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OVERHAUL
MANUAL
PART
NO.
X30586A
O
1992
TELEDYNE INDUSTRIES,
INC.
(MODELS)
0-470-A
0-470-B
0-470-E
0-470-G
0-470-J
0-470-K
0-470-L
0-470-M
0-470-P
0-470-R
0-470-S
0-470-U
FAA APPROVED
OCTOBER 1992
OCTOBER
1992
THE ORIGINAL DATE
OF
THIS
PUBLICATION ISSEPTEMBER,
1988
INSERT
LATEST PAGES DESTROY SUPERSEDED PAGES
MODELS:
0-470-A,B,E,G,J,K,L,M,P,R,S,U
FORM
X30586A
ii
OCTOBER
1992
WARNING
(Please notethe following statements from
FAA
AdvisoryCircular20-62C entitled"ELIGIBILITY, QUALITY,AND IDENTIFICATION
OFAPPROVED REPLACEMENTPARTS):
3.
BACKGROUND.
An increasingamount of replacementparts(includingstandard parts),materials,
appliances,and instrumentsare offeredfor sale as beingof aircraft quality when actuallythe quality and
originoftheseunitsareunknown.Usersof suchunitsareusuallynotawareofthepotentialhazardsinvolved
with replacement parts that are not eligible for use on certificated aircraft. Frequently such units are
deceptivelyadvertised or presented as "unused," "like new," or "remanufactured." This impliesthat the
qualityof such unitsis equalto an original or appropriatelyrepaired or overhauled unit.
The performancerulesfor replacement of partsand materials used inthe maintenanceand alteration of
U.S. certificatedaircraft are specified in FederalAviation Regulations (FAR)
43.13
and FAR
145.57.
The
responsibilityforthecontinuedairworthinessof theaircraft,whichincludesthe replacement of parts,isthe
responsibility of the owner/operatoras outlined in FAR
91.163,
FAR
121.363,
FAR
123.45,
FAR
127.131
and FAR
135.143
(a).
4.
IDENTIFICATIONOFTHEAPPROVED PARTS.
Approved serviceable replacement
partsare identifiedasfollows:
a. Byan FAA Form
8130-3
(FormerlyFAA Form
186),
AirworthinessApproval Tag. An Airworthiness
Approval Tag identifies a part or group of parts that have been approved by authorized FAA
representatives.
b. ByanFAATechnicalStandardOrder (TSO) numberandidentificationmarkthat indicatesthe partor
appliancehas beenmanufacturedunderthe requirementsof FAR
37.
c. ByanFAA/PMA symbol,togetherwiththemanufacturer'sname,trademark orsymbol, part number,
andthe makeand modelof thetype certificatedproduct onwhichthe part is eligiblefor installation,
stampedonthe part. An FAA Parts ManufacturerApproval (FAA/PMA) is issued under FAR
21.305.
The makeand model informationmay beon atag attachedtothe
part.
d. Byshippingticket, invoice, or other documentwhich provides evidencethatthe part was produced
bya manufacturer holding an FAA Approved Production InspectionSystem issued under FAR
21,
SubpartF, orbyamanufacturerholdinganFAA ProductionCertificateissuedunderFAR
21,
Subpart
G.
e.
Bya certificateof airworthiness for export issued bya foreign government under the provisionsof
FAR
21,
Subpart
N.
11.
KNOW YOUR SUPPLIER.
It has come to our attention that many reproduced parts and
components, particularlyinstrumentswhich have been manufacturedby personsother than the original
manufacturer,areavailablefor purchaseandinstallationon
U.S.
certificatedaircraft. Often, anoriginalpart
isusedasasampletoproduceduplicates.The reproducedpartsappeartobeasgoodas theoriginalpart;
however, there are many unknown factors to be considered that may not be readily apparent to the
purchaser,i.e., heattreating, plating,inspections,testsand calibrations.All too oftenthe faultypart is not
discovereduntila malfunctionor anaccidentoccurs.
12.
SUMMARY.
In
accordancewithFAR'S,certificationof materials, parts,andappliancesforreturn
toservice, for useonaircraft, isthe responsibility ofthe person oragency who signsthe approval.
The ownerloperator, as denoted inparagraph
3
ofthis advisory circular, is responsiblefor the continued
airworthinessof the aircraft.To assure continuedsafetyinaircraftoperation,
it
isessential that great care
beused when inspecting, testing, and determiningthe acceptabilityof all partsand materials. Particular
cautionshould be exercisedwhen the identityof materials, parts, and appliances cannot be established
orwhentheir originisindoubt.
OVERHAUL MANUAL
FOR
0-470
SERIES
AIRCRAFT ENGINE
-
NOTICE
-
The overhauler must comply with all the 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 responsibilityunderitswarranty.
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,aswell as TeledyneContinentalMotors'
0-470
Series PartsCatalogX30587A.
CHAPTER
1
-
Introduction
4
-
Airworthiness Limitations
5
-
Time Limits/Maintenance Checks
70
-
StandardPractices
72
-
Engine Reciprocating
73
-
EngineFuelSystem
74
-
Ignition
75
-
Air
76
-
EngineControls
77
-
EngineIndicating
78
-
Exhaust
79
-
Oil
80
-
Starting
81
-
Turbines
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
separationof contents, (Chapters)within each group.
The chapters are broken down into major systems, Engine
-
Reciprocating, Exhaust, Starting, etc. The
System Chapters are arranged alphabetically. 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 inthis 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" isfor the "disassembly"of the engine.
The Subsection is 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
-
"EngineReciprocating" "Disassembly" "Cylindersand Pistons"
In
producing this publication, considerable effort has been put forth to provide grammatically clear and
accurate information. Teledyne Continental Motors solicits the users assistance in providing information
for reviewon changesthatthe user may suggest.
TABLE
OF
CONTENTS
SECTI0 ~~~~~~~~~~~~PAGE
Ii
~~~current
Status
Of
Pages
.
.......
i
III
~~~Warning
.............
....
iii
...
IV
Notice.
..........................
I
v
Introduction
......................... V
VI
Table
of
Contents........... .......... VI
xi!
List
of
Illustrations
........... ..........
xii
CHAPTER
I
INTRODUCTION
1.00-00
SCOPE
i-00-01
Related
Publications.
...................
1-00-03
1-00,02
Service Bulletins
......................
1-00-04
1-00-03 Service
Reports and
Inquiries
................ 1
-0-04
1
-00-04
I1O0%
Replacement
Parts.
.................
1-00-04
1-10-00
DEFINITIONS
&
ABBREVIATIONS
1-10-01
~~Abbreviations
/
Symbols.
.................
1-10-01
1-10-02
Definitions.
........................
1-10-02
1-10-03
Description
of
Engine
Model
Code.
.............
1-10-06
1-10-04
Basic Design
Features.
.................. 1
-10-06
1-20-00 TOOLS
1-20-01
Special
Tools.
......................
1-20-01
1-30-00
PRODUCTS
1-30-01
Product
List
........................
CHAPTER
4
AIRWORTH-INESS
UMITATIONS
4-00-00
Airworthiness
Limitations.
..................
4-00-03
CHAPTER 5
TIME
IIMITS/MAINTENANCE
CHECKS
5-00-00
GENERAL.
........................
5-00-03
5-10-00
TIME
LIMITS/INSPECTION
PROGRAM.
...........
5-10-01
5-20-00
SCHEDULED MAINTENANCE.
...............
5-20-01
5-20-01
Preflight
Inspection.
....................
5-20-01
5-20-02
50
Hour
Inspection.
....................
5-20-01
5-20-03
100
Hour Inspection.
...................
5-20-01
5-30-00
UNSCHEDULED
MAINTENANCE.
.............
5-50-1
CHAPTER 70
STANDARD
PRACTICES
70-00-00
GENERAL.
........................
70-00-3
70-10-00
LOCKWIRE PROCEDURE.
.................
70-10-01
70-20-00
CRANKCASE THREADING
PROCEDURE.
..........
70-20-01
70-30-00
APPLICATION
OF
ADHESIVES...............
70-30-01
70-40-00
INSTALLATION
OF
GASKETS.
...............
70-40-01
70-50-00
CYLINDER
LEAKAGE
CHECK................
70-50-01
70-60-01
Leakage
Checks.
.....................
70-50-02
70-50-02
-
Equipment.
........................
70-50-02
70-50-03
PerformIng
The
Check.
..................
70-50-03
VI
SECTION
PAGE
CHAPTER
72-00
ENGINE
RECIPROCATING
72-00-D0
GENERAL.
........................
72-00)-02
72-00-01
Introduction.
........................
72-00-06
72-00-02
Crankcase.
........................
72-00-06
72-00-03
Crankshaft
.........................
72400-06
72-00-04
Connecting
Rods.
.....................
72-00-07
72-00-05
Camshaft
.
.
........................
72-00-08
72-00-06
Pistons.
..........................
72-00-08
72-00-07
Lifters.
..........................
72-00-08
72-00-08
Cylinders.
.........................
72-00-08
72-00-09
Gear
Train.
........................
72-00-09
72-00-10
Lubrication
System.
....................
72-00-11
72-00-11 Valve
Mechanism.
.....................
72-00-13
72-00-12
Induction
System.
.....................
72-00-13
72-00-13
Exhaust
System.
......................
72-00-14
72-00-14
Ignition
System.
......................
72-00-14
CHAPTER
72-10
DISASSEMBLY
72-10-01
General
..........................
72-10-03
72-10-02 Extent
of
Disassembly.
...................
72-10-04
72-10-03
Parts
to
be
Discarded.
...................
72-10-04
72-10-04
Preliminary Cleaning.
....................
72-10-04
72-10-05
Ignition
System.
......................
72-10-04
72-10-06
Fuel
Pump.
........................
72-10-04
72-10-07
Induction
System
......................
72-10-06
72-10-08 Magneto
and
Accessory
Drives
................
72-10-11
72-10-09
Oil
Sump.
.........................
72-10-12
72-10-10
Oil
Cooler.
.........................
72-10-14
72-10-11
Generator.
.......................
72-10-17
72-10-11
Alternator
Assembly.
....................
72-10-18
72-10-12
Starter
and
Starter
Drive
Adapter.
..............
72-10-20
72-10-13
Oil
Pump
Assembly.
....................
72-10-22
72-10-14
Cylinders
and
Pistons.
...................
72-10-25
72-10-15
Crankcase.
........................
72-10-28
72-10-16
Camshaft
Assembly.
....................
72-10-30
72-10-17
Crankshaft
Group.
.....................
72-10-31
72-10-18
Exhaust
System.
......................
72-10-32
CHAPTER
72-20
CLEANING,
REPAIR
AND
REPLACEMENT
72-20-01
GeneraL.
.........................
72-20-03
72-20-02
Cylinders.
.........................
72-20-03
72-20-03
Pistons.
..........................
72-20-04
72-20-04
Valves.
..........................
72-20-04
72-20-05
Rocker
Shafts.
.......................
72-20-04
72-20-06
Pushrods.
Valve
Rockers and
Other
Small Steel
Parts.
.....
72-20-04
72-20-07 Camshaft and
Crankshaft.
.................
72-20-04
72-20-OB
Crankcase.
........................
72-20-04
72-20-09
Gears.
..........................
72-20-04
72-20-10
Sheet
Metal Parts
and
Intake
Manifold.
............
72-20-04
72-20-11
Castings.
.........................
72-20-05
72-20-12 Stud
Replacement.
.....................
72-20-05
72-20-13 Helical
Coil
Insert
Installation.
................
72-20-08
Vii
SECTI ~~~~~~~~~~~~~PAGE
CLEANING,
REPAIR
AND
REPLACEMENT
(CONTINUED)
72-20-14
Spark
Plug
Hole
Helical
Coil
Inserts.
.............
72-20-13
72-20-15 Fin
Repairs.
........................
72.20-13
72-20-16
Valve
Guides.
.......................
72-20-13
72-20-17
Valve Rockers.
.......................
72-20-14
72-20-18
Hydraui~c Valve Lifters.
...................
72-20-14
72-20-19
Connecting
Rods.
.....................
72-20-14
72-20-20
Piston
Pin
Bushing
Replacement.
..............
72-20-14
72-20-21
Crankshaft Assembly.
...................
72-20-15
72-20-22
Idler
Gear.
.........................
72-20-16
72-20-23
Magneto
and
Accessory
Drive
Adapter
Assembly.
.......
72-20-16
72-20-24
Tachometer
Drive
Housing.
.................
72-20-16
72-20-25
Starter
Drive
Adapter.
....................
72-20-16
72-20-26
OH
Pump
Assembly.
....................
72-20-17
72-20-27
IgnItion
Cables.
......................
72-20-17
CHAPTER
72-30
INSPECilON
72-30-01
General..........;
.
...............
72-30-03
72-30-02 Visual
Inspection
.......... ............
72-30-04
72-30-03
Magnetic
Particle
Inspection
....... ..........
72-30-04
72-30-04
UltrasontIc
Inspectkion........
............
72-30-06
72-30-05
Flouresoent
Particle
Inspection
......
.
.........
72-30-09
72-30-06
Dimensional
Inspection
........ ...........
72-30-09
72-30-07
DimensIonal
Urnits,......... ............
72-30-09
72-30-08
Table
of
Limits
.......... .............
72-30-11
72-30-09
Original
Dimension
......... ............
72-,30-25
72-30-10
Protective Coating
.......... ............
72-30-26
72-30-11
Application
of
Anodizing
........ ...........
72-30-26
72-30-12
Repair
of
Adnodized Surfaces
........ .........
72-30-27
72-30-13
Enamel
Coatings........... ............
72-30-27
CHAPTER
72-40
SPECIFIC
INSPECTIONS
72-40-01
Crankcase
.........................
72-40-03
72-40-02
Crankshaft
........... ..............
72-40-03
72-40-03
Crankshaft
and
Counterweight
Pins
and
Bushings,.
.
.....
72-40-03
72-40-04
Camshatt
............ ..............
72-40-04
72-40-05
Connecting
Rods
.......... ............
72-40-04
72-40-06
Gears
............ ...............
72-40-04
72-40-07
PIstons
and
Rings
.......... ............
72-40-04
72-40-08
Cylinders
............ ..............
72-40-06
72-40-09
Hydraulic
Valve
Lifters
......... ...........
72-40-07
72-40-10
Intake
Tubes
........... .............
72-40-07
72-40-11
Lubrication
System......................
72-40-07
p2-40-12
Fuel
Injection
System
......... ...........
72-40-07
12-40-13
Igniltion System
.......... .............
72-40-07
'2-40-14
Exhaust
System
.......... .............
72-40-08
2-40-15
Inspection
Chart
...... ............
72-40-09
CHAPTER
72-50
ASSEMBLY
OF
SUBASSEMBLIES
!-50-01
General............. ..............
72-50-03
'-50-2
Oil
Pump
Assembly
......... ............
72-50-05
Hii
SEcTIn
FA§Q
CHAPTER 72-50
ASSEMBLY
OF
SUBASSEMBLIES
(CONTINUED)
72-50-03
Starter
and
Drive
Assembly.
.................
72-50-05
72-50-04
Cyvi~nder
Assembly.
.....................
72-50-06
72-50-05
Piston
and
Ring
Assemblies.
................
72-50-07
72-50-06
Pushrod Housing.
.....................
72-50-07
72-50-07
Crankshaft
and
Connecting
Rods.
..............
72-50-07
72-50-08
Camshaft.
.........................
72-50-08
72-50-09
Crankcase.
........................
72-50-08
72-50-10
Carburetor.
........................
72-50-08
CHAPTER
72-60 FINAL
ASSEMBLY
72-60-1
General.
..........................
72-60-03
72-60-02
Crankcase.
........................
72-60-03
72-60-03
Cylinders
and
Pistons.
...................
72-60-06
72-60-04
OilPump.
.........................
72-60-07
72-60-05
Fuel
Pump.
........................
72-60-08
72-60-06 Starter
Drive
Adaptler.
....................
72-60-08
72-60-7
Generator
Assembly.
....................
72-60-08
72-60-07 Optlonial
Alternator.
.....................
72-60-08
72-60-08
Magneto
and
Accessory
Drive
Adapters.
...........
72-60-08
72-60-09
03
Cooler.
.........................
72-60-08
72-60-10 Valve
Mechanism.
.....................
72-60-09
72-60-11
ON
Sump.
.........................
72-60-10
72-60-12
Induction
System.
.......... I..........72-60-l0
72-60-13
Carburetor.
........................
72-60-11
72-60-14
Magneto
Drive
Gears.
...................
72-60-12
72-60-15
PlacIng
Crankshaft
in
liming
Position.
............
72-60-13
72-60-16
Magnetos.
.........................
72-6014
72-60-17
Ignition
Harniess.
......................
72-60-14
72-60-18
Fuel
Uines.
........................
72-60-15
72-60-19
Exhaust
System.
......................
72-60-15
CHAPTER
72-70
TESTING AFTER
OVERHAUL
72-70-01
Operation
After
Major
Overhaul.
...............
72-70-03
72-70-02
rest
Club.
.........................
72-70-03
72-70-03
Cooling
Air
Scoop.
.....................
72-70-03
72-70-04
Induction
Air
Intake.
....................
72-70-03
72-70-05
Exhaust System.
......................
72-70-03
72-70-06
Controls.
.........................
72-70-03
72-70-07
Electrdcal
Wiring.
......................
72-70-04
72-7G-08
Instruments.
........................
72-70-04
72-70-09
Breather.
.........................
72-70-04
72-70-10
Fuel
System.
.......................
72-70-05
72-70-11
Governor
Pad
Cover.
....................
72-70-05
72-70-12
Engine
Test.
........................
72-70-06
72-70-13
Starting
Procedure.
....................
72-70-06
72-70-14
Overhaul
Test
Run.
.....................
72-70-07
ix
CHAPTER
72-80
ENGINE
PRESERVATION
72-80-01
General.
..........................
72-80-03
72-80-02
Flyable Storage.
......................
72-80-03
72-80-03
Temporary
Storage.
....................
72-80-04
72-80-04
Indefinite
Storage.
.....................
72-80-05
CHAPTER
73-00
ENGINE
FUEL
SYSTEM
73-10-01
Metered
Fuel
Pressure
Adjustment.
.............
73-00-03
73-10-02
Flushing
Regulator
Needle
Valve.
..............
73-00-04
73-10-03
Idle
Adjustment
Bendix
Stromberg
Carburetor.
........
73-00-04
73-10-04
Fuel
Pump.
........................
73-00-06
CHAPTER
74
IGNITION
(TCM
IGNITON
SYSTEM)
74-00-00
GENERAL.
........................
74-00-03
74-00-01
Magneto
Installation.
....................
74-00-03
74-00-02
Harness
Assembly
Installation.
...............
74-00-04
74-10-00
IGNIION
TROUBLESHOOTING.
..............
74-00-06
(SUCK
IGNITION
SYSTEM)
74-30-00
GENERAL.
........................
74-00-07
74-30-01
Magneto
Installation.
....................
74-00-07
74-30-02
Harness Assembly Maintenance.
...............
74-00-08
74-50-00
IGNITION
TROUBLESHOOTING.
..............
74-00-10
CHAPTER
75
AIR
75-00-00
GENERAL.
........................
75-00-03
CHAPTER
76
ENGINE
CONTROLS
76-00-00
GENERAL.
........................
76-00-03
76-10-00
CRUISE
CONTROL
BY
PERFORMANCE
CURVE...
.. ...
76-00-03
76-20-00
CRUISE
CONTROL
BY
E.G.T............ ......
76-00-03
76-30-00
PERFORMANCE
CHARTS...........
.
.......
76-00-04
CHAPTER
77
ENGINE
INDICATING
77-00-00
GENERAL
.
.........
-
.......
70-03
77-10-00 OPERATING
UMITS.
....................
77-00-04
77-20-00 ENGINE TROUBLESHOOTING
CHART.
...........
77-00-05
CHAPTER
78
EXHAUST
78-00-00
GENERAL.
........................
78-00-02
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