Continental refrigerator Ltsio-520-ae User manual

Publication X30575 CHANGE 6

TSIO-520-C,G,H

M,P,R,T

AE,AF,CE

CONTINENTAL®AIRCRAFT ENGINE

SANDCAST SERIES ENGINE

OVERHAUL

MANUAL

TECHNICAL CONTENT ACCEPTED BY THE FAA

ii TSIO-520 Sandcast Series Engine Overhaul Manual

1 December 2012

Supersedure Notice

This manual revision replaces the front cover and list of effective pages for Publication Part No. X30575, dated

February 1987. Previous editions are obsolete upon release of this manual.

Effective Changes for this Manual

0 ..............February 1987 4.............31 August 2011

1 ......................July 1987 5....... 30 November 2011

2 ........... November 1987 6......... 1 December 2012

3 ..............February 1989

List of Effective Pages

Document Title: TSIO-520 Sandcast Series Engine Overhaul Manual

Publication Number: X30575 Initial Publication Date: February 1987

Page Change Page Change Page Change Page Change

Cover .................................... 6 72-10-01 thru 72-10-35......... 0 72-50-05 ............................... 0 74-00-01 thru 74-00-10..........3

ii ............................................ 6 72-10-36 thru 72-10-39......... 1 72-50-06 ............................... 3 75-00-01 thru 75-00-04..........0

iii thru xviii ............................. 3 72-10-40 thru 72-10-48......... 0 72-50-07 thru 72-50-11......... 1 76-00-01 thru 76-00-66..........3

1-00-01 thru 1-00-06 ............. 5 72-20-01 thru 72-20-10......... 0 72-50-12 thru 72-50-13......... 0 77-00-01 thru 77-00-04..........3

1-10-01 thru 1-10-10 ............. 3 72-20-11 thru 72-20-18 ......... 3 72-50-14 thru 72-50-18......... 3 77-10-01 thru 77-10-06..........3

1-20-01 thru 1-20-40 ............. 3 72-30-01 ............................... 5 72-60-01 thru 72-60-02......... 0 77-20-01 thru 77-20-06..........3

1-30-01 thru 1-30-06 ............. 3 72-30-02 ............................... 3 72-60-03 ............................... 3 78-00-01 thru 77-00-04..........3

4-00-01 thru 4-00-04 ............. 3 72-30-03 thru 72-30-07......... 5 72-60-04 ............................... 0 78-10-01 thru 78-10-02..........3

5-00-01 thru 5-00-04 ............. 3 72-30-08 thru 72-30-11 ......... 3 72-60-05 ............................... 3 78-20-01 thru 78-20-02..........3

5-10-01 thru 5-10-02 ............. 3 72-30-12 ............................... 0 72-60-06 ............................... 0 79-00-01 thru 79-00-04..........3

5-20-01 thru 5-20-04 ............. 3 72-30-13 thru 72-30-14......... 3 72-60-07 ............................... 3 79-10-01 thru 79-10-02..........3

5-30-01 thru 5-30-02 ............. 3 72-30-15 ............................... 0 72-60-08 thru 72-60-20......... 0 79-20-01 thru 79-20-02..........3

70-00-01................................ 1 72-30-16 ............................... 3 72-70-01 thru 72-70-05......... 0 80-00-01 thru 80-00-10..........3

70-00-02 thru 70-00-04......... 3 72-30-17 ............................... 0 72-70-06 thru 72-70-07......... 2 81-00-01 thru 81-00-02..........3

70-10-01 thru 70-10-02......... 3 72-30-18 thru 72-30-22......... 3 72-70-08 thru 72-70-10......... 0 81-10-01 thru 81-10-06..........3

70-20-01 thru 70-20-02......... 3 72-40-01 thru 72-40-03......... 0 72-80-01 thru 72-80-08......... 0 81-20-01 thru 81-20-02..........3

70-30-01 thru 70-30-02 ......... 3 72-40-04 thru 72-40-05......... 3 73-00-01 thru 73-00-02......... 0

70-40-01 thru 70-40-02 ......... 3 72-40-06 thru 72-40-20......... 0 73-00-03 ............................... 2

70-50-01 thru 70-50-06 ......... 3 72-50-01 thru 72-50-03......... 0 73-00-04 ............................... 0

72-00-01 thru 72-00-16......... 3 72-50-04 ............................... 3 73-10-01 thru 73-10-06......... 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

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.

WARNING

(Please

note

the

following statements from

FAA

Advisory

Circular

2O-62C

entitled

"ELIGIBILITY,

QUALITY,

AND

IDENTIFICATION

OF

APPROVED

REPLACEMENT

PARTS"):

3.

BACKGROUND.

An

increasing

amount

of replacement

parts

(including standard

parts),

materials,

appliances,

and

instruments

are

offered

for

sale

as

being

of aircraft quality

when

actually the quality

and

originofthese

units

are

unknown.

Users

of

such

units

are

usually

not

aware

of

the

potential

hazards

involved

with

replacement

parts that

are

not

eligible

for

use

on

certificated aircraft. Frequently such

units

are

deceptively

advertised

or

presented

as

"unused," "like new,"

or

"remanufactured."

This

implies that

the

quality

of

such

units

is

equal

to

an

original

or appropriately

repaired

or

overhauled

unit.

The

performance

rules

for

replacement

of

parts

and

materials

used

in

the maintenance

and

alteration

of

U.S.

certificated aircraft

are

specified

in

Federal

Aviation

Regulations

(FAR)

43.13

and

FAR

145.57.

The

responsibilityforthe continued

airworthiness

ofthe aircraft, which includesthe replacement of

parts,

is

the

responsibility of the owner/operator

as

outlined

in

FAR

91.163,

FAR

121.363,

FAR

123.45,

FAR

127.131

and

FAR

135.143

(a).

4.

IDENTIFICATION OFTHEAPPROVED PARTS. Approved

serviceable

replacement

parts

are

identified

as

follows:

a.

By

an

FAA

Form

8130-3

(Formerly

FAA

Form

186),

Airworthiness Approval

Tag.

An

Airworthiness

Approval

Tag

identifies

a

part

or group of parts that

have

been

approved

by

authorized

FAA

representatives.

b.

By

an

FAA

Technical

Standard

Order

(TSO)

number

and

identification

mark

that indicates

the

part

or

appliance

has

been

manufactured

underthe

requirements

of

FAR

37.

c.

By

an

FAA/PMA

symbol,

togetherwith the manufacturer's

name,

trademark or

symbol,

part

number,

and

the

make

and

model

of

the

type

certificated product

on

which the part

is

eligible for

installation,

stamped

on

the part

An

FAA

Parts

Manufacturer

Approval

(FAAlPMA)

is

issued

under

FAR

21.305.

The

make

and

model

information

may

be

on

atag

attached

tothe part.

d.

By

shipping ticket,

invoice,

or other document which provides evidencethat the

part

was

produced

by a manufacturer holding

an

FAA

Approved Production Inspection

System

issued

under

FAR

21,

Subpart

F,

orbyamanufacturer holding

an

FAA

ProductionCertificate

issued

under

FAR

21,

Subpart

G.

e.

By

a certificate of airworthiness for export

issued

by a

foreign

government under the provisions

of

FAR

21,

Subpart

N.

11.

KNOW

YOUR SUPPLIER. It

has

come

to our attention that many reproduced

parts

and

components, particularly

instruments

which

have

been

manufactured

by persons other than the

original

manufacturer,

are

available

for

purchase

and

installation

on

U.S.

certificated aircraft.

Often,

an

original

part

is

used

as

a

sample

to produce

duplicates.

The

reproduced

parts

appearto

be

as

good

as

the

original

part;

however,

there

are

many

unknown

factors to

be

considered that

may

not

be

readily

apparent to

the

purchaser,

i.e.,

heat

treating,

plating,

inspections, tests

and

calibrations.

All

too often

the

faulty

part

is

not

discovered

until

amalfunction

or

an

accident occurs.

12.

SUM

MARY. InaccordancewithFAR's, certificationofmaterials, parts,and appliancesforreturn

to

service, for use onaircraft, is the responsibility ofthe person oragency who signs the approval.

The

owner/operator,

as

denoted

in

paragraph

3 ofthis advisory circular,

is

responsible for the

continued

airworthiness ofthe aircraft.

To

assure

continued

safety

in

aircraft operation, itis

essential

that

great

care

be

used

when

inspecting,

testing,

and

determining the acceptability of

all

parts

and

materials.

Particular

caution

should

be

exercised

when

the

identity of

materials,

parts,

and

appliances cannot

be

established

or

when

their origin

is

in

doubt.

February

1989

iii

OVERHAUL MANUAL

FOR

TSIO-520 SANDCAST SERIES

AIRCRAFTENGINE

-NOTICE-

The overhauler must comply with all instructions contained

in

this manual

in

order

to

assure safe and

reliable engine performance. Failure

to

comply will be deemed misuse, thereby relieving the engine

manufacturer

of

responsibility under its warranty.

This manual contains no warranties, either expressed

or

implied. The information and procedures

contained herein provide the overhauler with technical information and instructions applicable

to

proper

overhaul procedures.

Prior

to

overhaul, the mechanic must meet requirements

of

Federal Aviation Regulation 65 and must

follow

FAR

parts

43,

91, and

145,

as applicable. This manual must be used in conjunction with the

FAA

Advisory circular 43.13-1A, Acceptable Methods, Techniques and Practices -Aircraft Inspection and

Repair,

as

well as Teledyne Continental Motors' TS10·520 Sandcast Series Parts Catalog X30579A.

CHAPTER

1

Introduction

4

Airworthiness

Limitations

5

Time

Limits/Maintenance

Checks

70 Standard Practices

72

Engine

Reciprocating

73

-

Engine

Fuel System

74 -

Ignition

75 -

Air

76 •

Engine

Controls

77

Engine

Indicating

78 -Exhaust

79 -

Oil

80 Starting

81

Turbines

iv

February 1989

..

INTRODUCTION

This Teledyne Continental Motors Overhaul

Manual

is

prepared

in

accordance with the

GAMA

(General

Aviation Manufacturers Association) format.

The

manual

is

divided into groups which enable a broad

separation of contents (Chapters) within

each

group.

The chapters

are

broken down into major

systems,

Engine -Reciprocating,

Exhaust,

Starting,

etc.

The

System Chapters

are

arranged numerically.

All

System

Chapters

are

assigned a number which becomes

the first element of a standardized numbering

system.

The

element

"72"

of the number series

72-00-00

refers to the System Chapter

on

"Engine Reciprocating.·

All

information pertaining to the engine

will

be

covered

in

this System Chapter.

The major System Chapters are then broken down into Sub-System Sections. These sections are identified

by

the second element of the standardized numbering

system.

The

number

"10"

of the basic number

series

"72-10-00"

is

forthe "disassembly" of the engine.

The Subsection

in

the third element of the standardized numbering system

"72-10-12."

This number

is

the

final breakdown of the Chapter. Number

"12"

is

for ·Oil

Pump

Assembly," that

is

"disassembled" from the

"Engine."

EXAMPLE:

-Chapter - - Section - - Subsection-

"Engine Reciprocating" "Disassembly" ·Oil Pump

Assembly"

.....

1

_____

72

-lb

-12

-----~I

In producing this publication, considerable effort

has

been put forth

to

provide grammatically clear and

accurate information. Teledyne Continental Motors solicits the user assistance

in

providing information

for review on changes that the user may suggest.

February 1989 V

SECTION

ii

iii

iv

v

vi

vii

1-00-00

1-00-01

1-00-02

1-00-03

1-00-04

1-10-00

1-10-01

1-10-02

1-10-03

1-10-04

1-20-00

1-20-01

1-30-00

1-30-01

4-00-00

5-00-00

5-10-00

5-20-00

5-20-01

5-20-02

5-20-03

5-30-00

70-00-00

70-10-00

70-20-00

70-30-00

70-40-00

70-50-00

70-50-01

70-50-02

70-50-03

70-50-04

vi

February 1989

TABLE

OF

CONTENTS

Current

Status

of

Pages

Warning

....

.

Notice

.....

.

Introduction. . . .

Table

of Contents.

List

of Illustrations.

SCOPE

CHAPTER 1 INTRODUCTION

Service

Bulletins.

. . . . . .

Service

Reports

and

Inquiries.

100%

Replacement

Parts

...

DEFINITIONS

&

ABBREVIATIONS

Abbreviations/Symbols . . . . .

Definitions . . . . . . . . . . .

Description of Engine Model Code

Basic

Design

Features. . . . . .

TOOLS

Special

Tools .

PRODUCTS

Product

List.

CHAPTER 4 AIRWORTHINESS LIMITATIONS

Airworthiness Limitations. . . . . . . . . . . . . . . . .

CHAPTER

5 TIME LIMITS/MAINTENANCE CHECKS

GENERAL

............

.

TIME

liMITS/INSPECTION

PROGRAM

SCHEDULED

MAINTENANCE

Preflight Inspection . . . . . . .

50

Hour Inspection . . . . . . .

100

HourInspection. . . . . . .

UNSCHEDULED

MAINTENANCE.

CHAPTER

70

STANDARD PRACTICES

GENERAL

.............

.

LOCKWIRE

PROCEDURE

. . . . . . .

CRANKCASE

THREADING

PROCEDURE

APPliCATION

OF

ADHESIVES.

INSTALLATION

OF

GASKETS.

CYliNDER

LEAKAGE

CHECK

Leakage

Checks.

. . .

Equipment

.....

.

Performing

The

Check.

Dynamic

Seal

Check. .

ii

iii

iv

v

vi

vii

1-00-03

1-00-04

1-00-05

1-10-01

1-10-02

1-10-06

1-10-Q7

1-20-01

1-30-01

4-00-03

5-00-03

5-10-01

5-20-01

5-30-01

70-00-03

70-10-01

70-20-01

70-30-01

70-40-01

70-50-01

70-50-02

70-50-03

70-50-05

SECTION

72-00-00

72-00-01

72-00-02

72-00-03

72-00-04

72-00-05

72-00-06

72-00-07

72-00-08

72-00-09

72-00-10

72-00-11

72-00-12

72-00-13

72-00-14

72-10-01

72-10-02

72-10-03

72-10-04

72-10-05

72-10-06

72-10-07

72-10-08

72-10-09

72-10-10

72-10-11

72-10-12

72-10-13

72-10-14

72-10-15

72-10-16

72-10-17

72-10-18

CHAPTER 72-00 ENGINE RECIPROCATING

GENERAL

Introduction

...

.

Crankcase

...

.

Crankshaft . . . .

Connecting

Rods.

Camshaft.

Pistons

..

Lifters . . . . . .

Cylinders

....

.

GearTrain

...

.

Lubrication System

Valve Mechanism .

Induction

System.

Exhaust

System.

Ignition

System.

CHAPTER 72-10

DISASSEMBLY

General.

..•.

Extent

of

Disassembly .

Parts

to

be Discarded .

Preliminary Cleaning. .

Ignition

System.

. . .

Fuel Injection System (C,G,H,M,P,R, & AF).

Fuel Injection System

(TSI0-520-AE~

. . .

Fuel Injection System (TSI0-520-CE) . . .

Magneto and Accessory Drive . . . . . .

Induction System (TSIO-520-C,G,H,M.P,R, & AF) .

Induction System (TSIO-520-T)

..

Induction System (TSIO-520-AE) . . . .

Induction System (TSIO-520-CE) . . . .

Oil

Sump

(TSIO-520-C,G. M &T) . . . .

on

Sump

(TSIO-520-H,P,R,AE,AF & CE) .

Oil Cooler

..•............

Alternator

Assembly.

. . . . . . . . .

Starter and Starter Drive Adapter (TSIO-520-C,G,H,M.P,R &

AF)

Starter

and

Starter Drive Adapter (TSI0-520-T,AE & CE) .

Oil

Pump

Assembly (TSIO-520-C,G,H,M,P,R & AF)

Oil

Pump

Assembly (TSIO-520-T)

..........

.

Oil

Pump

Assembly (TSIO-520-AE) . . . . . . . . . .

Oil

Pump

Assembly (TSIO-520-CE) . . . . . . . . . .

Cylinder

and

Piston Assembly (All ExceptTSI0-520-AE) .

Cylinder

and

Piston Assembly (TSI0-520-AE).

Crankcase

...•.....

Camshaft

Assembly.

. . . .

Crankshaft . . . . . . . . .

Exhaust System (TSI0-520-T).

72-00-03

72-00-06

72-00-07

72-00-08

72-00-09

72-00-11

72-00-13

72-00-14

72-10-03

72-10-04

72-10-06

72-10-08

72-10-10

72-10-12

72-10-14

72-10-16

72-10-18

72-10-20

72-10-21

72-10-22

72-10-24

72-10-26

72-10-28

72-10-30

72-10-32

72-10-34

72-10-36

72-10-38

72-10-40

72-10-44

72-10-46

February 1989

vii

SECTION

72-20-01

72-20-02

72-20-03

72-20-04

72-20-05

72-20-06

72-20-07

72-20-08

72-20-09

72-20-10

72-20-11

72-20-12

72-20-13

72-20-14

72-20-15

72-20-16

72-20-17

72-20-18

72-20-19

72-20-20

72-20-21

72-20-22

72-20-23

72-20-24

72-20-25

72-20-26

72-20-27

72-30-01

72-30-02

72-30-03

72-30-04

72-30-05

72-30-06

72-30-07

72-30-09

72-30-10

72-30-12

72-30-13

72-30-14

72-30-15

72-40-01

72-40-02

72-40-03

72-40-04

72-40-05

72-40-06

72-40-07

viii

February 1989

CHAPTER 72-20 CLEANING, REPAIR AND REPLACEMENT

General. .

Cylinders

..

.

Pistons

...

.

Valves

...

.

Rocker Shafts.

Pushrods, Valve Rockers and Other Small Steel Parts.

Camshaft and Crankshaft.

Crankcase . . . . . . . . . . . . .

Gears

..............

.

Sheet Metal Parts and Intake Manifold.

Castings

............

.

Stud Replacement

........

.

Helical Coil Insert Installation

...

.

Spark Plug Hole Helical Coil Inserts .

Cylinders

......

.

Valve Guides . . . . .

Valve Rockers. . . . .

Hydraulic Valve Lifters .

Connecting Rods . . .

Piston Pin Bushing Replacement

Crankshaft Assembly. . . . . .

IdlerGear

..........

.

Magneto and Accessory Drive Adapter Assembly.

Tachometer Drive

Housing.

Starter Drive Adapter.

Oil

Pump

Assembly . . . .

Ignition Cables . . . . . .

CHAPTER 72-30 INSPECTION

General

........

.

Visuallnspection

....

.

Magnetic Particle Injection .

Crankshaft Ultrasonic Inspection

F10urescent Particle Inspection .

Dimensionallnspection . . .

Dimensional Umits. . . . . .

Original Dimension . . . . .

New Parts and Service Umits .

Protective Coating

.....

Application

of

A10dine . . .

Repair of A10dized Surfaces.

Enamel Coatings . . . . .

CHAPTER 72-40 SPECIFIED INSPECTIONS

Crankcase

.................

.

Crankshaft . . . . . . . . . . . . . . . . . .

Crankshaft

and

Counterweight Pins and Bushings.

Camshaft

.....

Connecting Rods .

Gears

.....

.

Pistons

and

Rings.

72-20-03

72-20-04

72-20-05

72-20-09

72-20-13

72-20-14

72-20-15

72-20-16

72-20-17

72-30-02

72-30-03

72-30-05

72-30-07

72-30-08

72-30-21

72-30-22

72-40-03

72-40-04

SECTION

72-40-08

72-40-09

72-40-10

72-40-11

72-40-12

72-40-13

72-40-14

72-50-01

72-50-02

72-50-03

72-50-04

72-50-05

72-50-06

72-50-07

72-50-08

72-50-09

72-50-10

72-60-01

72-60-02

72-60-03

72-60-04

72-60-05

72-60-06

72-60-07

72-60-08

72-60-09

72-60-10

72-60-11

72-60-12

72-60-13

72-60-14

CHAPTER 72-40 SPECIFIED INSPECTIONS (Continued)

Cylinders

......

.

Hydraulic

Valve

Lifters .

Intake Tubes . . . .

Lubrication

System

.

Fuel

Injection

System

Ignition System. . .

Exhaust System. . .

CHAPTER 72-50 ASSEMBLY

OF

SUBASSEMBLIES

General

..............•..•.

Oil

Pump

Assembly

(TSIO-520-C.G,H,M,P,R

&

AF)

Oil

Pump

Assembly (TSIO-520-T). . . . • . . •

Oil

Pump

Assembly

(TSIO-S20-AE)

. . . . . . .

Oil

Pump

Assembly

(TSIO-S20-CE)

. . . . . . .

Starter

and

Drive Assembly

(TSIO-520-C,G,H,M,P,R

&

AF)

.

Starter

and

Drive Assembly

(TSIO-520-T,AE

&

CE)

Cylinder Assembly

(All

Except

TSIO-520-AE)

.

Cylinder Assembly

(TSIO-S20-AE)

.

Piston

and

Ring

Assemblies . . .

Pushrod Housing . . . . . . . .

Crankshaft

and

Connecting

Rods

.

Camshaft

...........

.

Crankcase

..........

.

Fuel

Injection Control

and

Air

Throttle Body

CHAPTER

72-60 FINAL ASSEMBLY

GeneraL

.••.•..........

Crankcase

...•....•..•..

Cylinders and Pistons . . . . . . . • .

Oil Pump

(TSIO-520-C,G,H,M,P,R

&

AF)

.

on

Pump (TSIO-520-AE). . .

Oil Pump

(TSIO-520-T

&

CE)

•

Fuel

Pump

.............

.

Starter Drive Adapter. . . . . . . . . .

Alternator Assembly. . . . . . . . . .

Magneto and Accessory

Drive

Adapters .

Oil Cooler

....•..........

Valve

Mechanism . . . . . . . . . . .

Oil

Sump

(TSIO-520-C,G,M

&

T).

. • . .

Oil

Sump

(TSIO-520-H,P,R,AE,AF

&

CE)

.

Induction System • . • . . . . . . . .

Induction System

(TSIO-520-C,G,H,M,P,R

&

AF)

Induction System

(TSIO-520-T)

..•.....

Induction System

(TSIO-520-AE)

. . . . . . .

Induction System

(TSIO-S20-CE)

......

.

Fuel

Injection

System

(TSIO-520-C,G,H,M,P,R,T

&

AF).

Fuel

Injection

System

(TSIO-520-AE}

Fuel

Injection System

(TSIO-520-CE)

Magneto Drive Gears • . . . . • • • . . . . . . .

72-40-06

72-40-07

72-40-09

72-50-03

72-50-OS

72-50-06

72-50-07

72-50-08

72-50-09

72-50-10

72-60-03

72-60-07

72-60-08

72-60-09

72-60-10

72-60-12

72-60-13

72-60-14

72-60-15

February 1989 ix

SECTION

72-60-15

72-60-16

72-60-17

72-60-18

72-60-19

72-70-01

72-70-02

72-70-03

72-70-04

72-70-05

72-70-06

72-70-07

72-70-08

72-70-09

72-70-10

72-70-11

72-70-12

72-70-13

72-70-14

72-80-01

72-80-02

72-80-03

72-80-04

73-00-00

73-10-00

73-10-01

73-10-02

73-10-03

74-00-00

74-00-01

74-00-02

74-10-00

74-30-00

74-30-01

74-30-02

74-50-00

X February 1989

CHAPTER 72-60

FINAL

ASSEMBLY

(Continued)

Placing Crankshaft in Timing Position .

Magnetos

.........

.

Ignition Harness

......

.

Fuel Lines & Hoses

....

.

Exhaust System (TSIO-520-T).

CHAPTER 72-70 TESTING AFTER OVERHAUL

Test Stand

...

.

Test

Club

....

.

Cooling

Air

Scoop.

Induction

Air Intake

Exhaust System.

Controls

....

Electrical Wiring.

Instruments. . .

Breather

....

Fuel

System

. .

Governor

Pad Cover.

EngineTest

....

Starting Procedure. .

Overhaul Test Run. .

CHAPTER 72-80

ENGINE

PRESERVATION

General.

.....

.

Flyable

Storage.

. .

Temporary

Storage .

Indefinite Storage

..

CHAPTER 73-00

ENGINE

FUEL SYSTEM

Engine Fuel

System.

. .

Set

up

Procedure.

. . .

Turbocharged

Engines. .

Fuel Pressure Regulators.

Special Set

up

Procedures .

GENERAL

....

CHAPTER

74

IGNITION

(TCM IGNITION SYSTEM)

Magneto

Installation

.....

.

Harness Assembly Installation .

IGNITION TROUBLESHOOTING

GENERAL

........

.

Magneto

Installation

....

.

Harness Assembly Installation

IGNITIONTROUBLESHOOTING

72-60-16

72-60-17

72-60-19

72-70-03

72-70-04

72-70-05

72-70-06

72-80-03

72-80-04

72-80-05

73-00-03

73-10-01

73-10-02

74-00-03

74-00-04

74-00-06

74-00-07

74-00-08

74-00-10

SECTION

75-00-00

76-00-00

76-00-01

76-00-02

n-Oo-Oo

n-10-oo

n-20-00

78-00-00

78-10-00

78-20-00

79-00-00

79-10-00

79-20-00

80-00-00

80-00-01

80-00-02

80-00-03

80-00-04

80-00-05

80-00-06

80-00-07

80-00-08

80-00-09

81-00-00

81-10-01

81-10-02

81-10-03

81-10-04

81-20-01

CHAPTER

75

AIR

GENERAL

CHAPTER 76 ENGINE CONTROLS

GENERAL

...............

.

CRUISE

CONTROL

BY

PERFORMANCE

CURVE. . .

CRUISE

CONTROL

BY

E.G.T..

. . . . . . . . . . .

CHAPTER n ENGINE INDICATING

GENERAL

.........

.

OPERATING

LIMITS

.............

.

ENGINE

TROUBLESHOOTING. . • . . . . . .

CHAPTER 78 EXHAUST

GENERAL

..............

.

EXHAUST

SYSTEM

(TSIO-520-T)

.....

.

EXHAUST

SYSTEM

TROUBLESHOOTING. .

CHAPTER

79

OIL

GENERAL

...........

.

APPROVED

PRODUCTS. . . . . . . . . .

OIL

SYSTEM

TROUBLESHOOTING. . . . .

GENERAL

....

Prestarting . . . .

Starting

.....

.

Ground Warm-Up.

Pre-takeoff Check .

Flooded Engine. .

CHAPTER

80

STARTING

Cold

Weather Operation .

Preheating . . . . . . .

Hot Weather Operation .

Ground Operating

At

High Altitude Airports.

GENERAL

..

Turbocharger.

Wastegates. .

Controllers . .

CHAPTER

81

TURBINES

Turbocharger Lubrication System.

Turbocharging System Troubleshooting.

75-00-03

76-00-03

n-OO-03

n-10-01

n-20-01

78-00-03

78-10-01

78-20-01

79-00-03

79-10-01

79-20-01

80-00-03

80-00-04

80-00-05

80-00-06

80-00-07

80-00-09

80-00-10

81-00-02

81-10-01

81-10-03

81-10-05

81-20-01

February 1989

xi

FIGURE

NO.

1-10-04

1-20-01

(1)

1-20-01

(2)

1-20-01

(3)

1-20-01

(4)

1-20-01

(5)

1-20-01

(6)

1-20-01

(7)

1-20-01

(8)

1-20-01

(9)

1-20-01

(10)

1-20-01

(11)

1-20-01

(12)

1-20-01

(13)

1-20-01

(14)

1-20-01

(15)

1-20-01

(16)

1-20-01

(17)(18)

1-20-01

(19)

1-20-01

(20)

1-20-01

(21)

1-20-01

(22)

1-20-01

(23)

1-20-01

(24)

1-20-01

(25)

1-20-01

(26)

1-20-01

(26)

1-20-01

(27)

1-20-01

(28)

1-20-01

(29)

1-20-01

(30)

1-20-01

(31

)(32)

1-20-01

(33)

1-20-01

(34)

1-20-01

(35)

1-20-01

(36)

1-20-01

(37)

1-20-01

(38)

1-20-01

(39)

1-20-01

(40)

1-20-01

(41)

1-20-01

(42)

1-20-01

(43)

1-20-01

(44)

1-20-01

(45)

1-20-01

(46)

1-20-01

(47)

1-20-01

(48)

1-20-01

(49)

1-20-01

(50)

xii

February 1989

LIST

OF ILLUSTRATIONS

TITLE

Three

Quarter

Right

Front

View

of the TSI0520 Sandcast

Series

Engine

Three

Quarter

Left

Rear

View

of the TSI0520

Sandcast

Series Engine.

Installation Drawing TSI0520

Series

Sandcast

Strap Wrench. . . . . . . . . . .

Oil

Filter

Can

Cutter. . . . . . . .

Cylinder

Base

Nut Wrench. . . . .

Cylinder

Base

Nut Wrench Bonanza.

Cylinder

Base

Nut Wrench. . . . .

Piston

Removers.

. . . . . . .

Cylinder

Hone.

. . . . . . . . . .

Crankshaft

Blade

and

Dampener Bushing Removers/Replacers

Holding Fixture Adapters. . . . .

Universal

Cylinder Holding

Fixture.

Valve

Guide

Cleaner. .

Seal

Seat

Cutter. . . .

Spring Checker. . . .

Valve

Guide Removers.

Valve

Guide Replacers.

Rocker

Arm

Bushing Remover Installer Set.

Piston

Ring

Compressors . . . . . .

Floating

Holder.

. . . . . . . . . .

Valve

Spring Compressor. . . . . . .

Push

Rod

Housing Spring Compressor

Flaring

Tool

Push

Rod

Housing

...

Valve

Guide

Remover

. . . . . . .

Valve

Seat

Insert Remover/Replacer.

Valve

Seat

Installer

.....

Common Parts Kit. . . . .

Valve

Guide

to

Seat

Aligner.

Valve

Stem

Hole Reamer.

Boring

Bars.

. . . . . .

Reamers

.......

.

Expanding Guide Bodies.

Valve

Seat

Insert Cutters.

RosarfIDStud

Remover

..

Connecting

Rod

Reaming

and

Alignment Checking

Fixture.

Adapter

Kits.

. . . . . . . . . . . . . . . . • . . . .

Reamers.

Connecting

Rod

Bushing. . . . . . . . . . .

universal

Connecting

Rod

Bushing Removers & Installer Set.

Common

Drive

Handle & Pilots. . . . . . . . . . . . . .

Needle Bearing Installers. . . . . . . . . . . . . . . . .

Hydraulic Crankshaft Dampener Bushing Remover/Replacer

Sets

Counterweight Bushing Remover/Installer.

All

Position Engine Stand. . . .

Torque

Band

Tension Adjuster.

Generator Drive Holders. . . .

Cylinder Heating

Stand.

. . . .

Blind

Needle

Bearing Puller

...

Starter Clutch Shaft Bearing

Pullers

.

Differential Pressure Gage . . . . .

Differential Pressure Cylinder Checker.

Belt

Tension

Gage. . . . . . . . . .

PAGE

NO.

1010-08

1-10-08

1-10-09

1-20-08

1-20-09

1-20-10

1-20-11

1-20-12

1-20-13

1-20-14

1-20-15

1-20-16

1-20-17

1-20-18

1-20-19

1-20-20

1-20-21

1-20-22

1-20-23

1-20-24

FIGURE

NO.

1-20-01

(51)

1-20-01

(52)

1-20-01

(53)

1-20-01

(54)

1-20-01

(55)

1-20-01

(56)

1-20-01

(57)

1-20-01

(58)

1-20-01

(59)

1-20-01

(60)

1-20-01

(61)

1-20-01

(62)

1-20-01

(63)

1-20-01

(64)

1-20-01

(65)

1-20-01

(66)

1-20-01

(67)

1-20-01

(68)

1-20-01

(69)

1-20-01

(70)

1-20-01

(71)

1-20-01

(72)

1-20-01

(73)

1-20-01

(74)

1-20-01

(75)

1-20-01

(76)

1-20-01

(77)

1-20-01

(78)

1-20-01

(79)

1-20-01

(80)

1-20-01 (81)

1-20-01

(82)

1-20-01

(83)

1-20-01

(84)

1-20-01

(85)

1-20-01

(86)

1-20-01

(87)

1-20-01

(88)

1-20-01

(88)

1-20-01

(89)

1-20-01

(90)

1-20-01

(91)

1-20-01

(92)

1-20-01

(93)

1-20-01

(94)

1-20-01

(95)

1-20-01

(96)

1-20-01

(97)

1-20-01

(98)

1-20-01

(99)

1-20-01

(100)

1-20-01

(101)

1-20-01 (102)

Hydraulic LifterTester.

GeneratorTester . . .

Engine

Timing Disc . .

Pulley

Holder. . . . .

Pulley

Alignment

Gauge

Bar

TITLE

Crankcase Drill Fixture for Starter Clutch Adapter.

Vacuum

Pump . . . . . . . . .

Generator Pulley

Puller.

. . . . .

Bearing

and Bushing Drill Fixture .

Spark

Plug Insert Replacer.

Thru

Bolt Bore Step Cutters.

Spark

Plug Insert

Tap

. . .

Spark

Plug Insert Remover.

Slide

Hammer. . . . . . .

Spark

Plug

Tap.

. . . . .

Rosan@LockRing Installer.

Stud

Drivers

505

Series . .

Scavenge

Pump

Drill

Fixture .

Drill

Fixture. . . . . . . . .

Crankcase Splitter

Set.

. . .

Propeller Shaft

Oil

Seal

Installer.

Oil

Pressure

Relief

Spot Facers .

Runout

Block

Set

. . . . . . .

Polishing Tools for Crankshaft Bearings

8087

Series.

Injector Nozzle Remover and Installer.

Crankcase Thru-Boit Removers.

Hex

Drive for Hex Tube Nuts .

Rotobroach Cutter.

Pullers.

Pullers

.....

.

Pullers

.....

.

Pullers

.....

.

Outside Micrometers.

Dial

Bore Gages. . .

Blade

Micrometers. .

Screw Thread Micrometers 126.226 .

Depth

Micrometers . . . . . . . .

Reamers,

Rocker Shaft Support

Boss

.

Reamers,

Rocker

Arm

& Shaft

Bushing.

Reamers,

Valve

Guide

Boss.

. . . . .

Engine

Application Chart for

Valve

Guide

Stem

Hole

Reamers

.

Square

Shank

Reamers

. . . . . .

Valve

Guide

Stem

Hole Plug Gauges

Dial

Thickness Gauge . . . . . . .

Precision Vernier Calipers . . . . .

Inside Measuring Instruments

....

Altemator, Voltage Regulator Tester.

Altemator, Regulator, BatteryTester.

Multiple Voltage & Circuit

Tester.

Magneto Timing Ught .

Timing Indicator. . .

Cold

CylinderTester.

.Hi-Voltage Tester . .

PAGE

NO.

1-20-24

1-20-25

1-20-26

1-20-27

1-20-28

1-20-29

1-20-30

1-20-31

1-20-32

1-20-33

1-20-34

1-20-35

1-20-36

1-20-37

1-20-38

1-20-39

February 1989 xiii

FIGURE

NO.

1-20-01

(103)

1-20-01

(104)

1-20-01

(105)

70-10-00

70-20-00

70-S0-01

70-S0-02

70-S0-03

70-S0-04

72-00-03

72-00-09

72-00-10

72-00-11

72-00-14

72-10-OS

72-10-06A

72-10-068

72-10-06C

72-10-07

72-10-08A

72-10-088

72-10-08C

72-10-08D

72-10-09A

72-10-098

72-10-10

72-10-12A

72-10-128

72-10-13A

72-10-138

72-10-13C

72-10-13D

72-10-14A

72-10-148

72-10-15

72-10-16

72-10-17

72-10-18

72-20-12A

72-20-13

72-20-14A

72-20-148

72-20-14C

72-20-17

72-20-1

SA

72-20-1S8

72-20-18

72-20-20

72-20-27

72-30-04

72-40-03

72-40-07A

72-40-078

72-40-13A

xiv February 1989

Master Orifice Tool

.....

.

Alcor Portable Digital

EGT

Unit .

Alcor Portable Digital

CHT

Unit

.

Lockwire Procedure

.....

.

TITLE

Permatex

and

Threading Procedure.

Master Orifice Assembly Tool. . . .

Cylinder Slatic

Seal

& Dynamic Seal.

Differential

Pressure

Tester .

Dynamic

Seal

Check. .

Crankshaft Numbering.

Gear

Train

Diagram . . . .

Lubrication System . . . .

Hydraulic Lifter . . . . . .

Pressurized Magneto Installation

Exploded

View

of Ignition System.

Fuel

Injection

System

TSI0-S20-C,G,H,M,P,R,T

&

AF

Fuel

Injection

System

TSI0-S20-AE

.....

.

Fuel

Injection

System

TSI0-520-CE. . . . . .

Magneto & Accessory Drives. . . . . . . . .

Induction System

TSI0-52O-C,G,H,M,P,R

&

AF

.

Induction System TSI0-520-T. . .

Induction System LjTSI0-520-AE

..

.

Induction System TSI0-520-CE

...

.

Oil

Sump TSI0-520-C,G,M &T . . . .

Oil

Sump

TSI0-52O-H,P,R,AE,AF

&

CEo

Oil

Cooler

.............

.

Starter

and

Starter Drive Adapter TSI0-520-C,G,H,M,P,R &

AF

.

Starter Adapter

TSI0-52O-T,AE

&

CEo

. . . . . .

Oil

Pump

AssemblyTSI0-520-C,G,H,M,P,R &

AF

.

Oil

Pump

Assembly

TSI0-52O-T.

. . . . . . . .

Oil

Pump Assembly LjTSI0-52O-AE. . . . . . .

Oil

Pump AssemblyTSI0-52O-CE. • . . . . • .

Cylinder and Piston Assembly

(All

Except LjTSI0-520-AE).

Cylinderand Piston Assembly LjTSI0-S20-AE .

Crankcase

Assembly.

. . . . .

Camshaft Assembly. . . . . .

Crankshaft Group

......

.

Exhaust Assembly

(TSI0-520-T).

Crankcase Stud Setting

Heights.

Installing Typical Helical Insert .

Installing Spark Plug Hole

Helical

Insert .

Expanding Spark

Plug

Hole

Helical

Insert

Removing

Spark

Plug

Hole

Helical

Insert.

Valve,

Rocker 8ushing Dimensions . . .

Cylinder Assembly Dimensions (Inclined

Valve)

.

Cylinder Assembly Dimensions (Straight

Valve)

.

Hydraulic Lifter . . . . . . . . . . . . . .

Connecting

Rod

and 8ushing Dimensions. .

Ignition Wiring Diagram

.........

.

Crankshaft Ultrasonic Inspection Procedure .

Counterweight Bushing Diameter Check.

Inspection

Ring

Side Clearance.

Measuring

Ring

Gap

in

Cylinder.

Spark

Plugs.

. . . . . • . . .

PAGE

NO.

1-20-39

1-20-40

70-10-01

70-20-01

70-50-01

70-50-02

70-50-03

70-50-05

72-00-07

72-00-10

72-00-12

72-00-13

72-00-15

72-10-05

72-10-07

72-10-09

72-10-11

72-10-12

72-10-13

72-10-15

72-10-17

72-10-19

72-10-20

72-10-21

72-10-22

72-10-25

72-10-27

72-10-29

72-10-31

72-10-33

72-10-35

72-10-37

72-10-39

72-10-43

72-10-44

72-10-45

72-10-47

72-20-06

72-20-10

72-20-11

72-20-12

72-20-14

72-20-15

72-20-17

72-30-07

72-40-04

72-40-05

72-40-08

FIGURE

NO.

72-40-138

72-40-14A

72-40-148

72-50-07

72-50-10A

72-50-108

72-50-10C

72-50-100

72-50-10E

72-50-1

OF

72-50-10G

72-60-02A

72-60-02B

72-60-02C

72-60-020

72-60-03A

72-60-03B

72-60-03C

72-60-04

72-60-10

72-60-11

72-60-14

72-60-17

72-70-05

73-00-00

74-00-04A

74-00-048

81-00-00

81-10-03

81-20-00

81-20-01

81-30-00

81-30-01

81-30-02

81-30-03

81-30-04

81-30-05

81-40-00

Reverse

Spark

Plug

Procedure .

Slipjoint Assembly. . . . . . .

Multi-Segment "Y.

Band

Clamp .

Valve

Spring Installation

....

TITLE

Fuel

manifold

Valve

Fitting Locations for

TSIO-520-CE.

Fuel

Manifold

Valve

Fitting Locations for

TSIO-520-C,G,H,M,P,

R,

T,

AE

&AF

..............

.

Fuel

Control

Valve

Fitting Locations

............

.

Fuel

Pump

Fitting Locations for

TSIO-520-T.

........

.

Fuel

Pump

Fitting Locations for

TSIO-520-AE.

. . . . . . . .

Fuel

Pump

Fitting Locations forTSI0-520-C,G,H,M,P,R,A,F &

CE.

Air Throttle & Metering Assembly Fitting Location for TSI0-520-AE .

Left Crankcase

and

Shafts Assembled

on

Stand

Alignment ofTiming Marks. . . . . . . .

Torquing Sequence. . . . . . . . . . .

Left

Side

of Complete Crankcase on Stand.

Installing NO.6 Cylinder

........

.

Tightening Cylinder

Base

Nut. . . . . . .

Cylinder Flange Torque Sequence for Single Cylinder Installation.

Oil

Pump,

Fuel

Pump

and

Starter Adapter Installed . . . . . . .

Installing Pushrod Housing

.................

.

Bottom

View

with

Valve

Mechanism and

Oil

Sump

Suction Tube .

Position of Magneto Couplings .

Ignition Wiring Diagram . .

Exhaust Flange Dimensions

Fuel

System

Schematic . .

Coating Insulationg

Sleeve

.

Installation of Elbow Oamp.

8asic Turbocharger System

Basic Turbocharger. . . .

Fixed

Orifice Wastegate . .

Hydraulic Wastegate. . • .

Absolute Pressure Controller .

Absolute Pressure Controllerand Rate of Change Controller Combined .

Rate

ofChange Controller . . . . . .

Ratio Controller. . . . • . . . . . .

Variable Absolute

Pressure

Controller .

Throttle Connection. . . . . . .

Turbocharger Lubrication System. . .

PAGE

NO.

72-40-08

72-40-10

72-50-08

72-50-11

72-50-12

72-50-13

72-50-14

72-50-15

72-50-16

72-50-18

72-60-04

72-60-05

72-60-06

72-60-07

72-60-08

72-60-11

72-60-15

72-60-18

72-70-03

73-00-03

74-00-04

81-00-02

81-10-01

81-10-02

81-10-03

81-10-04

81-10-05

81-10-06

February 1989

XV

FIGURE NO.

1-10-04

1-20-01

1-30-00

70-50-05

72-20-128

72-20-12A

72-20-12C

72-30-03

72-30-08

72-30-11

72-40-1S

72-S0-01A

72-S0-018

72-S0-01C

72-S0-01D

72-S0-10A

72-S0-108

72-S0-10C

72-S0-10E

72-50-1

OF

72-S0-10G

72-60-02C

72-60-1S

72-70-14A

72-70-148

72-70-14C

73-10-05

73-10-06

74-00-04C

74-20-00

74-30-04

74-S0-00

76-00-03

77-10-00

77-20-00

xvi February 1989

LIST

OF CHARTS

TITlE

Engine Dimensions . . . . . . .

Special Tools Procurement Sources.

Identification Code forTools . . . .

Special Too/Index

........

.

Application Chart Sealants/Lubricants.

Cylinder Leakage Check. . . . . . .

Standard and

Oversize

Stud Identification .

Crankcase Stud Setting Heights. . .

Miscellaneous Stud Setting Heights.

Magnetic Particle Inspection .

Table of Umits Chart

(1)

.

Table of Umits Chart

(2)

.

Table of Umits Chart

(3)

.

Table of Umits Chart

(4)

.

Table of Umits Chart

(S)

.

Critical New Part Dimensions.

Inspection

Chart.

. . . . . .

General

Use

-Tightening Torques.

Table ofTightening Torques . . .

Pipe Plugs

..•........

HydrauliC Une Fittings. . . . . .

Fuel

Manifold

Valve

Fitting Locations for

TSIO-S20-CE.

Fuel

Manifold

Valve

Fitting Locations for

TSIO-520-C,G,H,M,P,R,T

AE&AF

.•...............

Fuel

Control

Valve

Fitting Locations

.............

.

Fuel

Pump Fitting Locations for

TSIO-S2O-t

. . . . . . . . . .

Fuel

Pump Fitting Locations for

TSIO-S20-AE.

. . . . . . . . .

Fuel

Pump Fitting Locations for

TSIO-S2O-C,G,H,M,P,R,AF

&

CE

.

Crankcase Assembly Procedure

Magneto-to-EngineTiming. . .

Standard Acceptance

Test.

. .

Oil Consumption Determination.

Test Operating Umits . . . . .

Fuel

System Pressure

and

Flow

Value

Charts.

Fuel

Injection System Troubleshooting Chart.

Coupling NutTorque

Values

. . . .

Ignition Troubleshooting

.....

.

Coupling Nut Torque

Values

(Slick) .

Ignition Troubleshooting (Slick) .

Performance Charts .

Operating Umits. . .

Engine Trouble Shooting.

PAGE NO.

1-10-09

1-20-02

1-20-03

1-20-04

thru

07

1-30-01

thru

05

70-50-06

72-20-06

72-20-07

72-20-08

72-30-04

72-30-09

72-30-10,

11,12

.72-30-13,14,15

72-30-16,17

72-30-18,19

72-30-20,21

72-40-11

thru

19

72-50-03

72-50-04

72-50-OS

72-50-oS

72-50-11

72-50-12

72-50-13

72-50-14

72-50-15

72-50-17

72-60-05

72-60-16

72-70-06

72-70-07

72-70-08,09

73-10-03

73-10-04

74-00-05

74-00-06

74-00-09

74-00-10

76-00-05

thru 65

77-10-01

thru06

77-20-01

thru 06

FIGURE

NO.

78-20"()0

79-10"()0

79-20"()0

81-50"()0

TITLE

Exhaust

System

Troubleshooting .

Approved

Oil

Products. . . . . .

Lubrication

System

Troubleshooting.

Turbocharging

System

Troubleshooting.

Maximum Allowable Manifold

Pressure

vs.

Altitude

PAGE

NO.

78-20-01

79-10-01

79-20-01

81-20-01

81-20-02

February 1989

xvii

xviii

February 1989

INTENTIONALLY

LEFT

BLANK

November 2011 1-00-01

CHAPTER 1

INTRODUCTION

1-00-00 SCOPE

1-00-01 Advisories

1-00-02 Related Publications

1-00-03 Service Documents

1-00-04 Service Reports and Inquiries

1-00-05 100% Replacement Parts

1-10-00 DEFINITIONS & ABBREVIATIONS

1-10-01 Abbreviations/Symbols

1-10-02 Definitions

1-10-03 Description of Engine Model Code

1-10-04 Basic Design Features

1-20-00 TOOLS

1-20-01 Special Tools

1-30-00 PRODUCTS

1-30-01 Product List

1-00-02 November 2011

1-00-00 SCOPE

This manual provides maintenance and overhaul instructions for the turbocharged, 520 cubic

inch displacement, “Sandcast Series” aircraft engines with horizontally opposed cylinders listed

below, manufactured by Continental Motors:

Instructions in this manual are specific to the TSIO-520 Sandcast Series engines. For

information specific to other Continental Motors engine series, accessories, or the airplane,

refer to the appropriate manual.

1-00-01 ADVISORIES

This manual uses three type of advisories, 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.

• LTSIO-520-AE • TSIO-520-G

• TSIO-520-A • TSIO-520-H

• TSIO-520-AE • TSIO-520-M

• TSIO-520-AF • TSIO-520-P

• TSIO-520-C • TSIO-520-R

• TSIO-520-CE • TSIO-520-T

Continental Refrigerator LTSIO-520-AE User manual

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