Teledyne 0-470-A User manual
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LATEST PAGES DESTROY SUPERSEDED PAGES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
K(
SECTI
PAG
CHAPTER
79
OIL
79-00-00
GENERAL.
........................
79-00-03
79-10-00
'APPROVED
PRODUCTS.
..................
79-00-03
79-20-00
OIL
SYSTEM
TROUBLESHOOTING
CHART.
.........
79-00-04
CHAPTER
60
STARTING
80-00-00
GENERAL
.
.............
0-00-03
80-00-01
Prestarting.
........................
80-00-03
80-00-02
Starting.
..........................
80-00-03
80-00-03
Ground
Warm-Up,.80.......
......
8-00-04
80-00-04 Pre-takeoff Check.
.....................
80-00-04
80-00-05
Flooded
Engine
.......................
80-00-06
80-00-06
Cold Weather
Operation
...................
80-00-07
80-0-07
Preheating.
........................
80-00-07
80-00-08
Hot
Weather
Operation
..........
800-00-9
80-00-09
Ground
Operating
At
High
Altitude
Airports.
..........
80-00-10
CHAPTER
81
TURBINES
81-00-00
GENERAL.
........................
81-00-02
xi
LIST
OF
1LLUS"TATIONS
FIGURE
NO
.
1-10-04
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(1
0)
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
-20-0
1
(46)
1-20-01(47)
1-20-01
(48)
1-20-01(49)
1
-20-01 (50)
1-20-01(51)
TITLE PAGE
NO
.
Three Quarter Right Rear View of the
0-470
Series
......
1-10-07
InstallationDrawing
....................
1-10-08
Strap Wrench
.......................
1-20-08
Oil Filter Can Cutter
....................
1-20-08
.................
CylinderBase NutWrench
1-20-09
.............
Cylinder Base Nut Wrench Bonanza
1-20-09
.................
CylinderBase NutWrench
1-20-09
....................
PistonPinRemovers
1-20-10
CylinderHone
.......................
1-20-10
Crankshaft Bladeand Dampener BushingRemovers/Replacers
1-20-10
HoldingFiureAdapters
..................
1-20-11
..............
UniversalCylinder HoldingFixture
1-20-11
....................
Valve Guide Cleaner
1-20-12
Seal Seat Cutter
......................
1-20-12
......................
SpringChecker
1-20-12
...................
Valve Guide Removers
1-20-12
Valve Guide Replacers
...................
1-20-1
3
RockerArm BushingRemover InstallerSet
..........
1-20-1
3
.................
PistonRingCompressors
1-20-13
......................
FloatingHolder
1-20-14
Valve SpringCompressor.
.................
1-20-14
...........
PushRod HousingSpringCompressor
1-20-14
...............
FlaringTool PushRodHousing
1-20-14
...................
Valve Guide Remover
1-20-14
Valve Seat InsertRemover/Replacer
.............
1-20-15
Valve Seat Installer
.....................
1-20-15
.....................
Common Parts
Kit
1-20-16
.................
Valve Guideto Seat Aligner
1-20-1
6
..................
Valve Stem HoleReamer
1
-20-17
BoringBars
........................
1-20-17
.........................
Reamers
1-20-17
..................
ExpandingGuideBodies
1-20-17
Valve Seat InsertCutters
..................
1-20-18
@
Rosan Stud Remover
...................
1-20-18
ConnectingRod ReamingandAlignment CheckingFixture
.
.
1-20-19
Adapter
Kits
.......................
1-20-19
.............
Reamers, ConnectingRod Bushing
1-20-1
9
UniversalConnectingRod BushingRemovers
&
InstallerSet
.
.
1-20-20
...............
Common Drive Handle
&
Pilots
1-20-20
..................
NeedleBearingInstallers
1-20-21
HydraulicCrankshaftDampener BushingRemover/Replacer Sets
1-20-21
..........
Countetweight BushingRemover/lnstaller
1-20-21
All PositionEngineStand
..................
1
-20-22
...............
Torque BandTensionAdjuster
1-20-22
Generator DriieHolders
..................
1-20-22
Cylinder HeatingStand
...................
1-20-23
.................
BlindNeedleBearingPuller
1-20-23
.............
Starter Clutch Shaft BearingPullers
1-20-23
DifferentialPressureGage
.................
1-20-24
............
DifferentialPressure Cylinder Checker
1-20-24
BeltTension Gage
.....................
1-20-24
...................
HydraulicLifterTester
1-20-24
FIGURE
NO
.
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)
1-20-01(103)
1-20-01(104)
1-20-01(105)
TITLE
GeneratorTester
.....................
EngineTiming Disc
....................
PulleyHolder
.......................
PulleyAlignment Gauge Bar
................
Crankcase DrillFixturefor Starter ClutchAdapter
.......
Vacuum Pump
......................
...................
Generator PulleyPuller
..............
Bearingand BushingDrillFixture
Spark PlugInsertReplacer
.................
Thru-Bolt BoreStep Cutters
................
Spark PlugInsertTap
...................
.................
Spark PluglnsertRemover
Slide Hammer
.......................
Spark PlugTap
......................
~osan@LockRinginstaller
.................
..................
Stud Drivers
505
Series
................
Scavenge PumpDrillFixture
DrillFixture
........................
...................
CrankcaseSplitterSet
...............
PropellerShaft Oil Seal Installer
...............
Oil PressureRelief Spot Facers
.....................
Runout Block Set
PolishingToolsfor Crankshaft Bearings
8087
Series
......
Injector NozzleRemoverand Installer
............
...............
CrankcaseThru-Bolt Removers
................
Hex Drivefor HexTube Nuts
RotobroachCutter
.....................
..........................
Pullers
..........................
Pullers
..........................
Pullers
..........................
Pullers
....................
Outside Micrometers
DialBoreGages
......................
....................
BladeMicrometers
.............
ScrewThread Micrometers
126,226
DepthMicrometers
....................
Reamers. RockerShaft Support Boss
............
Reamers. RockerArm
&
Shaft Bushing
...........
................
Reamers.Valve Guide Boss
EngineApplication Chart for Valve Guide Stem HoleReamers
.
..................
SquareShank Reamers
Valve Guide Stem Hole PlugGauges
............
DialThicknessGauge
...................
.................
PrecisionVernier Calipers
................
InsideMeasuringInstruments
.............
Alternator.Voltage RegulatorTester
.............
Alternator. Regulator.BatteryTester
...............
MultipleVoltage
&
CircuitTester
...................
MagnetoTiming Light
Timing Indicator
......................
....................
ColdCylinderTester
.....................
Hi-VoltageTester
....................
MasterOrificeTool
...............
Alcor PortableDigitalEGT Unit
...............
AIcor PortableDigitalCHT Unit
PAGE
NO
.
xiii
FIGURE
NO.
70-10-00
70-20-00
70-50-01
70-50-02
70-50-03
70-50-04
72-00-03
72-00-09
72-00-10
72-00-11
72-10-05
72-10-06
72-1
0-07A
72-10-07B
72-1
0-07C
72-10-08
72-10-09A
72-10-09B
72-10-10A
72-10-1OB
72-10-10C
72-10-11A
72-1
0-
1
B
72-10-12
72-10-13A
72-10-1
3B
72-10-1
4A
72-10-14B
72-10-15
72-10-16
72-10-17
72-10-18
72-20-1
2A
72-20-13
72-20-1
4A
72-20-1
4B
72-20-1
4C
72-20-15A
72-20-1
5B
72-20-17
72-20-18
72-20-20
72-20-27
72-30-03
72-30.04
72-30-08
72-30-08
72-30-08
72-30-08
72-30-08
72-40-03
'2-40-08
72-40-07A
& B
2-40-1
3A
2-40-13B
TITLE
Lockwire
Procedure
........
Pernatex
and
Threading
Procedure.
Master
Orifice
Tool
............
Static
&
Dynamic
Seal
...........
Differential Pressure
Tester
.........
Dynamic
Seal
Check
............
Crankshaft
Numbering
...........
Gear
Train
Diagram
............
Lubrication
System
............
Valve Mechanism
.............
Ignition
System
..............
Fuel
Pump
................
Induction
System,
AJ,JK.LR,S,U
.......
Inuction
System,
B,EM...........
Induction
System, G,P
............
Magneto
&
Accessory
Drives
.........
Oil
Sump,
AB,E,J,K.L,M,R,S,U
........
On
Sump,
G.P
................
Oil
Cooler,
A,E,J,K
..............
Oil
Cooler,
G,LP,R,S,U
............
Oil
Cooler,
B,M
...............
Generator,
AB,E,G,J,K,M,P,R
.........
Alternator
Assembly
.............
Starter
Drive
Adapter
.............
Oi
Pump
..................
Oil
Pump
and
Tack
Drive
...........
Cylinder
Assembly (Incline
Valve)
.......
Cylinder
Assembly
(Straight
Valve)
......
Crankcase
Assembly
.
-
Camshaft
Assembly
.............
Crankshaft
Group
..............
Exhaust
System
...............
Crankcase
Stud
Setting
Heights
........
Helical
Coil
Installation
............
Helical
Coil
Installation
(Spark
Plug)
......
Helical
Coil
Expanding
(Spark
Plug)
......
Helical
Coil
Removal
(Spark
Plug)
.......
Cylinder
Assembly Dimension
(Inclined
Valve)-
Cylinder
Assembly
Dimension
(Straight
Valve)
Valve
Rocker
Bushing
Dimensions.
Hydratiic
Lifter
.............
Connecting
Rod
&
Bushing
Dimensions....
Ignition
Wiring
Diagram
...........
Magnetic
Partical
Inspection
.........
Crankshaft Ultrasonic Inspection
Procedure
.
Limits
Chart
(1)...............
Limits
Chart
(2)...............
Limits
Chart
(3)...............
Limits
Chart
(4)...............
Limits
Chart
(5)...............
Counterweight
Bushing
Diameter
Check
....
Piston
to
Cylinder
Dome
Clearance
......
Inspecting
Ring Side Clearance
........
Spark
Plug
Wear
..............
Reverse Spark
Plug
Polarity
.........
PAGE
NO.
70-1
0-01
70-20-01
70-50-01
70-50-02
70-50-03
70-50-05
72-00-08
72-00-11
72-00-13
72-00-14
72-10-05
72-10-06
72-10-07
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
72-10-21
72-10-23
72-10-24
72-10-26
72-10-27
72-10-29
72-10-30
72-10-31
72-10-32
72-20-06
72-20-10
72-20-10
72-20-10
72-20-10
72-20-11
72-20-12
72-20-10
72-20-14
72-20-15
72-20-17
72-30-05
72-30-08
72-30-11
72-30-12
72-30-16
72-30-19
72-30-24
72-40-04
72-40-08
72-40-06
72-40-08
72-40-08
. . . .
....
. . . . . .
. . . . . .
. . . . . .
......
. . . . . .
. . . . . .
FIGURE
TITLE
PAGE
NO.
72-50-04
Valve Spring
Installation.
.................
72-50-06
72-60-02A
Alignment
of Timing
Marks.
................
72-60-04
72-60-028
Torquing
Sequence.
...................
72-60-05
72-60-03A
Installing
No.
6
Cylinder.
.................
72-60-06
72-60-03B Tightenting
Cylinder
Base
Nut.
...............
72-60-06
72-60-03C
Cylinder
Flange
Torque Sequence.
.............
72-60-07
72-60-04
Oi
Pump
Cover
Threading
Procedure.
...........
72-60-07
72-60-14
Position
of
Magneto
Couplings
...............
72-60-12
72-60-17
Ignition
Wiring
Diagram.
.................
72-60-1
5
72-70-05
Exhaust
Flange
Dimensions.
...............
72-70-05
72-70-10
Three-Quarter Right Front
View of
Stromberg
PSD-5C
Carburetor.
..................
72-70-06
.73-00-00
Three-Quarter
Left
Rear
View
of
Stromberg
PSD-5C
Carburetor.
..................
73-00-06
74-00-04
Coating
Insulating
Sleeve.
.................
74-00-04
74-00-04
Installation
of Elbow Clamp.
................
74-00-04
Xv
LIST
OF
CHARTS
FIGURE
NO.
1-10-04
1-20-01
1-20-01
1-20-01
1-30-00
70-50-05
72-20-1
2A
72-20-1
2B
72-20-13
72-30-03
72-30-08
72-30-08
72-30-08
72-30-08
72-30-08
72-30-09
72-40-15
72-50-01A
72-50-01
B
72-50-01
C
72-60-02B
72-60-15
72-70-1
4A
72-70-1
4B
72-70-1
4C
73-10-05
74-00-04C
74-20-00
74-30-04
74-50-00
76-00-04
77-20-00
79-20-00
TITLE
PAGE
NO.
Engine
Dimensions
............
Special
Tools
Procurement
Sources
.....
Identification
Code for
Tools
........
Special
Tool
Index
.............
Products
..............
Cylinder
Leakage
Check
.......
Standard
&
Oversize
Stud
Identification
Crankcase
Stud Setting
Heights
.......
Helical
Coil
&
Special
Tool
Data
.......
Magnetic
Particle
Inspection
........
Table
of
Lmits
(Chart1)
..........
Table
of
Limits
(Chart
2)..........
Table
of
Limits
(Chart
3)..........
Table
of
Limits
(Chart
4)..........
Table
of
Limits
(Chart
5)..........
Critical New
Part
Dimensions
........
Inspection
Chart
.............
General
Use
-
Tightening
Torques
.....
Table
of
Tightening
Torques
........
Pipe
Plugs
................
Crankcase
Assembly
Procedure
......
Magneto Timing
..............
Overhaul
Test
Run
Standard Acceptance
Test
Oil
Consumption
Determination.
.
.
Overhaul Test
Run
.........
Fuel
System
Troubleshooting
Charts,
Coupling
Nut
Torque
Values
.
Ignition
Troubleshooting
......
Coupling
Nut
Torque
Values
.
-
Ignition
Troubleshooting
......
Performance
Charts
........
Engine
Troubleshooting
Chart...
Oil
System Troubleshooting
Chart.
1-10-08
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
72-20-09
72-30-05
72-30-11
72-30-13,14,15.
72-30-17,18
72-30-20,21
72-30-22,23
72-30-25,26
72-40-09
thru17
72-50-03
72-50-04
72-50-04
72-60-05
72-60-13
72-70-08
72-70-09
72-70-10
73-10-7,8,9
74-00-05
74-00-06
74-00-09
74-00-10
76-00-05
thru
26
77-00-07
thru
12
79-00-04
~Vi
. . . . . .
. . . . . .
. . . . . .
. . . . . .
. . . . . .
. . . . . .
CHAPTER
1
INTRODUCTION
1-00-00 SCOPE
1-00-01 Related Publications
1-00-02 Service Bulletins
1-00-03 Service ReportsAnd Inquiries
1-00-04 100%Replacement Parts
1-10-00 DEFINITIONS
&
ABBREVIATIONS
1-10-01 Abbreviations
/
Symbols
1-10-02 Definitions
1-10-03 Description
Of
EngineModelCode
1-10-04 Basic Design Features
1-20-00 TOOLS
1-20-01 SpecialTools
1-30-00 PRODUCTS
1-30-01 ProductList
INTENTIONALLY
LEFT
BLANK
1-00.00 SCOPE
Recommendations, cautions and warnings regarding overhaul of this engine are not intended to
impose undue restrictions. They are insetted to obtain maximum performance from the engine
in accordance with safety and efficiency. Abuse, misuse, or neglect of any piece of equipment
can cause eventual failure. For an aircraft engine
it
is obvious that a failure may have
disastrous consequences. Failure to observe the instructions, contained in this manual, consti-
tutes unauthorized operation in areas unexplored during development of the engine, or in areas
inwhich experience has provedto be undesirableor detrimental.
NOTES,
CAUTIONS
and
WARNINGS
are included throughout this manual. Application is as
follows:
NOTE
...
Specialinterest informationwhich mayfacilitatethe operationof equipment.
GlUTION
.
.
.
Information issued to emphasize certaiit instructions or to prevent possible
damage toengine oraccessories.
WARNING
.
.
.
Information which, if disregarded, may result in severe damage to or
destruction of the engineor endangermentto personnel.
1-00-01
RELATED
PUBLICATIONS
A. EngineManuals:
1. Maintenanceand OverhaulManualfor 0-470Series Aircraft Engine, FormX30586A.
2.
IllustratedPartsCatalogfor 0-470SeriesAircraft Engine, FormX30587A.
3. TeledyneContinental MotorsAircraft EngineServiceBulletins.
4. FuelInjectionManual, FormX30593A.
The above publications can be ordered through your Teledyne Continental Motors Distributor
or ordereddirectly,
if
prepaid, from:
TeledyneContinentat Motors
Aircraft ProductsDivision
P.
0.
Box
90
Mobile,Alabama36601
ATTN: Accounts Receivable
B. Accessory Manuals:
1.
IgnitionSystem Master ServiceManual
TCM IgnitionSystems andComponents
FormX40000
TeledyneContinentalMotors
Aircraft ProductsDivision
P.O. Box
90
Mobile, Alabama 36601
ATTN: PublicationsDept.
ServiceManual
SlickElectrolnc.
530 BlackhawkParkAvenue
Rockford, Illinois
61
100
2. Alternator
3. Starter
Alternator ServiceInstructions
FormX30531-2
Teledyne ContinentalMotors
Aircraft ProductsDivision
P.
0.
Box
90
Mobile, Alabama 36601
Attn: PublicationsDepartment
TeledyneContinentalMotors
Aircraft Products Division
P.
0.
Box
90
Mobile,Alabama 36601
Attn: PublicationsDepartment
1-00-02
BULLETINS. Bulletins that are issued to Distributors and subscribers from Teledyne Continen-
tal Motors are divided into three separate groups: (1) Customer lnformation Bulletins;
(2)
ServiceBulletins, and (3) MandatoryService Bulletins.
(1) Customer lnformation Bulletins are published to help provide the latest information on
TCM marketingprocedures,policiesand productinformation.
(2) Service Bulletins provide current information related to service, maintenance and technical
support of the product.
(3) Mandatory Service Bulletins are issued with required compliance information that may
affectsafetyof flight.
These bulletins are also available to owners, operations or maintenance personnel on an annual
subscription basis.
NOTE:TeledyneContinentalBulletinsare easilydistinguished bytheirtitle color:
(1) Customer lnformationBulletins
-
Blue;
(2) Service Bulletins
-
Black;
(3) MandatoryService Bulletins
-
Red.
1-00-03
SERVICE REPORTS AND INQUIRIES. If for any reason you have an inquiry or require
technical assistance beyond the scope of your service facility, contact your local TCM
distributor or TCM field representative. Requests for copies of Teledyne Continental Aircraft
Engine Service publications should
be
made through your distributor or Teledyne Continental
Motors,
P.
0.
Box
90,
Mobile,AL 36601, Attn: Publications Department.
1-00-04 100%
REPLACEMENTPARTS.
It is recommended that the following parts be replaced 100 percent during the major overhaul
of anyTeledyneContinentalMotors'aircraftengineregardlessof their condition.
HydraulicLifters All 10-346,lO-360,LTSIO/
TSIO-360,0-4?0,10-4?0,
TSIO-470,G10-4?0,10-520,
GTSIO-520, TSIO-520,lO-550and
6-285
Models
CrankshaftGear and Valve Springs GTSIO-520 Models
All rubbergoods diaphragms, 0-Rings
Gaskets Packings,Hosesand Seals All Models
Circlips, Lock Plates
&
RetainingRings All Models
PistonRings All Models
Valve Keepers All Models
This manual suits for next models
12
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