Continental Refrigerator IO-240-A User manual

Publication OI-6
©2011 CONTINENTAL MOTORS, INC. OCT 2011
IO-240-A
B
CONTINENTAL®AIRCRAFT ENGINE
INSTALLATION
AND
OPERATION
MANUAL
FAA APPROVED

A IO-240 Series Engine Installation & Operation Manual
31 October 2011
Supersedure Notice
This manual is a revision of the Continental Motors IO-240 Operation and Installation Manual, Part No. X30620,
released on January 1996. Upon FAA Approval, thismanual supersedes X30620 in its entirety.
Effective Changes for this Manual
0.......... 31 October 2011
List of Effective Pages
Document Title: IO-240 Series Engine Installation & Operation Manual
Publication Number: OI-6 Initial Publication Date: 31 October 2011
Page Change Page Change Page Change Page Change
Cover............................0
A...................................0
i-xii................................0
1-1 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 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. Other products and companies mentioned herein may be trademarks of the respective owners.

IO-240 Series Engine Installation & Operation Manual i
31 October 2011
Service Document and Technical References
Technical information in the service documents listed below relevant to the engine models
covered by this engine manual have been incorporated in the manual. The full content of active
Continental Motors engine service documents is available http://continentalmotors.aero. Refer to
Section 1-3, “Contact Information” for Continental Motors web site details.
Service Document Subject Affected Chapter
M64-18, Turbocharger Field Conversion Engine Modification N/A
M72-17R1, Maximum Weight Difference Allowance Between
Connecting Rods and Pistons in the Same Engine Engine Assembly and Overhaul N/A
M73-13, Reaming and Bushing Rocker Shaft Bosses Cylinder Repair and
Overhaul N/A
M75-6R1, Conversion ofEngines From One Model to Another Engine Configuration N/A
M76-4, Installation Of Propeller Shaft Or Nose Oil Seals Oil Seal Replacement N/A
M76-5R1, Remote Mounted Oil Coolers Engine Installation and Oil
Servicing N/A
M76-8, Intake Valve Change Engine Maintenance and
Overhaul N/A
M76-15, Fuel Pumps Fuel Pump and Camshaft
Replacement 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 Unscheduled Maintenance 4
M88-10, Contaminated Fuels Unscheduled Maintenance 3 & 4
M89-7R1, Engine Operation after Cylinder Replacement and/or
Major Overhaul Engine Operation-break-in 4
M89-9, Excessive Crankcase Pressure Unscheduled Maintenance 4
M89-18, EGT Recommendations EGT Leaning 4
M90-9, New TCM Magneto and Harness Applications Magneto and Ignition
Harness Replacement N/A
M90-13, Exhaust Valve Stem Corrosion/Erosion Inspection & Overhaul N/A
M90-17, Crankcase Inspection Criteria Inspection N/A
M91-4, Piston Identification and Piston Ring Application Bulletin Piston Replacement N/A
M91-9, Cam and Lifter Lubrication during Rebuild Overhaul N/A
M93-8, Rocker Arm to Rotocoil Clearance Rocker Arm Clearance N/A
M93-10, TCM Ignition Systems Service Bulletin 639 Inspection N/A
SIL93-11A, New Service Document Format Service Documents 1
MSB93-12, Valve Retainer Key Installation Inspection Inspection N/A
SIL93-14, CFC Compliance N/A N/A

ii IO-240 Series Engine Installation & Operation Manual
31 October 2011
SIL93-15, General Practices for Installation of Lock Wire, Tab
Washers, and Cotter Pins Standard Practices Appendix C
CSB94-1, TCM Ignition CSB641 Magneto Coil N/A
SIL94-5, Mobil AV-1 Oil Authorized Lubricants N/A
MSB94-8D, Magneto to Engine Timing Service N/A
SB95-2, Inspection and Maintenance of Engine Control Cables
and Linkage Inspection N/A
SB95-3B, Alternator/Generator Drive Couplings Inspection N/A
CSB95-4, Intake Valve Guide Seal Inspection N/A N/A
SIL95-5, Hose and Tubing Installation Hose and tubing installation Appendix C
CSB96-1, Starter Gear and Clutch Assembly, P/N 653575 Starter Replacement N/A
SID96-6, TCM Ignition SB653 Engine Operation-Hot
magneto Test 4
SB96-7C, Torque Limits fastener torque Appendix B
MSB96-10, Requirements for Ultrasonic Inspection Crankshaft Removal &
Replacement N/A
SB96-11B, Propeller Strikesand Hydraulic Lock Scheduled Inspection 4
SB96-12, Continued Airworthiness for TCM Cylinders Scheduled Inspection N/A
SIL97-1, Airworthiness Limitations Airworthiness Limitations N/A
SID97-2B, TCM Cylinder Warranties N/A N/A
SID97-3E,Procedures and Specifications for Adjustment of TCM
ContinuousFlow 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 Cylinder Assembly Cylinder Replacement N/A
SB97-15, TCM Ignition Service Bulletin SB660 N/A N/A
CSB98-1B, Intake and Exhaust Valve Inspection Service Limits N/A
SIL98-9A, Time Between Overhaul Periods Engine Specifications,
Scheduled Maintenance 2
SIL99-1, Engine Preservation for Active and Stored Aircraft Engine preservation and returning an engine to
service after storage 3
SIL99-2C, Current Listing of Sealants, Lubricants and Adhesives
Authorized by TCM Materials Throughout
SB99-8, Engine Fuel Injection System Preservation Fuel Injection system
storage 3
SB00-3A, Crankshaft, Counterweight and Connecting Rod
Repair Information Repair Specifications N/A
SB00-4A, Australian AVGAS Contamination Inspection and Operation N/A
SIL00-7A, Oil Gauge Rod Application Oil Servicing N/A
SIL00-9A, Engine Data Plates N/A N/A
SB00-10, Fuel Pump Seal Fuel Pump Installation N/A
Service Document Subject Affected Chapter

IO-240 Series Engine Installation & Operation Manual iii
31 October 2011
SIL00-11B, Release of new Cylinder Induction Port Drain
Connector Cylinder Assembly N/A
CSB02-8, TCM Ignition Systems CSB664 N/A N/A
SIL03-1, Cold Weather Operation – Engine Preheating Preheating procedures 4
SIL03-2B, CurrentlyActive Approved Spark Plug Application Spark plugs 2 & 3
SIL03-3, Differential Pressure Test and Borescope Inspection Inspection Criteria N/A
SIL03-7, IO-240 Series Magneto Drive Gear Inspection Criteria N/A
SIL04-2, Cylinder Barrel Ultrasonic Inspection N/A N/A
SB04-4, Manifold Valve Spring Replacement Overhaul Repairs N/A
CSB04-5A, TCM Ignition Systems CSB665A Magneto Service N/A
SB04-10, Piston Pin Marking Overhaul Repairs N/A
SB04-11, Valve Guide Application, Installation and Reaming Valve Guide Repairs N/A
SIL04-1A, Installation of Optional Altitude Compensating Fuel
Pump on IO-240-B Series Engines Fuel System Specification
and Engine Operational
Check 3, 4
SIL04-8 Optional Replacement Starter fo IO-240 Series Engines Engine Specification and
Parts Replacement 3, 4
SIL04-9, IO240B13B Manifold Valve Replacement, Heat Isolation
Modifications, and Throttle Body Modifications Engine 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 Filter Installation
and Inspection Procedures Engine Specification,
Inspection, Component
Replacement 3
SIL05-5A, IO-240-B Series Manifold Valve Fuel Scavenge
System Installation Engine Specification,
Inspection, Component
Replacement 3
SIL05-6A, IO-240-B Series Product Upgrades Engine Specification, Inspection, Component
Replacement 3
SB07-1, Connecting Rod Piston Pin Bushing Inspection Inspection N/A
SB07-3, Procedures and Specifications for adjustment of TCM
IO-240-B17B Fuel Injection System installed on Diamond DA20-
C1 Aircraft
Engine Specification,
Inspection, Component
Replacement 3 & 4
SB07-8, Recommended Minimum RPM & Manifold Pressure
Cruise Operations Limits Engine Operation 4
SB08-3A, Throttle & Mixture Control Arms N/A 4
SB08-4, Fuel Injection System Contamination Engine Specification,
Inspection, Replacement 3
SB08-8, Slick Service Bulletin SB2-08 Magneto Inspection N/A
SB08-9A, Slick Service Bulletin SB3-08A Magneto Inspection N/A
Service Document Subject Affected Chapter

iv IO-240 Series Engine Installation & Operation Manual
31 October 2011
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
Chapter 1, 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.
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 Document Format Service Documents Preface & 1
SB643B, Maintenance Intervals for TCM Bendix Magnetos Inspection & Operation N/A
SB653, Hot Magneto Test Inspection & Operation 3 & 4
Service Bulletins Release After This Manual
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Title:
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Title:
Service Document Subject Affected Chapter

IO-240 Series Engine Installation & Operation Manual v
31 October 2011
Bulletin Number: Release Date: / / Affected Sections:
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Service Bulletins Release After This Manual

vi IO-240 Series Engine Installation & Operation Manual
31 October 2011
PREFACE
Continental Motors provides Instructions for Continued Airworthiness based on the design,
testing, and certification of engines and parts for which Continental Motors is the holder of the
Type Certificate (TC) or Parts Manufacture Approval (PMA) issued by the Federal Aviation
Administration (FAA). Instructions in Continental Motors engine manuals, which include
maintenance, repair limits, overhaul, and installation, are applicable only to engines and parts
supplied by Continental Motors.
Except for FAR part 43.3 authorized owner preventive maintenance, Continental Motors ICAs are
written for exclusive use by FAA (or equivalent authority) licensed mechanics or FAA (or
equivalent authority) certified repair station employees working under the supervision of an FAA
licensed mechanic. Information and instructions contained in this manual anticipate the user
possesses and applies the knowledge, training, and experience commensurate with the
requirements to meet the prerequisite FAA license and certification requirements. No other use is
authorized.
Installation of aftermarket parts on a Continental Motors engine constitutes a deviation from FAA
approved type-design criteria. Continental Motors has not participated in design, test, or
certification of any aftermarket parts. 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 and accepted by the FAA for the subject
installation. Continental Motors ICAs must not be used for such parts.
Service documents may contain general information or information specific to a group of engines
or be in effect for a limited time frame. Service Documents may also contain advance changes to
the ICAs. It is the responsibility of the organization/person maintaining or operating the engine to
verify that current and complete information, including Service Documents, FAA Airworthiness
Directives (ADs), and publications are used.
To facilitate the use of current data, Continental Motors provides information on the Continental
Motors web site. The information available includes a listing of the latest manual versions,
service documents, FAA ADs, and other information applicable to the ICAs.
Manuals published since 2003 are available on the Continental Motors web site to Fixed Base
Operators (FBOs) who subscribe to Continental Motors Internet Services. Information available
to Continental Motors engine owners is also available to FBOs. Printed manuals and service
subscriptions are also available. Refer to “Publication Access” in Section 1-2.3.

IO-240 Series Engine Installation & Operation Manual vii
31 October 2011
TABLE OF CONTENTS
Chapter 1. Introduction
1-1. Scope and Purpose of This Manual ................................................................. 1-1
1-1.1. Effectivity Symbols...................................................................................................... 1-1
1-1.2. Advisories .................................................................................................................... 1-1
1-1.3. Using this Manual........................................................................................................ 1-1
1-2. Publications...................................................................................................... 1-3
1-2.1. Service Documents ...................................................................................................... 1-3
1-2.2. Related Publications..................................................................................................... 1-4
1-2.3. Publication Access....................................................................................................... 1-5
1-2.4. Publication Changes..................................................................................................... 1-5
1-2.4.1. Update/Change Distribution..............................................................................1-5
1-2.4.2. Suggestions and Corrections .............................................................................1-7
1-3. Contact Information......................................................................................... 1-8
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. 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 Pressure Relief Valve ................................................................................2-12
2-2.5.4. Oil Cooler Adapter ..........................................................................................2-12
2-2.6. Ignition System .......................................................................................................... 2-14
2-2.7. Fuel System................................................................................................................ 2-16
2-2.7.1. Fuel Pump........................................................................................................2-16
2-2.7.2. Fuel Injectors...................................................................................................2-18
2-2.8. Starter Assembly........................................................................................................ 2-18
2-2.9. Alternator ................................................................................................................... 2-18
2-2.10. Engine Cooling .......................................................................................................... 2-19
2-2.11. Induction System........................................................................................................ 2-20
2-3. Engine Specifications and Operating Limits ................................................. 2-21
2-3.1. Accessory Drive Ratios.............................................................................................. 2-25
2-3.2. Performance Data....................................................................................................... 2-25

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31 October 2011
2-3.2.1. IO-240-A Performance Charts ........................................................................ 2-26
2-3.2.2. IO-240-B Performance Charts......................................................................... 2-28
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...................................................................................... 3-1
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....................................................................................... 3-2
3-1.3. Engine Transport.......................................................................................................... 3-2
3-2. Installation Procedures..................................................................................... 3-4
3-2.1. Prepare the Airframe 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.................................................................................................... 3-9
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 Requirements........................................................................................... 4-2
4-2.3. Flight Check and Break-In........................................................................................... 4-2
4-2.3.1. Engine Break-In ................................................................................................ 4-3
4-2.3.2. Flight Check ...................................................................................................... 4-5
4-3. Normal Operation............................................................................................ 4-7
4-3.1. Pre-operational Requirements...................................................................................... 4-7
4-3.2. Engine Start.................................................................................................................. 4-8
4-3.2.1. Cold Start........................................................................................................... 4-9
4-3.2.2. Flooded Engine................................................................................................ 4-10
4-3.2.3. Hot Start .......................................................................................................... 4-10
4-3.3. Ground Run-up .......................................................................................................... 4-10
4-3.4. Taxi Preparation......................................................................................................... 4-12
4-3.5. Power Control............................................................................................................ 4-12
4-3.6. Take-Off..................................................................................................................... 4-13
4-3.7. Climb ......................................................................................................................... 4-14
4-3.8. Cruise......................................................................................................................... 4-15
4-3.9. Descent....................................................................................................................... 4-16
4-3.10. Landing...................................................................................................................... 4-16

IO-240 Series Engine Installation & Operation Manual ix
31 October 2011
4-3.11. Engine Shutdown....................................................................................................... 4-17
4-4. Emergency Operation .................................................................................... 4-18
4-4.1. Engine Fire During Start............................................................................................ 4-18
4-4.2. Engine Fire During Flight.......................................................................................... 4-18
4-4.3. In-Flight Restart......................................................................................................... 4-19
4-4.4. Engine Roughness...................................................................................................... 4-19
4-4.5. High Cylinder Head Temperature.............................................................................. 4-19
4-4.6. High Oil Temperature ................................................................................................ 4-20
4-4.7. Low Oil Pressure........................................................................................................ 4-20
4-5. Engine Operation in Abnormal Environments .............................................. 4-21
4-5.1. Engine Operation in Extreme Cold............................................................................ 4-21
4-5.1.1. Engine Preheating............................................................................................4-22
4-5.2. Engine Operation in Hot Weather.............................................................................. 4-26
4-5.2.1. Cooling an Engine in Hot Weather..................................................................4-26
4-5.2.2. Engine Restart in Hot 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 Calculations.................................................... B-3
Appendix C.Standard Practices
C-1. Handling Parts.................................................................................................. C-1
C-2. Replacement Parts............................................................................................ C-2
C-2.1. Background................................................................................................................. C-2
C-2.2. Acceptable Replacement Parts.................................................................................... C-2
C-2.2.1. Know Your Supplier......................................................................................... C-3
C-2.3. 100% Parts Replacement Requirements ..................................................................... C-3
C-2.4. Mandatory Overhaul Replacement Parts .................................................................... C-4
C-2.5. Authorized Oversize/Undersize Parts......................................................................... C-4
C-3. Torque.............................................................................................................. C-4
C-4. Safety Wiring Hardware .................................................................................. C-5
C-5. Tab Washer Installation.................................................................................... C-7

x IO-240 Series Engine Installation & Operation Manual
31 October 2011
C-6. Helical Coil Insert Replacement...................................................................... C-8
C-6.1. Helical Coil Removal................................................................................................... C-9
C-6.2. Helical Coil Insertion................................................................................................. C-10
C-7. Stud Replacement.......................................................................................... C-11
C-7.1. Stud Removal............................................................................................................. C-11
C-7.1.1. Size-on-Size Rosan® Stud Removal...............................................................C-11
C-7.1.2. Step-Type Rosan® Stud Removal...................................................................C-12
C-7.2. Stud Installation......................................................................................................... C-13
C-7.2.1. Rosan® Stud Installation.................................................................................C-14
C-8. Cotter Pin Installation.................................................................................... C-15
C-9. Fuel System Service ...................................................................................... C-16
C-9.1. Fuel System Purge..................................................................................................... C-16
C-10. Gasket Maker® 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 .......................................................................B-5
Table B-3. Hose Fitting (“B” Nut) Torque Specification ...............................................B-6
Table B-2. Tube Fitting Torque Specifications ..............................................................B-6
Table B-4. Component Specific Torque Specifications .................................................B-7
Table B-5. Specific Torque for Non-Lubricated Hardware ..........................................B-10
Table C-1. Rosan® Stud Primary & Secondary Bore Specifications ..........................C-12

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LIST OF ILLUSTRATIONS
Figure 1-1. Figure and Index Reference ................................................................... 1-2
Figure 1-2. Change Page Identification .................................................................... 1-6
Figure 1-3. List of Effective Pages ........................................................................... 1-7
Figure 2-1. Engine Model Definition ....................................................................... 2-2
Figure 2-2. Cylinder Number Designation ............................................................... 2-2
Figure 2-3. IO-240 Crankcase Features .................................................................... 2-3
Figure 2-4. Engine Drive Train ................................................................................ 2-4
Figure 2-5. Crankshaft .............................................................................................. 2-5
Figure 2-6. Connecting Rod .....................................................................................2-5
Figure 2-7. Camshaft ................................................................................................ 2-6
Figure 2-8. Accessory Case Features ....................................................................... 2-7
Figure 2-9. Cylinder Features ................................................................................... 2-8
Figure 2-10. Piston Features ....................................................................................... 2-9
Figure 2-11. IO-240-A Lubrication ......................................................................... 2-10
Figure 2-12. IO-240-B Lubrication ......................................................................... 2-11
Figure 2-13. Oil Pump .............................................................................................. 2-12
Figure 2-14. IO-240-A Oil Cooler Adapter ............................................................. 2-13
Figure 2-15. IO-240-B Oil Cooler Adapter ............................................................. 2-13
Figure 2-16. IO-240-B Oil Cooler/Filter Adapter ................................................... 2-13
Figure 2-17. Continental Motors Magneto Part Number Structure .......................... 2-14
Figure 2-18. Continental Motors 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 Flow vs. Brake Horsepower ........................................ 2-26
Figure 2-28. IO-240-A Sea Level Performance ....................................................... 2-27
Figure 2-29. IO-240-B Fuel Flow vs. Brake Horsepower ........................................ 2-28
Figure 2-30. IO-240-B Sea Level Performance ........................................................ 2-29
Figure 3-1. IO-240-A Top View ............................................................................. 3-11
Figure 3-2. IO-240-A Left Side View .................................................................... 3-12
Figure 3-3. IO-240-A Front View .......................................................................... 3-13
Figure 3-4. IO-240-A Rear View ........................................................................... 3-14
Figure 3-5. IO-240-B Top View .............................................................................3-15
Figure 3-6. IO-240-B Left Side View .................................................................... 3-16
Figure 3-7. IO-240-B Front View ........................................................................... 3-17
Figure 3-8. IO-240-B Rear View ............................................................................ 3-18
Figure 3-9. IO-240-B w/optional Oil Cooler-Filter Adapter Top View ................. 3-19
Figure 3-10. IO-240-B w/optional Oil Cooler-Filter Adapter Left Side View ........ 3-20
Figure 3-11. IO-240-B w/optional Oil Cooler-Filter Adapter Rear View ................3-21

xii IO-240 Series Engine Installation & Operation Manual
31 October 2011
Figure 3-12. Propeller Flange ................................................................................... 3-22
Figure 3-13. Exhaust Flange Dimensions ................................................................ 3-23
Figure 3-14. Standard Fuel Pump Installation .......................................................... 3-23
Figure 3-15. Standard Fuel Pump Adjustments ....................................................... 3-24
Figure 3-16. IO-240-B Altitude Compensating Fuel Pump Adjustments ................ 3-24
Figure 3-17. Throttle Lever Installation ................................................................... 3-25
Figure 3-18. Oil Cooler Adapter Connections ......................................................... 3-25
Figure 3-19. Oil Cooler Adapter Connections ......................................................... 3-26
Figure 3-20. Oil Cooler-Filter Adapter Connections ............................................... 3-26
Figure 3-21. IO-240-A Air Intake Flange ................................................................ 3-27
Figure 3-22. Alternator Connections ........................................................................ 3-27
Figure 3-23. Engine Mounts ..................................................................................... 3-28
Figure 3-24. Continental Motors Magneto Ignition Schematic ............................... 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 Threads ........................................C-6
Figure C-3. Tab Washer Installation .........................................................................C-7
Figure C-4. Helical Coil Extraction Tool ..................................................................C-9
Figure C-5. Installing a Helical Coil Insert .............................................................C-10
Figure C-6. Rosan® Stud Removal Tool ................................................................C-12
Figure C-7. Rosan® stud removal tool installed on stud ........................................C-12
Figure C-8. Stud Sizes ............................................................................................C-13
Figure C-9. Minimum Material Thickness for Helical Coil insertion ....................C-14
Figure C-10. Rosan® Stud Installation Dimensions .................................................C-14
Figure C-11. Cotter Pin Installation ..........................................................................C-15
Figure C-12. Installing Hoses and Fittings ...............................................................C-19

IO-240 Series Engine Installation & Operation Manual 1-1
31 October 2011
Introduction
Chapter 1. Introduction
1-1. Scope and Purpose of This Manual
This manual is part of the interface control document for IO-240-A and B engine models.
This manual provides airframe interface requirements, installation instructions and engine
operating instructions to supplement the Airplane Flight Manual (POH)/Pilot’s Operating
Handbook (POH).
Instructions in this manual are specific to the IO-240 Series engines. For information
specific to other Continental Motors engine series, accessories, or the airplane, refer to the
appropriate manual. Chapters are arranged in sequential order to install, test, and operate
the engine.
1-1.1. Effectivity Symbols
Variations in IO-240 Series engine models require specific instructions or illustrations. If
peculiar information pertains to only a specific engine model in the series, an effectivity
symbol will accompany the information. Effectivity symbols found in this publication are:
IO-240-A IO-240-B
IO-240-B with altitude compensating fuel pump
1-1.2. 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.
1-1.3. Using this Manual
Except for engine installation drawings, illustrations in this manual are for reference only,
depicting the most prominent configuration in the engine series. Consult the parts catalogs
for engine model-specific illustrated parts breakdowns.
This manual and the accessory manuals listed in Table 1-1 and certain service documents,
and other related publications constitute the Instructions for Continued Airworthiness
AA
BB

1-2 IO-240 Series Engine Installation & Operation Manual
31 October 2011
Introduction
(ICAs) prepared by Continental Motors and accepted by the Federal Aviation
Administration (FAA). This manual is prepared in a user-friendly format suited equally for
electronic viewing and print.
WARNING
Continental Motors ICAs are applicable only to Continental
Motors engines conforming to the approved, type certified
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 identified in parentheses, followed by the callout. In
subsequent parts references, only the callout will be specified unless the referenced
illustration changes.
Figure 1-1. Figure and Index Reference

IO-240 Series Engine Installation & Operation Manual 1-3
31 October 2011
Introduction
1-2. Publications
1-2.1. 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 cancelled or superseded.
1Procedure
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.

1-4 IO-240 Series Engine Installation & Operation Manual
31 October 2011
Introduction
1-2.2. Related Publications
The table below lists related publications, source, and accessibility relevant to IO-240
Series engine installation and operation.
WARNING
Use only the latest revision of all publications. Using superseded
information may jeopardize engine airworthiness
Table 1-1. Related Publications
Publication
Supplied
With
Engine
Available
download 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 have the latest revision of
the manual.
Printed
Manual
Available
for
Purchase
Maintenance and Overhaul Manual (M-6) Yes Yes Yes
S-20/S-200 MagnetoService Manual (X42002) Yes Yes Yes
Service Documents No Yes Yes
Parts Catalog No Yes (viewonly)No

IO-240 Series Engine Installation & Operation Manual 1-5
31 October 2011
Introduction
1-2.3. Publication Access
Contact an authorized Continental Motors distributor to discuss service subscription
options and pricing or visit the Continental Motors web site. Printed technical publications
may be ordered through authorized Continental Motors distributors or via the Internet at
http://continentalmotors.aero.
1-2.4. Publication Changes
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.
WARNING
New information may be contained in Continental Motors
service documents. Service documents applicable to engines
and accessories within the scope of this manual must be
complied with as defined in these documents. This manual and
other related publications noted herein constitute 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 published ICA
until the individual publications incorporate the latest technical information.
1-2.4.1. Update/Change Distribution
Document updates are available on our web site upon notification of FAA document
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.

1-6 IO-240 Series Engine Installation & Operation Manual
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Introduction
Figure 1-2. Change Page Identification
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.” 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
Date
Change Bar
Change
Number
Change
Date