:
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Service Bulletins Release After This Manual