Teledyne TSIO-360 Series User manual

OVERHAUL MANUAL
MODELS TSIO-360-A,AB
-B,BB
-C,CB
-D,DB
-E,EB
-F,FB
-GB
-H,HB
-JB
K, KB
-LB
-MB
-SB
FORM NO. X30596A
O 1997 TELEDVNE INDUSTRIES, INC.
FAAAPPROVED
OCTOBER 1997

CURRENT STATUS OF PAGES AS OF:
OCTOBER
1997
See "Manual Revisions," inrthe introductionsection for distributionprocedure.
THE ORIGINAL DATE
OF THIS PUBLICATION IS NOVEMBER 9988. INSERT LATEST PAGES;
DESTROY SUPERSEDEDPAGES.
WRNING
If the user of this manual is uncertain whether all current revisions have been
incorporated into the manual, contact Teledyne Continental Motors. Do not
perform any operation, maintenance, installation or other operation until the
manual is confirmed current.
1997 are for the
ii REVISED OCT 97

(Pleasenotethe followingstatementsfrom FAA Advisory Circular 20-62C entitled"ELIGIBILITY, QUALITY, AND IDENTIFICATION
OF APPROVED REPLACEMENT PARTS"):
3.
BACKGROUND. An increasingamountof replacement parts(includingstandardparts),materials,
appliances,and instrumentsare offered for sale as being of aircraft qualitywhen actuallythe quality and
originof theseunitsareunknown.Usersof suchunitsareusuallynotawareofthepotentialhazardsinvolved
with replacement parts that are not eligible for use on certificated aircraft. Frequently such units are
deceptively advertised or presentedas "unused," "likenew," or "remanufactured!' This impliesthat the
qualityof such units is equal to an originalor appropriatelyrepairedor overhauledunit.
The performancerulesfor replacementof parts and materials used inthe maintenance and alteration of
U.S. certificatedaircraft are specified inFederalAviation Regulations (FAR) 43.13 and FAR 145.57. The
responsibilityforthecontinuedairworthinessoftheaircraft,whichincludesthereplacementof parts, isthe
responsibility of the ownerioperatoras outlined inFAR 91.163, FAR 121.363, FAR 123.45, FAR 127.131
and FAR 135.143 (a).
4.
I DENTIFICATIONOFTHEAPPROVED PARTS. Approved serviceablereplacement
partsare identifiedas 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. Byan FAATechnicalStandardOrder 0)numberand identificationmarkthat indicatesthe part or
appliancehas been manufactured under the requirementsof FAR 37.
c. Byan FWPMAsymbol,togetherwiththe manufacturer'sname,trademark or symbol, partnumber,
andthe make and modelof the type certificatedproduct on which the part iseligiblefor installation,
stamped on the part. An FAA Parts ManufacturerApproval (FWPMA) is issued under FAR 21.305.
The makeand model informationmay beon atag attachedtothe part.
d. Byshippingticket, invoice, or other documentwhich providesevidencethat the partwas produced
bya manufacturer holdingan FAA Approved ProductionInspectionSystem issued utlder FAA 21,
SubpartF, orbyamanufacturerholdingan FAA ProductionCertificateissuedunderFAA 21, Subpart
G.
e. By a certificate of airworthiness for export issued bya foreigngovernment underthe provisionsof
FAR 21, Subpart
N.
I I.
KNOW YOUR SUPPLIER. It has come to our attention that many reproduced parts and
components, particularly instrumentswhich have been manufactured by persons other than the original
manufacturer,areavailablefor purchaseand installationon U.S. certificatedaircraft. Often, an originalpart
isusedas asampleto produceduplicates. The reproducedpartsappeartobeas goodasthe originalpart;
however, there are many unknown factors to be considered that may not be readily apparent to the
purchaser,i.e., heattreating, plating,inspections,tests and calibrations.All too oftenthefaulty part is not
discovered until
a malfunctionor an accident occurs.
I 2. SUM MARY. inaccordancewithFAR'S, certificationofmaterials, parts,andappliancesforreturn
to service, for useonaircraft,
is the responsibilityof the personor agencywho signstheapproval.
The ownerloperator, as denoted inparagraph
3 of this advisorycircular, is responsiblefor the continued
airworthinessof theaircraft.To assurecontinuedsafety inaircraft operation,
it isessential that great care
be usedwhen inspecting, testing, and determiningthe acceptabilityof all parts and materials. Particular
cautionshould be exercised when the identityof materials, parts, and appliances cannot be established
or whentheir originis indoubt.

OVERHAUL FOR
TSIO-360 SERIES
AIRCRAFT ENGINE
- 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
manufacturerof responsibilityunder itswarranty.
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 asTeledyneContinentalMotors'TSIO-360
- Series PartsCatalogX30597A.
CHAPTER
I - 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
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 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" isforthe "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:
- Chader - - Section - - Subsection -
"EngineF3eciprocating" "Disassembly" "Oil PumpAssembly"
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 maysuggest.

SECTION
TABLE OFCONTENTS
PAGE
. NOTE ... Thefollowing Sectionand GridNumbersare located on Fiche 1 of 2
...............
ii Current Statusof Pages ii
......................
iii Warning iii
iv Notice ....................... iv
v Introduction .................... v
..................
vi Table of Contents vi
.................
xii List of lllustrations xii
xvi List of Charts .................... xvi
CHAPTER f INTRODUCTION
1-00M) SCOPE
1-00-01 Related Publications ................ 1-00-03
1-00-02 ServiceBulletins .................. 1-00-04
1-00-03 ServiceReportsand Inquiries ............ 1-00-04
1-00-04 100% ReplacementParts .............. 1-00-05
1-10-00 DEFINITIONS & ABBREVIATIONS
1-1
0-01 Abbreviations / Symbols .............. 1-10-01
1-10-02 Definitions ..................... 1-10-02
1-1
0-03 Descriptionof Engine ModelCode .......... 1-10-06
1-10-04 Basic DesignFeatures
............... 1-10-07
1-20-00 TOOLS
1
-20-01 SpecialTools ................... 1-20-01
1-30-00 PRODUCTS
1-30-01 ProductList ......
CHAPTER 4 AIRWORTHINESS LIMITATIONS
4-00-00 Airworthiness Limitations .............. 4-00-01
CHAPTER 5 TlME LIMITS/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 PreflightInspection ................. 5-20-01
5-20-02 50 Hour Inspection ................. 5-20-01
5-20-03 100 HourInspection ................ 5-20-02
5-50-00 UNSCHEDULED MAINTENANCE .......... 5-50-01
CHAPTER 70 STANDARD PRACTICES
70-00-00 GENERAL
..................... 70-00-02
70-10-00 LOCKWIRE PROCEDURE .............. 70-00-03
70-20-00 CRANKCASETHREADINGPROCEDURE ....... 70-00-04
70-30-00 APPLICATIONOFADHESIVES ........... 70-00-05
70-40-00 INSTALMTIONOFGASKETS ............ 70-00-05
70-50-00 CYLINDER LEAKAGECHECK ............ 70-00-05
vi March 1989

SECTION AEROflCHE
GRID NO .
Leakagechecks ................... 70-00-07
Equipment ..................... 70-00-07
PerformingThe Check ............... 70-00-08
CHAPTER 72-00 ENGINE RECIPROCATING
..................... GENERAL
Introduction
....................
Crankcase .....................
..................... Crankshaft
.................. ConnectingRods
..................... Camshaft
Pistons
......................
....................... Liers
..................... Cylinders
..................... GearTrain
LubricationSystem
.................
Valve Mechanism ..................
InductionSystem ..................
ExhaustSystem ..................
IgnitionSystem ...................
CHAPTER 72-10 DISASSEMBLY
General
...................... 72-10-03
Extentof Disassembly
................ 72-10-04
Partsto
be Discarded ................ 72-10-04
PreliminaryCleaning
................. 72-60-04
IgnitionSystem .................. 72-10-04
FuelInjectionSystem
............. .72.1 0-06thru08
Accessory Case
.................. 72-10-10
InductionSystem
............... 72-10-12thru 22
OilSump ..................... 72-10-24
OilCooler
..................... 72-10-25
Alternator Assembly
................ 72-10-26
Starterand StarterDriveAdapter
........ 72-10-28thru32
Oil PumpAssembly
................. 72-10-34
Cylindersand Pistons ............. 72-10-37thru39
Crankcase
..................... 72-10-40
CamshaftAssembly
................. 92-10-42
Crankshaft Group
................. 72-10-42
Exhaust System ............... .72.1 0.44 thru51
CHAPTER
72-20 CLEANING. REPAIR AND REPUCEMENT
.................. General
Cylinders
.................
.................. Pistons
Valves
...................
RockerShafts ...............
Pushrods.Valve Rockersand Small Steel Pasts
..........
Camshaftand Crankshaft
Crankcase
.................
March 1989 Vii

AEROFICHE
GRID NO .
Gears .......................
........
Sheet MetalPartsand IntakeManifold
...................... Castings
Stud Replacement
.................
............
HelicalCoil InsertInstallation
.........
Spark PlugHole HelicalCoil Inserts
.................... FinRepairs
Valve Guides
....................
...................
Valve Rockers
HydraulicValve tiers
...............
.................. ConnectingRods
...........
PistonPinBushingReplacement
CrankshaftAssembly
................
MagnetoGear SupportShaft ............
........
Magnetoand Alternator DriveCoupling
.............
Tachometer DriveHousing
................ Starter DriveAdapter
Oil PumpAssembly
.................
IgnitionCables ...................
CHAPTER 72-30 INSPECTION
General
...................... 72-30-03
Visual Inspection .................. 72-30-04
Magnetic ParticleInspection ............. 72-30-05
Crankshaft UltrasonicInspection ........... 72-30-06
FlourescentParticleInspection ........... 72-30-08
DimensionalInspection ............... 72-30-08
DimensionalLimits ................. 7230-08
TaMe of Limits ................ 72-30-09thru 16
CriticalNew Part Dimension
............ .7230.1 7-18
ProtectiveCoating
................. 72-30-18
Applicationof Alodizing ............... 72-30-18
Repairof Alodized Surfaces ............. 72-30-18
EnamelCoatings
.................. 72-30-1 9
CHAPTER 72-40 SPECIFIC lNSPECTlONS
.....................
Crankcase
..................... Crankshaft
Crankshaftand Counterweight Pins and Bushings
...
.....................
Camshaft
.................. ConnectingRods
Gears
.......................
................. Pistonsand Rings
Cylinders
.....................
HydraulicValve tiers ...............
IntakeTubes ....................
.................
LubricationSystem
................ FuelInjectionSystem
viii March 1989

SECTION
AERORC1-1E
GRID NO .
...................
IgnitionSystem 72-40-07
..................
Exhaust System 72-40-09
...............
InspectionChart 724-11thru 19
CHAPTER 72-50 ASSEMBLY OF SUBASSEMBLIES
......................
General 72-50-03
.................
Oil PumpAssembly 72-50-05
.............
Starterand StarterAdapter 72-50-06
.................
CylinderAssembly 72-50-07
.............
Pistonand RingAssemblies 72-50-07
..................
PushrodHousing 72-50-07
Crankshaftand Connecting Rods .......... 72-50-08
.....................
Camshaft 72-50-08
.....................
Crankcase 72-50-08
FuelInjection.Air Throttle and Metering
.................
Assembly 72-50-09thru 13
CHAPTER 72-60 FINALASSEMBLY
General ...................... 72-60-03
Crankcase ..................... 72-60-03
Cylindersand Pistons ................ 72-60-08
Accessory Case .................. 72-60-09
FuelPump ..................... 72-60-10
Starter DriveAdapter ................ 72-60-10
Alternator Assembly ................ 72-60-10
OilCoder
..................... 72-60-1 1
Valve Mechanism .................. 72-60-11
IntercylinderAir Baffles
............... 72-60-11
OilSump
..................... 72-60-13
InductionSystem ............... 7240-1 3 thru 15
FuetlnjectionSystem ................ 72-60-15
IgnitionSystem .................. 72-60-15
ExhaustSystems
.................. 72-60-17
CHAPTER 72-70 TESTINGAFTER OVERHAUL
.....................
Test Stand 72-70-03
.....................
Test Club 72-70-03
.................
CoolingAir Scoop 72-70-03
.................
InductionAir Intake 72-70-03
..................
ExhaustSystem 72-70-03
......................
Controls 72-70-03
..................
ElectricalWiring 72-70-03
....................
Instruments 72-70-03
......................
Breather 72-70-04
....................
FuelSystem 92-70-04
................
GovernorPadCover 72-70-04
....................
EngineTest 72-70-04
.................
StartingProcedure 72-7064
..............
OverhaulTest Run 72-70-06thru09
.....................
Test Flight 72-70-10
March 1989 ix

AEROFICHE
GRID NO .
CHAPTER72-80 ENGINEPRESERVATION
General
...................... 72-80-03
FlyableStorage .................. 72-80-03
TemporaryStorage ................. 72-80-04
IndefiniteStorage .................. 72-80-05
NOTE . .. The following Section and GridNumbersare locatedon Fiche2 of 2 .
CHAPTER 73-00 ENGINEFUELSYSTEM
EngineFuelSystems
................ 73-00-03
Set-UpProcedure ................. 7340-04
TurbochargedEngines ............... 73-00-04
SpecialSet-UpProcedures ............. 73-00-06
..... FuelSystem Pressureand FlowValve Charts 73-00-07
FuelSystemTroubleshootingChart ........ 73-0048-09
CHAPTER 74IGNITION
(TCMIGNITIONSYSTEM)
GENERAL
..................... 74-00-02
MagnetoInstallation ................ 7440-02
HarnessAssembly Installation ............ 7440-03
(SLICK IGNITIONSYSTEM)
.....................
GENERAL 74-00-05
MagnetoInstallation ................ 74-00-05
HarnessAssembly Maintenance ........... 74-00-06
IGNITIONTROUBLESHOOTING ........... 74-00-08
CHAPTER 75 AIR
..................... GENERAL 7575-00-03
CHAPTER76ENGINECONTROLS
GENERAL
..................... 76-00-03
... CRUISECONTROL BY PERFORMANCECURVE 76-00-03
CRUISE CONTROL BY E.G.T. ............
76-00-03
PERFORMANCECHARTS .............. 7640-05
CHAPTER 77 ENGINEINDICATING
GENERAL
..................... 7740-03
OPERATING LIMITS ................ 7740-04
ENGINETROUBESHOOTINGCHART ..... 77-0 0-06thru 11
X March 1989

SECTION PAGE AEROFICHE
GRID NO .
CHAPTER 78 EXHAUST
GENERAL
.....................
ExhaustSystem ..................
ExhaustSystemTroubleshootingChart ........
CHAPTER 79 OIL
GENERAL .....................
APPROVED OILPRODUCTS ............
LUBRICATING SYSTEM TROUBLESHOOTINGCHART .
CHAPTER 80 STARTING
.....................
GENERAL
.....................
Prestarting
Starting
......................
.................
GroundWarm-Up
Pre-takeoffCheck
.................
FloodedEngine ..................
...............
CddWeather Operation
.....................
Preheating
HotWeather Operation
...............
GroundOperatingAt HighAltitude Airports ......
CHAPTER 81 TURBINES
.....................
GENERAL
TURBOCHARGER
.................
WASTEGATES ...................
CONTROLLERS ..................
LUBRICATIONSYSTEM ...............
TROUBLESHOOTING CHART ............
March 1989 )<i

LIST OF ILLUSTRATIONS
FIGURE NO . TPTLE PAGE AEROFICHE
GRID NO .
NOTE ... The following Figureand Grid Numbersare locatedonFiche 1 of 2 .
Three Quarter Right FrontView of the TS10-360
Series Engine ...................
Three Quarter Left Rear View of theTSIO-360
Series Engine ...................
InstallationDrawingTSIO-360Series Engine. ......
StrapWrench ....................
Oil FilterCan Cutter ..................
Cylinder Base NutWrenches .............
Cylinder Base Nut. Wrench ..............
Piston PinRemovers8121 Series ............
Cylinder Hone ....................
HoldingFixtureAdapters ...............
UniversalCylinder HoldingFixture ...........
Valve Guide Cleaner 122 ...............
Seal Seat Cutter ...................
SpringChecker ....................
Valve Guide Removers ................
Valve Guide Replacers ................
RockerArm BushingRemover/lnstaller Set .......
PistonRing Compressors ...............
Piston RingCompressors ...............
FloatingHolder ....................
Valve SpringCompressor ...............
PushRod SpringCompressor .............
FlaringToolfor PushRodHousing ...........
Valve Guide Remover .................
Valve Seat InsertRemoverand Replacer ........
InstallerValve Seat inserts ...............
Valve Guideto Valve Seat Alignment System ......
Valve Stem Hole Reamers ...............
BoringBars .....................
BoringBars .....................
ExpandingGuide Bodies ...............
Valve Seat Insert Cutters ...............
Step Side Cutters ...................
RosanStud Remover .................
ConnectingRod ReamingandAlignment Checking
Fiure ......................
Adapter Kiis .....................
Reamers. ConnectingRodBushing ...........
UniversalConnectingRodBushingRemoverand
InstallerSet
....................
CommonDriveHandleand Pilots ...........
................ NeedleBearinginstaller
HydraulicCrankshaft DampenerBushing
Remover/Replacer Set ...............
CounterWeight BushingRemover/lnstaller .......
All PositionEngineStand ...............
89
Bll
820
B20
821
821
821
821
822
822
823
B23
B23
B23
B24
B24
824
B24
C1
C1
C1
C1
C1
C2
C2
C3
C4
C4
C4
C4
C5
C5
C5
xii March 1989

FIGURE NO .
TITLE
Torque BandTensionAdjuster
...............................................
GeneratorDrive Holders ........................................................
Cylinder HeatingStand ..........................................................
StarterClutchShaft BearingPullers ......................................
Differential Pressure Gauge ...................................................
Differential Pressure Cylinder Checker ..................................
Belt Tension Gauge ................................................................
HydraulicValve Lifter Tester ..................................................
InAircraft Alternator GeneratorTester ...................................
EngineTiming Disc ................................................................
Pulley Holder .........................................................................
PulleyAlignment Gage Bar ....................................................
Vacuum Pump ........................................................................
GeneratorPulleyPuller ..........................................................
Spark Plug InsertReplacer ....................................................
Thru-Bolt BoreStep Cutters ...................................................
Spark Plug InsertTap .............................................................
Spark Plug Insert Remover ....................................................
Slide Hammer .........................................................................
Spark PlugTap .......................................................................
RosanLock Ring Installer ......................................................
Stud Drivers ............................................................................
CrankcaseSplitter Set ............................................................
PropellerShaft Oil Seal Installer ............................................
Oil PressureRelief Spot Facers ...........................................
Runout BlockSet ....................................................................
PolishingTools for Crankshaft Bearings ................................
InjectorNozzleRemover and Installer ..................................
CrankcaseThru-Boit Removers .............................................
Hex DriveFor HexTube Nuts ................................................
RotabroachCutters ................................................................
Pullers .....................................................................................
Pullers .....................................................................................
Pullers .....................................................................................
Pullers ......................... .. .......................................................
OutsideMicrometers ..............................................................
Dial BoreGauges ...................................................................
BladeMicrometers ...................................... .. .........................
ScrewThread Micrometer ......................................................
DepthMicrometers .................................................................
Reamers, RockerShaftSupport Boss ...................................
Reamers,Valve Guide Boss ..................................................
Valve GuideStem HoleReamers .........................................
Adapter, SquareShank Reamers ..........................................
Plug GaugesValve Stem Hole ...............................................
DialThicknessGauge .........................................................
PrecisionVernier Calipers ......................................................
Inside Measuring Instruments ..............................................
AlternatorAnalyzer ................................................................
PAGE
1-20-21
1-20-21
1-20-22
1-20-22
1-20-22
1-20-23
1-20-23
1-20-23
1-20-24
1-20-24
1-20-24
1-20-24
1-20-25
1-20-25
1-20-25
1-20-25
1-20-25
1-20-26
1-20-26
1-20-26
1-20-26
1-20-26
1-20-26
1-20-27
1-20-27
1-20-27
1-20-27
1-20-28
1-20-28
1-20-28
1-20-28
1-20-29
1-20-29
1-20-29
1-20-29
1-20-30
1-20-30
1-20-31
1-20-3
1
1-20-31
1-20-32
1-20-32
1-20-33
1-20-33
1-20-33
1-20-34
1-20-34
1-20-34
1-20-35
AEROFICHE
GRID NO .
C9
REVISED MAR 89 xiii

FIGURE NO .
TITLE
Alternator/Regulator/Battery Tester .......................................
MultipleVoltage & Circuit Tester ............................................
Aircraft MagnetoTiming Llght ................................................
AircraR Timing Indicator .........................................................
Cold CylinderTester ..............................................................
Hi-VdtageCable Tester ..........................................................
MasterOrHiceTod .................................................................
Alcor Portable Digital EGT Unit ..............................................
Alcor PortableDlgitalCHT Unit ..............................................
Lockwire Procedure ...............................................................
Permatex,ThreadingProcedure 8 Gasket Maker ..................
MasterOrificeAssembly Tool ................................................
Cylinder Static Seal & DynamicSeal .....................................
DifferentialPressureTester ...................................................
DynamicSeal Check ..............................................................
CrankshaftNumbering ...........................................................
Gear Train Diagram ................................................................
LubricationSystem .................................................................
Hydraulic Lifter .......................................................................
Wiring Diagram(Hamess) ......................................................
........................................... PressurizedMagneto Installation
.......................................... ExplodedView of IgnitionSystem
Fuel InjectionSystem
.............................................................
Fuel InjectionSystem, TSIO-360-MB,SB ...............................
Accessory Case .....................................................................
InductionSystem ....................................................................
InductionSystem, TSIO-360-C,CB.D,DB ...............................
InductionSystem, TSIO-360-E,EB,F,FB, LTSIO-E,EB ..........
InductionSystem, TSIO-360-GB.LB .......................................
InductionSystem, LTSIO-KB .................................................
InductionSystem, TSIO-360-MB,SB ......................................
OilSump .................................................................................
Oil Cooler ...............................................................................
Alternator Assembly ...............................................................
Starter andStarter DriveAdapter,
TSIO-360-A.AB,D,DB,OP. LB ..............................................
Starter andStarter DriveAdapter,
TSIO-360-B,BB.C,CB,H,HB, JB ..........................................
Starter andStarter DriveAdapter,
TSIO-360-E,EB,F,FB,GB,KB,MB, SB LTSIO-E,EB,KB .......
Oil PumpAssembly ................................................................
IntercylinderAir Baffles,
................ TSIOILTSIO-360-D,DB,F.FB,GB,KB,LB,MB, SB
Cylinder and PistonAssembly
...............................................
CrankcaseAssembly .............................................................
CamshaftAssembly ...............................................................
CrankshaftGroup ...................................................................
................... ExhaustAssembly LTSIOTTSIO-360-E,EB & KB
ExhaustAssemblyTSIO-360-F,FB
........................................
ExhaustAssemblyTSIO-360-GB & LB ..................................
ExhaustAssembly TSIO-360-MB & SB .................................
Crankcaseand Accessory CaseStud Setting Heights ..........
PAGE
10-20-35
10-20-35
10-20-36
10-20-36
10-20-36
10-20-37
10-20-37
10-20-38
10-20-38
70-00-03
70-00-04
70-00-05
70-00-06
70-00-08
70-00-10
72-00-07
72-00-10
72-00-1
2
72-00-13
72-00-15
72-00-15
72-10-05
72-10-07
72-10-09
72-10-11
72-10-13
72-10-1
5
72-10-17
72-10-1
9
72-10-21
72-10-23
72-10-24
72-10-25
72-1
0-26
72-10-29
72-10-31
72-10-33
72-10-35
72-10-37
72-10-38
72-10-41
72-10-42
72-10-43
72-10-45
72-10-47
72-10-49
72-10-50
72-20-06
AEROFICHE
GRID NO .
C23
xiv REVISED OCT 97

FIGURE NO .
NOTE .
TITLE
Standard & OversizedStud Identification .........
PryingSpark PlugHelical Coilfrom Cylinder .......
RemovingSpark Plug HoleHelical Insert .........
InstallingSpark PlugHole Helical Insert .........
ExpandingSpark PlugHoleHelical Insert ........
CylinderAssembly Dimensions .............
Valve. Rocker BushingDimensions ...........
HydraulicLifter ....................
ConnectingRodand BushingDimensions ........
................ IgnitionWiring Diagram
...............
lntakeValve Seat Refacing
.............. ExhaustValve Seat Refacing
................. IntakeValve Refacing
CrankshaftUltrasonicInspectingProcedure .......
CountetweightBushing DiameterCheck .........
InspectionRingSideClearance .............
MeasuringRingGap inCylinder .............
Spark Plugs ......................
ReverseSpark PlugProcedure .............
.................. SlipJoint Assembly
............. Multi-Segment "V" Bank Clamp
FuelManifold Valve Fitting Orientation
..........
Air Throttleand MeteringAssembly Fitting
..................... Orientation
Fuel Pump FittingLocations
..............
FittingOrientation.Air Throttle and MeteringUnit
....................
TSIO-360-ME3
LeftSide of Crankcaseon Stand ............
Alignment of Timing Marks ...............
RightCrankcaseand Support ..............
.................. TorquingSequence
InstallationNo . 6 Cylinder. ...............
TighteningCylinder Base Nut ..............
Cylinder FlangeTorque Sequencefor SingleCylinder
Installation
.....................
TorquingThruBolts ..................
............... InstallingPushrodHousing
BottomView. Valve Mechanism
.............
.................. Coupling DriveLugs
.................... Wiring Diagram
PAGE AEROflCHE
.
GRID NO .
72-20-09 HI7
72-20-09 HI9
72-20-09 HI9
72-20-09 HI9
72-20-09 HI9
72-20-10 H20
72-20-09 HI9
72-20-12 H22
72-20-13 H23
72-20-15
72-20-16
92-20-16
72-20-1
7
72-30-08
I1 I
110
72-40-04 $2
72-40-05 J3
72-40-05 J3
72-40-08 J6
72-40-08 J6
72-40-10 J8
72-40-10 J8
72-50-10 K4
. . The following Figureand Grid Numbersare located onFiche 2 of 2 .
FuelSystem Diagram ................. 73-00-03
Wastegate ...................... 73-00-06
CoatingInsulatingSleeve ................ 94-00-03
Installationof ElbowClamp ............... 74-00-03
BasicTurbochargerSystem .............. 81-00-02
BasicTurbocharger .................. 81-00-03
FixedOrifice ..................... 81-00-04
HydraulicWastegate .................. 81-00-05
Variable Absolute PressureController
.......... 81-00-06
ThrottleConnection .................. 81-00-06
Turbocharger LubricationSystem ............ 81-00-07
A4
A7
A15
A15
H7
H8
H9
H10
Hll
HI1
h12
DECEMBER 1992 XV

FIGURE NO .
LISTOF CHARTS
PAGE AEROflCHE
GRID NO .
NOTE ... The following Figureand Grid Numbersare locatedon Fiche 1 of 2 .
Engine Dimensions ..................
1-10-11
SpecialTools ProcurementSources
..........
1-20-02
IdentificationCodefor Tools ..............
1-20-03
SpecialTool Index .................. 1-20-04
Application Chart Sealants/Lubricants ......... 1-30-01
CylinderLeakageCheck ............... 70-00-11
CrankcaseAnd AccessoryCase Stud SettingHeights
. . 72-20-06
Standardand Oversize Stud Identification ........ 72-20-07
MiscellaneousStud SettingHeights .......... 72-20-07
Magnetic ParticleInspection .............. 72-30-05
Table of LimitsChart (1) ................ 72-30-09
Table of Limits Chart (2) ............... .72.30.10. 11
Table of LimitsChart (3)
............... .7230.12. 13
Table of LimitsChart (4)
................ 72-30-14
Table of LimitsChart (5A)
............... 72-30-15
Table of LimitsChart (5B)
............... 72-30-16
CriticalNew Part Dimensions
............ .72.30.17. 18
InspectionChart
................... 72-40-11
GeneralUse
. TighteningTorques ........... 72-50-03
Tableof TighteningTorques .............. 72-50-04
PipePlugs ...................... 72-50-05
Hydraulic LineFittings ................ 72-50-05
FuelManifoldValve FittingLocations .......... 72-50-10
Air Throttleand MeteringAssembly Fitting
Orientation
.................... 72-50-1 1
FuelPumpFiingLocations .............. 72-50-12
StandardAcceptanceTest
.............. 72-70-06
Oil ConsumptionDetermination ............ 72-70-07
Test OperatingLimits ................. 72-70-08
NOTE ... Thefollowing Figureand Grid Numbersare locatedon Fiche 2 of 2 .
Fuel SystemPressureand FlowValve Charts ......
Fuel InjectionSystem TroubleshootingChart ......
CouplingNutTorqueValues (TCM) ...........
CouplingNutTorqueValues (Slick) ...........
IgnitionTroubleshooting ...............
PerformanceCharts .................
................... OperatingLimits
EngineTroubleshooting
................
ApprovedOil Products ................
LubricationSystemTroubleshooting ..........
TurbochargingSysternTroubleshootingChart ......
xvi March 1989

CHAPTER 1
INTRODUCTION
SCOPE
Related Publications
Service Bulletins
ServiceReportsAnd inquiries
100%ReplacementParts
DEFINITIONS
& ABBREVIATIONS
Abbreviations/Symbols
Definitions
Descriptionof EngineModelCode
Basic Design Feature
TOOLS
SpecialTools
PRODUCTS
Product List

1-00-08 SCOPE
Recommendations, cautions and warnings regarding overhaul of this engine are not
intendedto impose undue restrictions. They are inserted to obtain maximumperformance
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 constitutes unauthorized operation in areas unexplored during
development of the engine, or in areas which experience has proved to be undesirableor
detrimental.
NOTES,
Cautions and Warnings are includedthroughout this manual. Application is as
follows:
NOTE.
. . Special interestinformationwhich mayfacilitate the operation of equipment.
CAUTION. . . Information issued fo emphasize certain instructions or to prevent possible
damage to engine or accessories.
WARNiNG. . . Information which, if disregarded, may result in severe damage to or
destructionof the engine or endangermentto personnel.
1-00-01 RELATED PUBLICATIONS
A. EngineManuals
1. Operator's Manualfor TSIO-360 (exceptLBand MB & SB) Series Aircraft Engine,
FormX30583.
Operator's Manualfor TS10-360 MB & -SB SeriesAircraft Engine, FormX30671.
1
a. Maintenanceand Operator's Manualfor TSIO-360-LB Series Aircraft Engine,
FormX30571.
b. MaintenanceManualfor TSIO-360-MB & -SB SeriesAircraft Engine, Form
X30672A.
2. IllustratedParts Catalogfor TSIO-360 SeriesAircraft Engine, FormX30597A.
3. Teledyne Continental MotorsAircraft Engine Service Bulletins.
4. FuelInjectionManualFormX30593A.
The above publications can be ordered through your Teledyne Continental Motors
Distributoror ordered directly, if prepaid, from:
Teledyne ContinentalMotors
Aircraft Products Division
P. 0. Box 90
Mobile,AL 36601
Attn: PublicationsDepartment
REVISEDOCT 97 "100-03

B. Accessory Manuals
I
1. Slick Magnetos ServiceManual
Slick Electro, Inc.
530 BlackhawkParkAvenue
Rockford, Illinois61100
2. TCM Magnetos ServiceManual-TCM IgnitionSystems-FormX40000
3. Alternator Alternator Service Instructions-FormX30531-2
4. Starter FormX30592
Teledyne Continental Motors
P.O. Box90
Mobile,AL 36601
Attn: PublicationsDepartment
1-00-02 SERVICE DOCUMENTS
TeledyneContinental Motorsservice documentsare divided intofive separate categories:
(1) MandatoryService Bulletin,
(2) CriticalService Bulletin, (3) Service Bulletin,(4) Service
lnformationDirectiveand (5) Service lnformation Letter.
SERVICE DOCUMENTCATEGORY DEFINITION
CATEGORY 1
: "MANDATORY SERVICE BULLETIN"(MSB)- Service documents, relating
to known or suspected hazards to safety, that have been incorporated in whole or in part
in anAirworthinessDirective(AD) issued by the FAA or have been issued,at the direction
of FAA, by the manufacturer in order to require compliance with an already issued AD (or
an equivalentissued by another country's airworthinessauthority).
CATEGORY 2: "CRITICAL SERVICE BULLETIN" (CSB)- Service documents (not
included in category 1) that have been determined by the product manufacturer to
constitutea threat to continued safe operation of an aircraft or to persons or property on
the ground unless some specific action (inspection, repair, replacement, etc..) istaken by
the product owner or operator. Documents in this category are candidates for
incorporationin an Airworthiness Directiveissuedby the FAA (but may not be).
CATEGORY 3: "SERVICE BULLETIN" (SB)- Service documents (not included in
categories 1 and
2) considered by the product manufacturer to constitute a substantial
improvementto the inherentsafety of an aircraft or component of an aircraft.This "Service
Bulletin"categoryalsoincludes updatesof instructionsfor continuedairworthiness.
CATEGORY 4: "SERVICE INFORMATIONDIRECTIVE" (SID)- Service documents (not
included in categories
1, 2 or 3) that have been determined by the manufacturerto be of
value to an ownerloperator in the use of a product by enhancing safety, maintenance or
economy.
CATEGORY 5: "SERVICE INFORMATION LETTER" (SIL)- This category includes all
information (not included
in categories 1 through 4) that may be of use to the
ownerloperatoror maintainerof the aircraft.
1-00-03 SERVICEREPORTSAND INQUIRIES.
If for any reason you have an inquiry or require technical assistance, contact your local
TCM distributoror TCM field representative.Requests for copies of Teledyne Continental
Aircraft Engine service publicationsshould be made through your distributor or Teledyne
ContinentalMotors, P.
0. Box 90, Mobile,AL 36601, ATTN: PublicationsDepartment.
1-00-04 REVISEDOCT 97